Beyond a Safety Function, a Safe State

Processes operate in a number of different states which range from down-time for maintenance to running in a steady state or any normal or abnormal state in between. State based control, also known as procedural automation, uses the state that the process is in to optimize the control of the process.

  • Improve the design process through the use of standard reusable architecture and instrument and alarm justification
  • Maximize the investment in your DCS by capturing knowledge in the form of operating discipline that can be leveraged with greatly reduced training costs in a dynamic workforce
  • Enhance safety and operability through the uses of safe states in units and the communication between units to optimize the response to degradation scenarios
  • Allow operators to manage the process through state changes while retaining the ability to see the big picture - avoiding problems and optimizing performance

Improve Profitability and Performance

The implementation of state based control can improve the profitability and performance of manufacturing from the initial design throughout the operating life of the facility.

  • Knowledge capture - Guarantees that the knowledge necessary to operate a facility is captured for future use
  • Leverage reusable control technology - Control modules, equipment modules and unit modules are reusable components for the control design which can be designed in a generic form to reuse in specific applications
  • Instrumentation and alarm justification - Dynamically rationalize alarms in accordance to the corporate alarm philosophy to both determine the correct alarms to have for the process and the instruments required
  • Coordinated safety response - state based control takes the entire unit operation to a safe state
  • Asset utilization - Some key areas of lost asset utilization such as equipment failures, operating discipline issues and reprocessing can be significantly reduced through automation

Benefits of State Based Control

Employing State Based Control significantly reduces all of the common causes of shutdowns and slowdowns by:

  • Changing control modes based on state reducing manual intervention to decrease process upset
  • Providing dynamically managed alarming where operator action is needed decreases process upset to reduce operator error
  • Executing proper start up and shutdown procedures diminish equipment failures

Other benefits include:

  • Increased productivity
  • Higher asset utilization
  • Minimizes environmental incidents and violations
  • More efficient use of resources
  • Less outputs to be managed in manual
  • Automated response and recovery from abnormal situations
  • Provides a mechanism to capture and transfer knowledge
  • Best operator is always on the board
  • Allows for the standardization and proliferation of best practices
  • State based control improves overall safety

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Part 5 - Change Your Board Operator to a Process Manager with State Based Control