Full Automation Maturity Assessment

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Industry sector *

Respondent role *

1. Field Instrumentation

Q2. Are more than 5% of field instrument measurements not connected to a control room or centralized monitoring location? *

YesNoUnknown / not assessed

Q3. Are the same instruments used for both process control and shutdown/interlock functions? *

YesNoOnly where permitted by approved design standards

Q4. Are instruments used for process control also used for alarms requiring operator response? *

Yes, in most cases and duplicate instrumentation is generally not providedYes, only where the controller is not in critical serviceNo, independent measurement is provided where requiredNot assessed

Q5. Do operators depend on alarms generated by a process data historian or operational data platform to prompt action in the control system? *

YesNoAdvisory use only

Q6. Are all priority process parameters identified in accordance with the Production Management System (PMS) and controlled or monitored from the control room? *

Not all; some priority parameters require manual field adjustmentYes, but distributed across multiple control roomsYes, in one centralized control roomNot assessed

Q7. What critical instrument asset information is maintained in the Enterprise Resource Planning (ERP) or maintenance system? *Select all that apply

Preventive maintenance / calibrationSpare availabilityMaintenance observationsFailure modesRoot cause findingsNone of the above

Q8. Is an analyzer calibration process in place? *

NoYesPartially / only for selected analyzers

Q9. Are analyzer-versus-laboratory comparison charts maintained and reviewed? *

NoYesOnly for selected quality measurements

Q10. What is the average online availability of critical analyzers? *

Less than 80%Between 80% and 95%Above 95%Not measured

Q11. Is adequate instrumentation available to perform the following balance checks? *

Mass balanceMass and heat balanceNeither / insufficient instrumentationNot assessed

Q12. Are smart sensors used for priority process-variable measurement? *

NoIn selected casesStandard practiceNot assessed

Q13. Is an Instrument Asset Management System (IAMS) in use? *

NoUsed only during commissioning and field testingUsed regularly for instrument condition monitoringNot assessed

Q14. Are Condition-Based Maintenance (CBM) processes in place for critical instrumentation assets? *

NoYesIn development

Q15. Is electronic marshalling or intelligent I/O technology used in the facility? *

NoUsed in selected areasStandard practice for new installationsNot assessed

Q16. Is a wireless instrumentation network in place? *

NoYes, connected only to an operational data platform for monitoringYes, connected to the process control network under approved architectureNot assessed

Q17. Are redundant measurements used to validate flows of raw materials and key products? *

NoYesOnly for selected critical flows

Q18. Is position feedback available for critical final control elements? *

NoYesOnly for selected critical valves or drives

Q19. Are inferential or analytics techniques used to predict instrument faults? *

NoYesPilot / limited use

Q20. Are infrared or visual cameras used for monitoring or operational decision support? *

NoYesPilot / limited use

Q21. What is the highest priority driver for new instrumentation? *

Existing instruments are obsolete or spares are difficult to obtainIndependent measurement is needed for alarms or shutdown initiationAdvanced control or optimization implementationCritical equipment condition monitoringQuality measurement improvementOther

2. Process Alarm Management

Q22. Is there an approved alarm register containing, at minimum, tag number, description, units, instrument range, alarm limits, alarm priority and operator response information? *

NoYesPartially complete

Q23. Is Management of Change (MOC) applied when alarms are added, deleted, reprioritized, suppressed by design or when alarm limits are changed? *

NoYesInconsistently applied

Q24. How often are control-system alarm limits compared with the approved engineering alarm register? *

NeverEvery 3 to 5 yearsEvery 1 to 3 yearsAfter significant change / periodically defined by site standard

Q25. Has an alarm-management philosophy been developed and have the alarms been rationalized? *

NoOnly during project implementationYes; maintained as a living processIn progress

Q26. Are the top alarm bad actors monitored and reviewed? *

NoMonthlyWeeklyDaily or during DMS reviewOther

Q27. Is an alarm-management system implemented in alignment with an applicable recognized standard, such as ISA-18.2 or EEMUA 191? *

NoImplemented without a recognized standardYes, aligned with a recognized standardIn progress

Q28. Is there a process for communicating suppressed or shelved alarm information during shift handover? *

NoYesPartially / dependent on operator practice

Q29. Approximately how many suppressed or shelved alarms exist per operator console? *

Greater than 100Between 10 and 100Less than 10Not measured

Q30. Approximately how many standing or stale alarms exist per operator console? *

Greater than 100Between 10 and 100Less than 10Not measured

Q31. Are control-room audible alarm annunciations suppressed? *

YesOnly during alarm flooding conditions under approved proceduresNoNot assessed

Q32. Is alarm-rationalization or alarm-performance monitoring software used? *

NoYesPlanned

Q33. Is dynamic alarming used to reduce alarm flooding during known operating modes or abnormal situations? *

NoYesIn development

Q34. Where is dynamic alarming logic configured? *

Does not existIn the DCS logicIn an external alarm-management applicationOther

Q35. Are alarms generated by a process data historian or operational data platform used to prompt action in the control system? *

Yes; operators are expected to act and the function is governed as a protection or control-support layerYes; advisory only and not relied upon as a protection layerNo; used strictly for trending and analysisNot applicable

Q36. Does the alarm register include the available response time for the operator? *

NoYesOnly for high-priority alarms

Q37. Are engineering calculations or approved justifications available to support alarm limits and operator-response time requirements? *

NoYesPartially complete

Q38. What is the operators' overall feedback on control-system alarms? *

Too many alarms; the system is not sufficiently usefulAlarms are manageable but require improvementAlarm system supports effective operator responseFeedback has not been formally collected

3. Basic Process Control System (BPCS) Performance

Q39. Have priority Basic Process Control System (BPCS) loops been identified, including their limits, setpoints and operating modes, in accordance with the approved site standard? *

NoIdentification startedCompletedNot assessed

Q40. Are priority process-control loops included in the maintenance or asset-information system with criticality defined according to an approved site standard? *

NoYesPartially complete

Q41. Is formal process-control loop performance monitoring in place? *

NoInformal / problem-driven review onlyYes, formal monitoring process

Q42. Is controller-tuning software or a documented tuning method used? *

NoYesPartially / selected loops only

Q43. Are key process-variable control-limit violations regularly discussed during the Daily Management System (DMS) stand-up review? *

NoReviewed through weekly analysisReviewed during daily DMS stand-up meetingsOnly after significant events

Q44. How often are controllers checked for tuning adequacy? *

Only when operations reports a problemMonthlyWeeklyBased on performance monitoring alerts

Q45. How is process-control loop performance rated in terms of operation in the correct mode? *

Less than 80%Between 80% and 95%Greater than 95%Not measured / correct mode not identified

Q46. How effectively do controllers maintain priority variables within approved operating limits? *

Less than 50% of the required timeBetween 50% and 80%Greater than 80%Not measured

Q47. What is the status of identified process-control performance gaps? *

Not assessedGaps identifiedImprovement plan in placeActions implemented and sustainment monitored

4. Safety Instrumented Systems (SIS)

Q48. What is the status of Layer of Protection Analysis (LOPA) for applicable process hazards? *

Not startedIn progressCompletedNot applicable

Q49. Has the LOPA process identified any potential Safety Instrumented Function requirement? *

NoYesAssessment in progress

Q50. Is an approved Safety Requirements Specification (SRS) available for the facility's Safety Instrumented System (SIS)? *

NoYesPartially complete

Q51. What is the highest residual risk identified in the LOPA, using the business owner's approved risk-ranking method? *

Critical / intolerableHighMediumLow / acceptableNot assessed

Q52. Are any final control elements assigned a Safety Integrity Level (SIL) requirement? *

NoYesNot assessed

Q53. Is there a process to analyze SIS failures or demands and implement corrective actions? *

NoYesIn development

Q54. Are flammable-gas or toxic-gas detection systems in place where required by the hazard assessment? *

NoYesPartially installed / gaps identified

Q55. Have identified SIS gaps been analyzed, risk-ranked and assigned corrective actions? *

NoIn progressYesNo gaps identified

5. Advanced Process Control (APC)

Q56. Is non-linear level control used where process dynamics justify its application? *

NoYesNot assessed

Q57. Is mandatory certification required for combustion-control systems in the applicable jurisdiction, and is the requirement met where applicable? *

No requirement / not applicableRequirement exists and is metRequirement exists; gap identifiedNot assessed

Q58. Is oxygen-trim control used for applicable combustion-control applications? *

NoYesNot applicable

Q59. Are furnace or combustion-equipment dampers characterized and maintained to support control performance? *

NoYes, based on original commissioning onlyYes, reviewed after fuel or system changesNot applicable

Q60. To what level are cause-and-effect relationships between key process variables documented for operator training and troubleshooting? *

Directional change onlyDirection and approximate magnitude documentedDirection, magnitude and response time documentedNot completed

Q61. How are boilers, kilns, dryers, furnaces or other applicable combustion equipment started? *

ManualSemi-automatic with personnel present at the equipmentAutomatic from the control roomNot applicable

Q62. Has gain scheduling been implemented where control dynamics vary materially by operating condition? *

NoYesNot assessed

Q63. Are controllers that frequently operate outside their normal control mode investigated despite repeated tuning attempts? *

NoYesOnly when production impact is significant

Q64. Has process-systems analysis been performed to understand interactions between important control loops and plant constraints? *

NoYesIn progress

Q65. Have advanced regulatory control opportunities been evaluated to reduce process variability? *

NoYesIn progress

Q66. Has work been performed to identify operating-cost reduction opportunities through reduced process variability? *

NoYes, in selected areas while justifying APC projectsYes, as a regular statistical process-control or performance-improvement activityIn progress

Q67. Are advanced regulatory control functions such as feedforward, setpoint ramping, dead-time compensation or state-based tuning used? *

NoYesIn selected applications only

Q68. How are advanced process-control applications supported? *

Not applicableSite personnelApproved external or vendor supportCombined site and external support

Q69. Is there a state-based control strategy to support start-up, ramp-up, mode changes and planned shutdown? *

NoYesPartially implemented

Q70. Is Model Predictive Control (MPC) in use? *

NoAreas identified and base controllers being improvedImplemented in selected areasImplemented in economically attractive areas

Q71. Does MPC handle relevant mode changes automatically where required? *

NoYes, applicable mode changes are handled within MPCNot applicable; no significant mode changesNot assessed

Q72. What is the online utilization of MPC applications? *

Not applicableLess than 50%Between 50% and 80%Greater than 80%Not measured

Q73. Has procedural automation been evaluated or implemented in line with ISA-106 principles for activities such as sequencing, equipment changeover, start-up or shutdown? *

NoYesIn progress

6. Process Modelling and Real-Time Optimization (RTO)

Q74. How is the plant currently modelled for performance analysis? *

Simple material balance or separation model in a spreadsheetLumped-parameter heat and material balance modelFully integrated process modelNo current model

Q75. How often are models used to reconcile heat and material balances and identify measurement issues? *

NeverAfter turnarounds or major changesMonthly before plant-performance reportingRegularly / online

Q76. Does the model automatically update relevant information from the process data historian or laboratory information system? *

NoYes, but much data is manually enteredYes, less than 10% entered manuallyYes, automated data update

Q77. Is Real-Time Optimization (RTO) implemented in the facility? *

NoConceptual or pilot stageFully implementedNot applicable

Q78. What is the purpose of the models currently used? *

Not applicableValidate material balanceScenario or debottlenecking analysisTrack performance in real timeCalculate economic operating targets

Q79. Does RTO assign targets or setpoints to APC applications or selected basic controllers? *

Not applicableNoYesPlanned

7. Control System Upgrade and Lifecycle Management

Q80. How many control rooms operate within the facility? *

Three to five control roomsTwo control roomsSingle integrated control roomOther

Q81. Is a control-system upgrade or lifecycle-management plan in place? *

NoYes, multi-year plan existsYes, multi-year plan is under implementation

Q82. Do packaged-equipment control panels require local field-operator intervention? *

YesNo; major OEM panels are integrated for monitoring but local control remains for start-upNo; major OEM panels are integrated for monitoring and supervisory setpoint interactionNot assessed

Q83. How many separate monitoring systems must control-room operators use to perform their duties? *

Three or more systemsTwo systemsOne common user interfaceNot assessed

Q84. Are 'first-out' identification graphics available for major shutdown logic? *

NoYesPartially available

Q85. Has a control-room ergonomics or human-factors study been completed? *

NoYesIn progress

Q86. Are any control-system components using an unsupported operating system? *

NoYesNot assessed

Q87. Is an inventory maintained for all PLC and SCADA components, including items supplied by Original Equipment Manufacturers (OEMs)? *

NoYesPartially complete

Q88. Is an annual maintenance or support agreement in place with the DCS/PLC system provider or approved service provider? *

NoYesNot applicable / internal support

Q89. What is the approximate number of control loops monitored by one control-room operator? *

More than 300 loopsBetween 100 and 300 loopsLess than 100 loopsNot measured

Q90. What is the level of integration of local PLCs, including OEM-supplied systems, into the central control system? *

LowMedium; major equipment connected for monitoring onlyHigh; monitoring and approved remote-setpoint capability existNot assessed

Q91. When was the control system last substantially upgraded? *

More than 10 years agoBetween 5 and 10 years agoWithin the past 5 yearsNot known

Q92. Is redundant control processing available in the PLC/DCS architecture where required? *

NoOnly where critical control or shutdown logic is executedYes, consistent with plant control philosophyNot assessed

Q93. Have control systems been audited for cybersecurity risk and compliance with the business owner's requirements? *

NoYesIn progress

8. Manufacturing Execution and Production Information Systems

Q94. Is a process data historian or operational data platform available for the facility? *

NoYesPartially implemented

Q95. Has an asset framework or structured equipment hierarchy been created within the operational data platform? *

NoIn progressImplemented

Q96. Is the facility operational data platform connected to a corporate or enterprise information platform? *

NoYesNot applicable

Q97. What is the Manufacturing Execution System (MES) or equivalent production-information capability currently used for? *

No formal systemProduction reporting and performance managementProduction schedulingQuality or laboratory integrationMaintenance and asset-performance integrationOther

Q98. Has a Production Management System (PMS) or Manufacturing Execution System (MES) capability assessment been completed for the facility? *

NoIn progressYes

Q99. What information is integrated into the MES or equivalent production-information capability? *Select all that apply

Process data historianProduct-quality / laboratory informationRegulatory complianceMaintenance dataFinancial informationEngineering data sheets and drawings

Q100. Is the MES or equivalent production-information capability used for production planning and scheduling? *

NoYesPartially

Q101. Does the MES hierarchy align with the asset framework or equipment hierarchy used in the ERP or maintenance system? *

NoIn progressImplemented

Q102. Which resource-management functions are supported through the MES or integrated business systems? *Select all that apply

Equipment maintenance managementLabour / certification / training managementMaterial or warehouse managementNone

Q103. Is the MES or integrated planning system used for supply-chain scheduling? *

NoYesPartially

Q104. Are data analytics used within production-information processes to generate operational intelligence alerts or improvement opportunities? *

NoYesPilot / limited use

9. Engineering and Control System Documentation

Q105. 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? *

Documents exist but status is not verifiedUpdated within the last 5 yearsAvailable electronically for read accessAvailable in a controlled document-management system

Q106. What is the status of I&C documents such as instrument data sheets, instrument index, loop diagrams, wiring diagrams and control-system network diagrams? *

Documents exist but status is not verifiedUpdated within the last 5 yearsAvailable electronically for read accessAvailable in a controlled document-management system

Q107. What is the status of operator manuals and operating guidance documents? *

Documents exist but status is not verifiedUpdated within the last 5 yearsAvailable electronically for read accessAvailable in a controlled document-management system

Q108. How often are operating procedures reviewed and revised? *

Not reviewed within the last 10 yearsAt least every 5 yearsUpdated following major MOC or operating changeDefined periodic review and change-based update

Q109. Is Radio-Frequency Identification (RFID) or another electronic tagging approach used for identifying equipment? *

NoPilot stageFully implementedOther technology used

Q110. Is audio-visual documentation available for complex operating or maintenance procedures? *

NoYesIn development

10. Technical Training and Capability

Q111. Is instrumentation calibration carried out using qualified resources available to the site? *

NoYesPartially / dependent on external support

Q112. Who carries out DCS and PLC maintenance functions? *

Business owner personnelApproved service providersHybrid model using bothNot defined

Q113. Are relevant staff trained and authorized to perform DCS/PLC configuration changes within their systems? *

NoYesLimited to designated staff only

Q114. Is qualified SIS or functional-safety competency available to support the facility? *

NoYesAvailable through approved external support

Q115. Is a technical training program in place for DCS technicians? *

NoYesIn development

Q116. Is a technical training program in place for instrumentation technicians? *

NoYesIn development

Q117. Are process-control engineers or equivalent technical support resources available to the site? *

NoYesAvailable through central or contracted support

Q118. Is a training simulator available for operator training? *

NoYesPlanned

Q119. Are DCS technicians trained using control-system simulator software or an equivalent safe training environment? *

NoYesPlanned

Q120. Are DCS technicians trained in advanced control functions such as feedforward, dead-time compensation, signal characterization, condition blocks and lead-lag functions? *

NoYesPartially

Q121. Are analyzer or instrumentation-maintenance staff trained or certified by the equipment manufacturer or approved training provider where required? *

NoYesPartially

Q122. How often are control-room operators retrained or reassessed for competency? *

Once during initial qualificationAnnuallyPeriodically according to the competency programOther

Q123. Are alarm and event records reviewed to coach control-room operators and promote consistent response across shifts? *

NoYesInformally only

Q124. Are operators trained in effective graphics navigation and response to abnormal situations, start-up and shutdown scenarios? *

NoYesPartially

Q125. Are operator training manuals updated to reflect current control configuration and graphics changes? *

NoYesIn progress

Q126. Does I&C staff have access to relevant international instrumentation and process-control standards? *

NoYesLimited access

Q127. Does the facility have access to qualified functional-safety personnel appropriate to its SIS needs? *

NoYesVia approved external support

Q128. Is a structured control-room operator training and competency program in place? *

NoYesIn development

11. Site-Specific Challenges and Priorities

Q129. Field instrumentation: What are the principal measurement, analyzer or final-control-element pain points? (optional)No facility names, locations, or confidential details please.

Q130. Process control: What are the principal challenges in keeping key process parameters on target and within approved operating limits? (optional)No facility names, locations, or confidential details please.

Q131. How could improved process control or instrumentation reduce risks identified through incident review or LOPA (Layer of Protection Analysis)? (optional)No facility names, locations, or confidential details please.

Q132. Which three facility challenges could be addressed through improved instrumentation, control or operational analytics? State the reason. (optional)No facility names, locations, or confidential details please.

Q133. Which five critical equipment reliability or performance challenges could be reduced through improved instrumentation, monitoring or control? State the reason. (optional)No facility names, locations, or confidential details please.

Q134. Rank the following improvement areas based on current facility challenges: *Select one priority level for each row.

Instrumentation required for identified risk-reduction actions

UrgentHighMediumLowN/A

Replace obsolete or unsupported instruments

UrgentHighMediumLowN/A

Improve alarm management

UrgentHighMediumLowN/A

Improve controller operation in correct mode

UrgentHighMediumLowN/A

Additional engineered controls instead of administrative controls

UrgentHighMediumLowN/A

Improve process data historian / operational data platform

UrgentHighMediumLowN/A

Instrumentation for critical-equipment monitoring

UrgentHighMediumLowN/A