Extracting senior staff knowledge and industry best practices into a plant’s Standard Operating Procedures (SOPs) is a huge commitment of resources – one that is often wasted as binders of SOPs sit idle on plant managers shelves. Paperless Procedures (PLP) is a patented NovaTech software package that converts static SOP documents into a dynamic checklist interface that can execute SOPs in manual, automated, or hybrid mode on operator consoles or tablets, ensuring correct and accountable execution of even rarely used procedures. Conversion of SOPs into the Paperless Procedures dynamic checklist interface is available as a service.
ISA-106 Procedural Automation
PLP provides an intuitive graphical tool to create accurate and consistent SOPs using a intuitive flow chart style of creation. Pre loaded libraries of operations allow the SOP developer to easily create and publish SOPs that interface/interact with the operator and the control system. PLP also provides advice and direction to the operator for control of equipment and processes. As conditions warrant, training information, procedures, or other information are provided just-in-time to the operator.
Procedures are created visually to ensure consistency of verbiage and execution, and linked directly to D/3 PCMs to allow manual, semi-automatic or fully automated execution. PLP features user credential and privilege authentication, extensive logging and reporting of all executed SOPs for data integrity. This results in improved documentation, revision control, and reliable, time-stamped execution for all SOPs. Operators, Supervisors and Managers can view the same procedures simultaneously and contribute comments and feedback to improve procedures.
All of which results in safer plant operations, reduced off-spec product, and improved process consistency, EH&S event responses, operator efficiency, and product quality.
Manufacturing operations culture, alarming methodologies, process safety management practices, standard operating procedures, and automated control strategies must work in harmony to prevent abnormal performance. As the issue becomes more and more dependent on human and machine integration, new technologies and implementation techniques like advanced procedural automation can be applied, which will greatly affect operational performance. Those who ignore these new advances in computer enabled manual and automated procedural automation will delay their adoption, and incur highly levels of process safety and productivity risk.
The D/3® Distributed Control System (DCS) is a leading edge process control system that includes a comprehensive suite of software applications, networks, and computing hardware. D/3 features system-wide redundancy and the ability to upgrade without stopping plant operations.
It is fair to say that without a fully functional distributed control system (DCS), a modern plant cannot operate safely and efficiently and in some cases, cannot operate at all. Therefore, it is vital to ensure the integrity of all DCSs and protect them from malicious attacks, accidental corruption, and data breaches that may jeopardize safety or production or may compromise the end user’s competitive advantage in the marketplace.
This paper describes the philosophy and guidelines for keeping your D/3® DCS secure from cyberattacks.
NovaTech announces that it has installed a fully integrated automation system at one of the largest grain loadout facilities on the U.S. West Coast. The facility is a rail receiving to ship loading system that processes corn, soybeans, and wheat.
NovaTech Product Marketing Director, Chris Kourliouros, presented a paper entitled “New Paradigms in Mitigating Unplanned Events Caused by Human Error” on October 25th at the 2017 Texas A&M Mary Kay O’Connor Process Safety International Symposium.
The editors of “Control” magazine were on site at the 2017 NovaTech Automation Summit in Baltimore. They offer coverage of some of the Summit’s presentations addressing process control’s most interesting challenges and pressing problems.
Manufacturing operations culture, alarming methodologies, process safety management practices, standard operating procedures, and automated control strategies must work in harmony to prevent abnormal performance.
As the issue becomes more and more dependent on human and machine integration, new technologies and implementation techniques like advanced procedural automation can be applied, which will greatly affect operational performance.
In 1999, NovaTech installed D/3® Version 9 at AbbVie’s North Chicago facility. Although the system was still running seventeen years later, it became increasingly difficult to maintain. The system was running on a VMS platform, which Corporate IT no longer wanted to support. With the backing from IT, engineering, and operations, AbbVie was ready to upgrade their NovaTech D/3 System in 2016.
FlexBatch integrates recipe management and the automation layer so operators can quickly and easily develop, scale up, modify and schedule batch manufacturing recipes for products ranging from beer to chocolate to specialty chemicals and more. FlexBatch delivers shorter time to first batch, reduced changeover times, increased throughput and production yield. New and existing products are brought to market faster and at lower cost, providing a strategic and financial advantage. Production staff can execute library procedures to overcome process upsets. All of which means a more nimble, responsive, and profitable process.
The latest release of the D/3 Distributed Control System includes new configuration tools that make the system easier for new and existing users. The webinar covers building tags with MDL Builder, writing automation code with D3Edit, web-accessible History and Reports, features to facilitate migration to High-Performance HMI, and OSIsoft PI integration.
This video introduces the D/3, the Distributed Control System trusted by many Fortune 100 companies to keep their global operations’ continuous and batch processes running smoothly and efficiently. Part one reviews the system architecture and configuration tools.