Plant Automation Maturity Assessment

Preliminary Diagnostic — Instrumentation · Control · Safety · Advanced Analytics

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No facility names, locations, or proprietary details. Acronyms are expanded inline where needed.

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1. Field Instrumentation
Question 1 of 25. Are more than 5% of field instrument measurements not connected to a control room or centralized monitoring location?
Question 2 of 25. Is an Instrument Asset Management System (IAMS) in use?
Question 3 of 25. Is a wireless instrumentation network in place?
2. Process Alarm Management
Question 4 of 25. Is there an approved alarm register containing, at minimum, tag number, description, units, instrument range, alarm limits, alarm priority and operator response information?
Question 5 of 25. Has an alarm-management philosophy been developed and have the alarms been rationalized?
Question 6 of 25. Is an alarm-management system implemented in alignment with an applicable recognized standard, such as ISA-18.2 or EEMUA 191?
3. Basic Process Control System (BPCS) Performance
Question 7 of 25. Have priority Basic Process Control System (BPCS) loops been identified, including their limits, setpoints and operating modes, in accordance with the approved site standard?
Question 8 of 25. How often are controllers checked for tuning adequacy?
Question 9 of 25. How is process-control loop performance rated in terms of operation in the correct mode?
4. Safety Instrumented Systems (SIS)
Question 10 of 25. What is the status of Layer of Protection Analysis (LOPA) for applicable process hazards?
Question 11 of 25. Is an approved Safety Requirements Specification (SRS) available for the facility's Safety Instrumented System (SIS)?
Question 12 of 25. Have identified SIS gaps been analyzed, risk-ranked and assigned corrective actions?
5. Advanced Process Control (APC)
Question 13 of 25. To what level are cause-and-effect relationships between key process variables documented for operator training and troubleshooting?
Question 14 of 25. Is Model Predictive Control (MPC) in use?
6. Process Modelling and Real-Time Optimization (RTO)
Question 15 of 25. How is the plant currently modelled for performance analysis?
Question 16 of 25. Is Real-Time Optimization (RTO) implemented in the facility?
7. Control System Upgrade and Lifecycle Management
Question 17 of 25. How many control rooms operate within the facility?
Question 18 of 25. When was the control system last substantially upgraded?
8. Manufacturing Execution and Production Information Systems
Question 19 of 25. Is a process data historian or operational data platform available for the facility?
Question 20 of 25. What is the Manufacturing Execution System (MES) or equivalent production-information capability currently used for?
Question 21 of 25. Has a Production Management System (PMS) or Manufacturing Execution System (MES) capability assessment been completed for the facility?
9. Engineering and Control System Documentation
Question 22 of 25. What is the status of core process documents such as the Process Design Basis, process flow diagrams, piping and instrumentation diagrams, control narratives and OEM manuals?
10. Technical Training and Capability
Question 23 of 25. Who carries out DCS and PLC maintenance functions?
Question 24 of 25. Is a structured control-room operator training and competency program in place?
Summary
No facility names, locations, or confidential details please.