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2009 IPS North American Client Conference: Chaos, Crisis, Clarity
2009 IPS North American Client Conference: Chaos, Crisis, Clarity
By Bill Lydon - Contributing Editor
Houston Texas September 20-24, 2009
Steve Blair, President, North America Region, Invensys Operations Management opened the conference with the theme, “Achieving Sustainable Performance” and two other speakers gave real world examples of how training and preparation brought clarity out of chaos and crisis.
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Steve Blair, President North America
Steve Blair is President of Invensys Operations Management, North America and started the conference by noting in these economic times there is a great deal of interest in maximizing and sustaining the value of assets. Blair defined sustainability as, “delivering consistency and quality day after day that keep you and your business responsible, safe and profitable.” He commented that with constant changes of regulations and other factors that the rules keep changing making it hard to see what is ahead. This requires agility and the ability to be productive while adapting to change. “The real prize is delivering actionable information to drive better decisions at all levels of the organization,” Blair adds. Empowering people with the right information to make decisions is a major part of achieving sustainable manufacturing based on factual insights.
IOM (Invensys Operations Management)
Blair discussed the new IOM (Invensys Operations Management) organization as a division of Invensys. Invensys Operations Management’s offerings are delivered under several industry brands, including Action Instruments, ArchestrA, Avantis, Barber-Colman, Chessell, Continental, Eurotherm, Foxboro, IMServ, InFusion, SimSci-Esscor, Triconex and Wonderware. Invensys Operations Management provides automation and information technology, systems, software solutions, services and consulting to the global manufacturing and infrastructure industries.
Since Wonderware was purchased, many in the industry have thought it would be combined with the controls group. Now this is a reality. The timing is good since the integration of information from sensor to enterprise is now becoming accepted as a business practice.
Blair reviewed some quick facts about the organization.
- $1.8 billion in annual revenue
- Approximately 9,000 employees
- Supports clients in more than 180 countries
- More than 570,000 active software licenses in use
- Installed safety systems have more than 480 million hours of operation without failure
- Helps generate 24 percent of the world’s electricity
- Helps produce 25 percent of the world’s chemicals
- Helps produce 70 percent of the world’s liquefied natural gas
- Helps refine 18 percent of the world’s crude oil
Blair indicated that IOM tools, knowledge, knowhow, and experience can help companies efficiently achieve sustainable operations.
Partnering
Invensys has moved from a “build everything attitude” that had been a hallmark of the company to partnering with strong suppliers in areas that are not core competencies. The level of partnerships recently announced illustrates a serious commitment to leveraging partners. Examples include relationships with PAS for system documentation and configuration management tools, and with Pepperl+Fuchs for Intrinsically Safe I/O modules.
Blair’s Challenge
Blair challenged the audience, “Will we be passive and allow the economy and regulations to dictate our course or will we step up to meet those challenges with insight and innovation? Sustainable performance is achievable for those who lead. We choose to lead.”
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Ken Anderson, ExxonMobil process control manager, was put in charge of getting the controls systems back in operation at ExxonMobil's multi-unit chemical facility in Beaumont, Texas after hurricane Ike. Ken started by noting that the recovery from hurricane Ike proceeded at a very fast pace with high quality work and was done safely in record time.
ExxonMobil's multi-unit chemical facility in Beaumont, Texas was under 6-10 feet of salt water for 3-4 days, ruining the control systems. Anderson was put in charge of restoring the control systems which was the first priority in getting the plant operational. Anderson was greeted by the plant manager, “Welcome to Beaumont. If there is anything you need, pencils, paper, anything…we hope you brought it with you because we have lost it all.”
Anderson described the situation where they had no power and cell phone service was unreliable. There were no hotels and no restaurants. Employees were dealing with their own house damages plus many other plants in the area were damaged and competing for materials and labor.

Hurricane Ike was described as the third most destructive storm to hit the United States. The National Weather Service warning was ominous, “escape or face certain death.” Hurricane Ike existed for 9 days 21 hours and was a Category 2 storm with 110 mph winds, 1 mph less than a category 3. Ike had the highest sustained winds recorded at 135 mph (September 7th off Cuba) and Texas experienced wind gust up to 112 mph.
After reviewing the situation it was decided that the DCS and PLC cabinets would be demolished and replaced. The marshalling cabinets would be replaced but the wring would be reused. Anderson determined they needed to be able to make decisions quickly and developed a Control System Recovery (CSR) guideline that gave clear objectives for decision making. It outlines unambiguous roles and responsibilities defining what would be done and what would not be done. It outlined the decision to “replace in kind where possible” in order to expedite getting the plant running quickly.
The results were impressive based on the actual timeline.
- September 5 Plant Turndown
- September 12 Plant Shutdown
- September 13 Hurricane Ike
- September 17 Pumped out water
- September 19 Control purchase orders cut
- October 14 First DCS Readiness Check
- December 7 First on Specification Production
Anderson mentioned the following key factor for success:
- Clear Chain of Command
- Clear Decision Making Criteria
- Team List and Contact Information
- Cell Phones and Jump Drives
- Laptops
- Inter and Intra Team Communications Daily
- Specified Work Scope Boundaries
- Direct Vendor Factory Contact
- Short Shipped Expedited Orders
- Offsite System Staging
Anderson talked about getting a phone call from Steve Blair asking to visit the site with his people to determine what they could do to help. Anderson’s initial reaction, “What do I need a Vice President for?” He summed up his feelings about Invensys in his closing remarks after noting a number of Invensys people by name and stated, “If you are in a disaster recovery mode these are the people you want on your team.”
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Flying & Process Engineering - Jeff Skiles co-pilot of US Airways Flight 1549
Jeff Skiles talked about his experience as co-pilot of US Airways Flight 1549 when it crashed into the Hudson River in New York on January 15, 2009 and how his experience and lessons learned relate to control engineers.
Jeff Skiles lives in Oregon, Wisconsin and is based as a pilot out of Charlotte, North Carolinan. Skiles was flying the plane at takeoff as copilot with Chesley B. "Sully" Sullenberger as the lead pilot of Flight 1549. No one was seriously injured when US Airways Flight 1549 made a water crash-landing in New York City's Hudson River shortly after takeoff on Thursday, January 15, 2009.
Skiles has found most people fascinated not only by their story but how they go about their profession as airline pilots. For most it is a mystery that goes on behind closed doors. Skiles noted that what they do in the cockpit is not so much different than what automation professionals do with the basic building blocks of training, teamwork, procedures, and information that is critical in any profession where human beings interact.
Skiles wanted to be at a pilot at an early age. Both his parents were hobby pilots so Skiles was in airplanes at a young age. As a teenager, they flew up to Alaska following the Alcan Highway in their little four seat airplane. His first job was pumping gas at a local airport to get money to fund his flight training lessons to get his pilot license. He became a flight instructor while going to college, where he received a bachelor of science in geology. He started as a cargo pilot for the U.S. mail flying to places like North Platte, Nebraska and Wolf Point, Montana. He then worked for a commuter airline flying turboprops. In 1986 he went to work for US Airways.
Flight 1549 was the last leg of a four day trip and he had just met Sully three days before the beginning of the trip. People are surprised at this because people think to work as a team you need to work together for a long time. It is their training and strict adherence to procedure that enables them to act as a team. One pilot is flying and one pilot is monitoring each with specific duties. Sully taxied the plane onto the runway and then said “your aircraft” and Skiles responded, “my aircraft” signifying the transfer of control.

Skiles proceeded to fly the airplane for takeoff and Sully called out the airspeed. “We have specific commands and callouts and are not allowed to engage in any extraneous conversation below 10,000 feet. “Having such concentration, procedures and strict uniformity helps us to work as a team. We know exactly what we are responsible for and what we can depend on the other pilot for.” At 3,000 feet they saw a line of geese right in front of the nose, and they were too close to maneuver around them. “They sounded like hail hitting the airplane and then both engines rolled back to idle,” Skiles described. “Speed is declining rapidly and I am pushing the nose over to keep the airplane flying.”
Sully then took over the airplane by saying, “my aircraft” as Skiles responded, “your aircraft.” He and Sully assessed what they had and “it was clearly nothing.” Skiles worked through the dual engine failure checklist and Sully got on the radio and called “mayday, mayday, mayday!” They determined the safest thing to do was land the plane on the river. Sully informed the stewardess to “brace for impact.”
Skiles noted that even in this situation there were moments of levity they did not remember. When they listened to the NTSB tapes later Sully asked Skiles, “got any other ideas?” and he responded, “actually no.”
As Skiles walked back through the plane after the water landing he began throwing out the life vests located under the seats as noted in the flight briefing card which is “rarely read.” Passengers helped each other and there was no pushing or shoving. The entire flight took 5 ½ minutes; two minutes before hitting the geese and 3 ½ minutes to land in the Hudson River.
The politicians arrived and Governor Paterson coined the phrase the “Miracle on the Hudson.” Skiles commented, “Was it really a miracle? Sully and I brought a lifetime of experience and both have over 20,000 hours of flying experience.” Skiles observed that their training, teamwork, procedures, and also luck made this possible. Accidents happen due to chains of small events and if you break the chain you can prevent accidents, and the biggest factor is human error. The airline industry tracks human errors to learn and improve training and procedures. They are allowed to report mistakes they make without fear of punishment to keep an overall database of mistakes to identify patterns. Also, flight audits are done with someone observing operation in the cockpit to identify mistakes. The goal is to create better training and procedures to avoid errors. Skiles observed that automation professionals track information in real time to understand and improve operations.
Skiles concluded by emphasizing that this and other successes are based on training, procedures, teamwork, and using real information to learn and improve. Good advice!