Method and system for automation, safety and reliable operation performance assessment
In accordance with various embodiments described herein are systems and methods for collecting and analyzing parameter and properties data from an operation and using the data to determining Automation Safety and Operations Performance (ASOP) metrics indicative of various performance aspects of a given operation. Some embodiments are systems and methods for determining one or more ASOP metrics or metrics selected from a group consisting of elements including but not limited to Alarm System Performance Metric, an Operator Loading Metric, a Controllability Performance Metric, a Proximity to Safety System Metric, a Demand on Safety Systems Metric, and a Control System Integrity Metric.
1. A system, comprising:
a plurality of sensors, positioned within a facility;
at least one specially programmed computer processor that is configured to:
automatically receive, over a computer network, from the plurality of sensors in the facility, current performance data from a plurality of distinct sources associated with a plurality of distinct process units of at least one process, being performed at the facility;
wherein the received current performance data comprises measurements representative of an overall automation, safety and operations (ASOP) performance associated with the at least one process that is being performed at the facility;
execute at least one base application to:
i) determine at least one sub-metric, wherein the at least one sub-metric that is chosen from: at least one automation-related metric, at least one safety-related metric, and at least one operations-related metric,
ii) normalize the at least one sub-metric to form at least one normalized sub-metric, and
iii) determine at least one ASOP metric for at least one distinct source associated with at least one distinct process unit of the at least one process based at least in part on the at least one normalized sub-metric;
determine that the at least one ASOP metric is a proximity-to-safety system metric (PSSM) that is representative of an amount of time a process excursion from at least one pre-determined value of at least one process parameter is at risk of triggering a safety response, and is based on a process area between each respective alarm-trip limit pairs, a number of alarm-trip limit pairs, and a rolling time window; and
generate, based at least in part on the at least one ASOP metric, at least one dynamic graphical user interface having at least one dynamic graphical representation configured to visually convey a current overall performance state of the at least one process at the facility.
2. The system of claim 1 , wherein the at least one ASOP metric either is, or includes, an alarm system performance metric (ASPM); and wherein the at least one specially programmed computer processor is further configured to:
i) determine a plurality of alarm-related sub-metrics, chosen from:
1) an ALMH metric, identifying a percentage of hours containing more than a specified number of alarms being activated,
2) an ALMF metric, identifying a percentage of time in flood,
3) an ALMC metric, identifying a percentage of chattering alarms,
4) an ALMS metric, identifying a percentage of stale alarms,
5) an ALMD metric, identifying a percentage of disabled alarms, and
6) an ALMFO metric, identifying a percentage of frequently occurring alarms;
ii) normalize the plurality of alarm-related sub-metrics to form a plurality of normalized alarm-related sub-metrics; and
iii) determine the ASPM for the at least one distinct source associated with the at least one distinct process unit of the at least one process based at least in part on the plurality of normalized alarm-related sub-metrics.
3. The system of claim 2 , wherein the plurality of alarm-related sub-metrics is normalized using a set of respective weight contributions.
4. The system of claim 2 , wherein the at least one ASOP metric is an operator loading metric (OLM); and wherein the at least one specially programmed computer processor is further configured to:
i) determine a plurality of operator-related sub-metrics, chosen from:
1) the ASPM,
2) a setpoint changes metric (SPCM), and
3) other operator initiated changes metric (OPCM);
ii) normalize the plurality of operator-related sub-metrics to form a plurality of normalized operator-related sub-metrics; and
iii) determine the OLM for the at least one distinct source associated with the at least one distinct process unit of the at least one process based at least in part on the plurality of normalized operator-related sub-metrics.
5. The system of claim 4 wherein the plurality of operator-related sub-metrics is normalized using a set of respective weight contributions.
6. The system of claim 1 , wherein the at least one ASOP metric is a controllability performance metric (CLPM) that is based on a variability in a difference between each respective current value and each respective target value for each respective performance of control loop associated with the at least one process is measured using a normalized deviation calculation.
7. The system of claim 1 , wherein the current performance data comprises at least one type of data chosen from: i) temperature data, ii) pressure data, iii) flow data, iv) level data and v) control valve output data.
8. The system of claim 1 , wherein the at least one sub-metric is normalized based on historical data.
9. The system method of claim 1 , wherein the at least one specially programmed computer processor is further configured to continuously update, based at least in part on the at least one ASOP metric, the at least one dynamic graphical representation of the at least one dynamic graphical user interface to visually convey a continuous overall performance state of the at least one process at the facility.
10. The system of claim 1 , wherein the at least one ASOP metric corresponds to a value, on equidistantly radial axes, each value normalized from zero to one.
11. A computer-implemented method, comprising:
providing a plurality of sensors, positioned within a facility;
automatically receiving, by at least one specially programmed computer processor, over a computer network, from the plurality of sensors in the facility, current performance data from a plurality of distinct sources associated with a plurality of distinct process units of at least one process, being performed at the facility;
wherein the received current performance data comprises measurements representative of an overall automation, safety and operations (ASOP) performance associated with the at least on process that is being performed at the facility;
executing, by the at least one specially programmed computer processor, at least one base application to:
i) determine at least one sub-metric, wherein the at least one sub-metric that is chosen from: at least one automation-related metric, at least one safety-related metric, and at least one operations-related metric,
ii) normalize the at least one sub-metric to form at least one normalized sub-metric, and
iii) determine at least one ASOP metric for at least one distinct source associated with at least one distinct process unit of the at least one process based at least in part on the at least one normalized sub-metric;
determining, by the at least one specially programmed computer processor, that the at least one ASOP metric is a proximity-to-safety system metric (PSSM) that is representative of an amount of time a process excursion from at least one pre-determined value of at least one process parameter is at risk of triggering a safety response, and is based on a process area between each respective alarm-trip limit pairs, a number of alarm-trip limit pairs, and a rolling time window; and
generating, by the at least one specially programmed computer processor, based at least in part on the at least one ASOP metric, at least one dynamic graphical user interface having at least one dynamic graphical representation configured to visually convey a current overall performance state of the at least one process at the facility.
12. The method of claim 11 , wherein the at least one ASOP metric either is, or includes, an alarm system performance metric (ASPM); and wherein the at least one specially programmed computer processor is further configured to:
i) determine a plurality of alarm-related sub-metrics, chosen from:
1) an ALMH metric, identifying a percentage of hours containing more than a specified number of alarms being activated,
2) an ALMF metric, identifying a percentage of time in flood,
3) an ALMC metric, identifying a percentage of chattering alarms,
4) an ALMS metric, identifying a percentage of stale alarms,
5) an ALMD metric, identifying a percentage of disabled alarms, and
6) an ALMFO metric, identifying a percentage of frequently occurring alarms;
ii) normalize the plurality of alarm-related sub-metrics to form a plurality of normalized alarm-related sub-metrics; and
iii) determine the ASPM for the at least one distinct source associated with the at least one distinct process unit of the at least one process based at least in part on the plurality of normalized alarm-related sub-metrics.
13. The method of claim 12 , wherein the plurality of alarm-related sub-metrics is normalized using a set of respective weight contributions.
14. The method of claim 12 , wherein the at least one ASOP metric is an operator loading metric (OLM); and wherein the at least one specially programmed computer processor is further configured to:
i) determine a plurality of operator-related sub-metrics, chosen from:
1) the ASPM,
2) a setpoint changes metric (SPCM), and
3) other operator initiated changes metric (OPCM);
ii) normalize the plurality of operator-related sub-metrics to form a plurality of normalized operator-related sub-metrics; and
iii) determine the OLM for the at least one distinct source associated with the at least one distinct process unit of the at least one process based at least in part on the plurality of normalized operator-related sub-metrics.
15. The method of claim 14 , wherein the plurality of operator-related sub-metrics is normalized using a set of respective weight contributions.
16. The method of claim 11 , wherein the at least one ASOP metric is a controllability performance metric (CLPM) that is based on a variability in a difference between each respective current value and each respective target value for each respective control loop associated with the at least one process.
17. The method of claim 11 , wherein the current performance data comprises at least one type of data chosen from: i) temperature data, ii) pressure data, iii) flow data, iv) level data and v) control valve output data.
18. The method of claim 11 , wherein the at least one sub-metric is normalized based on historical data.
19. The method of claim 11 , wherein the at least one specially programmed computer processor is further configured to continuously update, based at least in part on the at least one ASOP metric, the at least one dynamic graphical representation of the at least one dynamic graphical user interface to visually convey a continuous overall performance state of the at least one process at the facility.
20. The method of claim 11 , wherein the at least one ASOP metric corresponds to a value, on equidistantly radial axes, each value normalized from zero to one.