Koppers Inc.

Technology in the Chemical Process Industry:

Understanding the Why

Presented to the 3rd Annual American Chemical

Manufacturing Council

James T. Dietz, PE

May 12-13, 2015

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Technology in the Chemical Process Industry

Understanding the Why

• When I was a young engineer, fresh out of school…..

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Technology in the Chemical Process Industry

Understanding the Why

• Then I needed to learn practical process control…..

These guys were my friends.

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Technology in the Chemical Process Industry

Understanding the Why

• Enter electronic process controls…..

These guys made life easier.

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Technology in the Chemical Process Industry

Understanding the Why

• Make sure you’re on the right bus with the right protocol…

These guys made life cheaper.

•AS-i

•BSAP

•CC-Link Industrial Networks

•CIP

•DeviceNet, CompoNet, ControlNet and EtherNet/IP

•Controller Area Network

•ControlNet

•DeviceNet

•DF-1

•DirectNet

•EtherCAT

•Ethernet Global Data (EGD)

•EtherNet/IP

•Ethernet Powerlink

•FINS

•FOUNDATION fieldbus

•HART Protocol

•HostLink Protocol

•Interbus

•MACRO Fieldbus

•MECHATROLINK

•MelsecNet

•Modbus PEMEX

•Modbus Plus

•Modbus

•OSGP

•Optomux

•PieP

•Profibus

•PROFINET IO

•RAPIEnet

•Honeywell SDS

•SERCOS III

•SERCOS interface,

•GE SRTP – GE Fanuc PLCs

•Sinec H1 – Siemens

•SynqNet – Danaher

•TTEthernet – TTTech

http://en.wikipedia.org/wiki/AS-Interfacehttp://en.wikipedia.org/wiki/AS-Interfacehttp://en.wikipedia.org/wiki/AS-Interfacehttp://en.wikipedia.org/wiki/Bristol_Standard_Asynchronous_Protocolhttp://en.wikipedia.org/wiki/CC-Link_Industrial_Networkshttp://en.wikipedia.org/wiki/CC-Link_Industrial_Networkshttp://en.wikipedia.org/wiki/CC-Link_Industrial_Networkshttp://en.wikipedia.org/wiki/CC-Link_Industrial_Networkshttp://en.wikipedia.org/wiki/Common_Industrial_Protocolhttp://en.wikipedia.org/wiki/DeviceNethttp://en.wikipedia.org/w/index.php?title=CompoNet&action=edit&redlink=1http://en.wikipedia.org/wiki/ControlNethttp://en.wikipedia.org/wiki/EtherNet/IPhttp://en.wikipedia.org/wiki/EtherNet/IPhttp://en.wikipedia.org/wiki/Controller_Area_Networkhttp://en.wikipedia.org/wiki/Controller_Area_Networkhttp://en.wikipedia.org/wiki/ControlNethttp://en.wikipedia.org/wiki/DeviceNethttp://en.wikipedia.org/wiki/DF-1_Protocolhttp://en.wikipedia.org/wiki/DF-1_Protocolhttp://en.wikipedia.org/wiki/DF-1_Protocolhttp://en.wikipedia.org/wiki/DirectNET_Protocolhttp://en.wikipedia.org/wiki/EtherCAThttp://en.wikipedia.org/wiki/Ethernet_Global_Data_Protocolhttp://en.wikipedia.org/wiki/Ethernet_Global_Data_Protocolhttp://en.wikipedia.org/wiki/EtherNet/IPhttp://en.wikipedia.org/wiki/EtherNet/IPhttp://en.wikipedia.org/wiki/Ethernet_Powerlinkhttp://en.wikipedia.org/wiki/Ethernet_Powerlinkhttp://en.wikipedia.org/wiki/FINShttp://en.wikipedia.org/wiki/FOUNDATION_fieldbushttp://en.wikipedia.org/wiki/FOUNDATION_fieldbushttp://en.wikipedia.org/wiki/HART_Protocolhttp://en.wikipedia.org/wiki/HostLink_Protocolhttp://en.wikipedia.org/wiki/HostLink_Protocolhttp://en.wikipedia.org/wiki/HostLink_Protocolhttp://en.wikipedia.org/wiki/Interbushttp://en.wikipedia.org/w/index.php?title=MACRO_Fieldbus&action=edit&redlink=1http://en.wikipedia.org/wiki/MECHATROLINKhttp://en.wikipedia.org/wiki/MelsecNethttp://en.wikipedia.org/wiki/Modbus_PEMEXhttp://en.wikipedia.org/wiki/Modbus_Plushttp://en.wikipedia.org/wiki/Modbushttp://en.wikipedia.org/wiki/Open_smart_grid_protocolhttp://en.wikipedia.org/wiki/Optomuxhttp://en.wikipedia.org/wiki/PiePhttp://en.wikipedia.org/wiki/Profibushttp://en.wikipedia.org/wiki/PROFINET_IOhttp://en.wikipedia.org/wiki/RAPIEnethttp://en.wikipedia.org/wiki/SDS_Protocolhttp://en.wikipedia.org/wiki/SDS_Protocolhttp://en.wikipedia.org/wiki/SERCOS_IIIhttp://en.wikipedia.org/wiki/SERCOS_IIIhttp://en.wikipedia.org/wiki/SERCOS_interfacehttp://en.wikipedia.org/wiki/Service_Request_Transport_Protocolhttp://en.wikipedia.org/wiki/GE_Fanuc_Automation_North_America,_Inc.http://en.wikipedia.org/wiki/Programmable_logic_controllerhttp://en.wikipedia.org/wiki/Sinec_H1http://en.wikipedia.org/wiki/Sinec_H1http://en.wikipedia.org/wiki/Sinec_H1http://en.wikipedia.org/wiki/Siemens_AGhttp://en.wikipedia.org/wiki/SynqNethttp://en.wikipedia.org/wiki/Danaher_Corporationhttp://en.wikipedia.org/wiki/TTEthernethttp://en.wikipedia.org/wiki/TTTech

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Technology in the Chemical Process Industry

Understanding the Why

• Enter better process stability for quality and productivity:

• Self-tuning controllers

• On-stream analysis and process simulation - APC

• Understanding multiple control loop interaction – MPC

Process technology advances quality.

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Technology in the Chemical Process Industry

Understanding the Why

• Is this your operations or plant manager?…..

Then process technology went OTT.

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Technology in the Chemical Process Industry

Understanding the Why

• But is easiness the Why?…..

Process control technology needs to address risk.

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Technology in the Chemical Process Industry

Understanding the Why

• Enter …Risk Based Process Safety & Event Management

Why not marry RBPS and EM into control systems? Figures from Ullmann’s Encyclopedia of Industrial Chemistry.

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Technology in the Chemical Process Industry

Understanding the Why

• Enter …The Life Cycle Standard of IEC 61511

and the SIS integrity standard of ISA-84.

This approach begins with identified SIS.

But why stop there?

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Technology in the Chemical Process Industry

Understanding the Why

• Now let’s get it in front of the operator through:

• Hierarchical alarm management: Flood prevention progressing.

• Live event SME coaching: Now on alarms…other situations.

• LOPA layer status and MOC: Operator disengaged protection.

• Unknown PHA combination flags: Haven’t seen this before!

• Off-line event reconstruction: Show it on screen, not logged.

Now we’re talking!

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Technology in the Chemical Process Industry

Understanding the Why

• Hierarchical alarm management:

Alarm flooding prevention is now on lower priced systems.

Color, event type display on Delta V

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Technology in the Chemical Process Industry

Understanding the Why

• Live event Subject Matter Experts coaching:

Now on alarms…why not other situations?

Add QC and efficiency expertise.

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Technology in the Chemical Process Industry

Understanding the Why

• LOPA layer status and MOC:

Operator disengaged protection. Ah, you just turned

something off that you need.

Manage IPLs and make sure

operators are aware of others.

Protection Layer Probability of FoD

Control Loop 1.0 x 10-1

Human performance (trained,

and under no stress) 1.0 x 10-2 to 1.0 x 10-4

Human performance (under stress) 0.5 to 1.0

Operator response to alarms 1.0 x 10-1

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Technology in the Chemical Process Industry

Understanding the Why

• Unknown PHA combination flags:

We haven’t seen this situation before!

Simulation HAZOP models exist – why not live?

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Technology in the Chemical Process Industry

Understanding the Why

• Off-line event reconstruction:

We have a display so show it on screen, not logged.

BPCS should be able to relive the event.

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Technology in the Chemical Process Industry

Understanding the Why

• Enter …..Interactive Field Devices w/ Procedure Checklists

Let’s make our people smarter with less risk.

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Technology in the Chemical Process Industry

Understanding the Why

Thank You!

Questions?