EXPORTING ALARM SETPOINTS IN SIEMENS PCS7

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1 2017 Siemens Automation Summit EXPORTING ALARM SETPOINTS IN SIEMENS PCS7 Jared Romano, Pigler Automation usa.siemens.com/summit

2 2017 Automation Summit Title: EXPORTING ALARM INFORMATION FROM SIEMENS PCS7 Track: Productivity & Efficiency Presenter: Jared Romano Company: Pigler Automation Session #: 5.1 Page 2

north of Denver 10 Employees and Growing Industries Served: Chemical, Power and

3 Pigler Automation, LLC was founded in 2005 We are a Siemens Solution Partner for PCS7 with 7 Siemens PCS7-Certified Engineers Located in Longmont, Colorado miles north of Denver 10 Employees and Growing Industries Served: Chemical, Power and Mining,. For more information please visit: Or call : (866) Page 3

4 Bio Slide Jared Romano B.S. in Electrical Engineering from Colorado State University Engineering Intern with Pigler Automation, LLC from April 2014 to May 2015 Process Controls Engineer with Pigler Automation, LLC since May 2015 PCS7 Certificed Process Control Engineer Page 4

Page 5 The Challenge: The Cost of Mismanaged Alarms Refining and Chemicals Alarms per Operator per Day Without Alarm Management 1350 With Alarm Management 250 One missed alarm resulting in a

5 Page 5 The Challenge: The Cost of Mismanaged Alarms Refining and Chemicals Alarms per Operator per Day Without Alarm Management 1350 With Alarm Management 250 One missed alarm resulting in a unplanned shutdown One misunderstood alarm as a result of operator error leading to a loss in containment Typical Cost $3.5M $15M (Impacted losses as direct result) 1. Honeywell Process Solutions - Alarm management and rationalization - Intelligent alarm handling rules - Aonghus Keegan 2. Honeywell Process Solutions - Uop Alarm Help Delivered Directly To Operators For Safer, More Productive Operations Page 5

6 Page 6 ISA 18.2 Alarm System Management In 2003, ISA started developing an Alarm System Management standard. In 2009 ANSI/ISA-18.2 Management of Alarm Systems for the Process Industries standard was published Page 6

7 What is Alarm Rationalization? A process where a cross-functional team of plant stakeholders reviews, justifies, and documents that each alarm meets the criteria for being an alarm as set forth in a company s alarm philosophy document. Involves defining the attributes of each alarm as well as documenting the consequence, response time, and operator action. The output of rationalization is a Master Alarm Database (also known as an alarm catalog) containing the alarm configuration requirements Page 7

8 Page 8 ISA 18.2 Rationalization ISA 18.2 defines specific requirements for alarm rationalization: 1. Alarm type 2. Priority 3. Class 4. Alarm setpoint value or logical condition 5. Operator action 6. Consequence of Inaction or incorrect action 7. Need for advanced alarm handling techniques if necessary Page 8

9 What will we cover? 1. Strategies for developing software to extract all alarm information required for rationalization 2. Methods of implementing rationalized information to improve plant operations Page 9

10 Page 10 How Can We See Alarm Information in PCS7? Messages tab in Process Object view Page 10

Operator action 6. Consequence of Inaction or incorrect action 7.

11 Page 11 What Is Missing? 1. Alarm type 2. Priority 3. Class 4. Alarm setpoint value or logical condition, disable or enabled 5. Operator action 6. Consequence of Inaction or incorrect action 7. Need for advanced alarm handling techniques if necessary. Page 11

12 Parameters Tab in Process Object View Page 12

Example: MonAnL Considerations HMI Alarm

Limits can also be interconnected MonAnL has two

13 Example: MonAnL Considerations HMI Alarm messages are turned off when either PV_MSG_EN or PV_EN are disabled PV_Unit is often Interconnected to a Channel Driver block Alarm Limits can also be interconnected MonAnL has two ALARM8 Objects Block comment is inserted for the event message Page 13

14 Example: MEAS_MON Considerations Ways to turn off HMI Alarm messages Suppression IO on MEAS_MON are set to 1 Unit is configured at the U as a string MEAS_MON as only one alarm objects Page 14

15 Overview of Process Page 15

16 Expected Result Page 16

17 Page 17 First Attempt: Excel Macro Problems: Required many tabs to manage data Additional formatting required Copy Data to Spreadsheet Messy and Complicated code Difficult to export configuration data Slow Processing Page 17

18 Page 18 VB.Net or C# in Visual Studio Advantages Easy to design a full UI Provides use of data tables o Easily export data tables to.xml configuration file o Run SQL queries to search for setpoints Minimizes Looping Quickly convert CSV exported from Process Object View to data table using OLEDB connector Page 18

19 Main Interface Page 19

Page 20 Configure PCS7 Block Types Use objects in a Windows form to help organize the input data Important Block Parameters: o Setpoint IO o Alarm

20 Page 20 Configure PCS7 Block Types Use objects in a Windows form to help organize the input data Important Block Parameters: o Setpoint IO o Alarm Enable IO o Msg Enable IO o Signal Identifier IO o Unit IO o MSG_Evid Name Import the data entered on the form into a DataTable for quick querying Page 20

through an interconnection Configured tables can be

21 Page 21 Configure Units and Interconnected Blocks Add a unit table and blocks that define the unit or setpoint through an interconnection Configured tables can be stored in.csv or.xml format using datatable.writexml(path) Page 21

Current view o o Includes the Block Comment column $$BlockComment$$ needs to be

22 Page 22 Exporting from Process Object View Parameters Tab - select Export All I/O o Prevents the need to select individual I/O Messages tab, select Export Current view o o Includes the Block Comment column $$BlockComment$$ needs to be replaced with the correct text Export Messages does not include block comment Page 22

23 Page 23 Coding: Importing the Data and Making Queries Use an OleDb adapter to quickly import the CSV into a data table SQL queries can be made to quickly search for relevant data. NO LOOPS! Greatly reduces seek time Uses less system resources Note: Data gets returned as DataRow array, not a DataTable. Convert back to data table by first checking the length. Page 23

24 Page 24 Convert to Excel Closed XML is an open source library to export data tables to.xlsx More info: Add additional rationalization columns and export to excel Page 24

25 Page 25 ISA 18.2 Rationalization ISA 18.2 defines specific requirements for alarm rationalization: 1. Alarm type 2. Priority 3. Class 4. Alarm setpoint value or logical condition 5. Operator action 6. Consequence of Inaction or incorrect action 7. Need for advanced alarm handling techniques if necessary. Page 25

26 New with PCS7 V9.0: Alarm Help Text Description Possible causes Suggested operator action Consequence Page 26

27 Filled out Excel Page 27

Page 28 Import Modified Excel and Export to CSV The modified Excel file can be converted back to a data table using Closed XML. Full tutorials for using Closed XML can be found at https://www.

28 Page 28 Import Modified Excel and Export to CSV The modified Excel file can be converted back to a data table using Closed XML. Full tutorials for using Closed XML can be found at The data table can be exported to CSV to import the data back to PCS7 Can be done just using a simple StreamWriter or there are open source tool to simplify o CSV Helper is a great.net library for reading and writing CSV files o It can be imported via the Visual Studio Package Manager Console Page 28

29 Page 29 Import to PCS7 V9.0 Process Object View Columns that must be maintained in order for the CSV to be imported to Messages in Process Object View Hierarchy Chart Block I/O name Subnumber Page 29

Page 30 ISA 18.2 Rationalization ISA 18.2 defines specific requirements for alarm rationalization: 1. Alarm type 2. Priority 3. Class 4. Alarm setpoint value or logical condition 5. Operator action 6.

30 Page 30 ISA 18.2 Rationalization ISA 18.2 defines specific requirements for alarm rationalization: 1. Alarm type 2. Priority 3. Class 4. Alarm setpoint value or logical condition 5. Operator action 6. Consequence of Inaction or incorrect action 7. Need for advanced alarm handling techniques if necessary. More information can be found at the User Community site from the 2014 Automation Summit Presentation on Smart Alarm Hiding Page 30

31 Support Operation with Voice Interaction Hey Alexa Page 31

32 Page 32 For Voice Interaction Export to SQL The Data Table can also be exported to a SQL Database to allow Third party software to query Anything other than SQL Server it is recommended to install a third-party connector Primary Keys o Chart o Block o IOname o Subnumber (Sig_#) Page 32

33 Page 33 Alexa can make SQL Queries for you! Amazon Alexa uses hands-free voice recognition to extract relevant data from SQL database Provides the operator with detailed information including the recommended course of action Alexa.. Start Alarms TI001 high Page 33

34 What s Next Alarm Tool Include an OPC connection Provide live data values and quickly determine if an alarm is enabled or disabled Retrieve units without interconnection algorithms Alexa Alexa notifications can be used to alert the operator of any issues in real time as they develop. (Future feature) Use OPC alarm tags to trigger Alexa to automatically query Alarm information Expand these concepts to create IO lists Page 34

EXPORTING ALARM SETPOINTS IN SIEMENS PCS7 Name: Jared Romano Company: Pigler Automation Email: Jared.

35 EXPORTING ALARM SETPOINTS IN SIEMENS PCS7 Name: Jared Romano Company: Pigler Automation Phone: (866) Ext. 8 Session #: 5.1 Please fill our your survey via the summit app. Page 35

General Specifications

General Specifications Model NTPC003 Exaquantum Alarm Master Database PROBLEM Poor alarm management is one of the leading causes of downtime and has contributed to some of the worst recorded industrial