OptiPlant AI
3 DCS
Portal:Process Intelligence/Smart Alarms
Active Alarms

10

56% reduction via AI dedup (28 of 64 raw)

By Severity

3 / 4 / 3 / 0

Crit / High / Med / Low

Avg Time-to-Ack

42 s

Target: 60 s βœ“

AI Root-Cause Accuracy

78%

Correct in last 30 days

Floods Suppressed Today

4

182 raw β†’ 12 consolidated

Active Alarms β€” AI-Prioritized

πŸ”΄14:27:10ns=2;s=PA.PaintShop.CureOven01.Zone2_PVTemperature high (178.4 > 175.0 Β°C)"Burner 2 modulation lag, gas regulator drift β€” 87%"
3 related
UNACK
πŸ”΄14:22:49ns=2;s=PA.Battery.Formation03.Cell_Voltage_STDCell voltage std > 0.05 V"Rack 47 hot cell (thermal imaging) β€” 92%"
2 related
ACK J.Novak
πŸ”΄14:18:22ns=2;s=PA.Utilities.CH-03.RefrigerantPressureLow refrigerant (8.2 bar < 10 bar)"Slow leak ~3 kg since Apr 14. Schedule service. β€” 89%"
1 related
UNACK
🟠14:14:05ns=2;s=PA.Utilities.AC-03.Motor_Current_UnbalCurrent unbalance 4.8% > 3%"Rotor bar degradation β€” 76%"
UNACK
🟠14:13:38ns=2;s=PA.PaintShop.Booth03.SupplyAirTempLow supply air (16.2 < 18.0 Β°C)"AHU-Paint cooling coil valve stuck open β€” 81%"
1 related
UNACK
🟠14:08:11ns=2;s=PA.WWTP01.EffluentNH3Ammonia rising (2.9 mg/L, permit 3.5)"Aeration DO drop correlated 8 min prior β€” 85%"
2 related
ACK
🟠14:05:52ns=2;s=PA.PaintShop.PCP-03.Vibration_RMSVibration RMS 6.1 mm/s > 5 mm/s"Bearing wear β€” 79%"
UNACK
🟑14:01:19ns=2;s=PA.Body.WR-02.J3_CurrentAxis-3 current > spec"Axis 3 servo drive thermal β€” 72%"
UNACK
🟑13:58:44ns=2;s=PA.Utilities.CompAir01.DewpointDewpoint rising (+4.2Β°C vs baseline)"Dryer desiccant saturation β€” 88%"
UNACK
🟑13:54:02ns=2;s=PA.PaintShop.Phosphate.BathTempSlow drift upward"Steam valve hunting β€” 74%"
ACK

Alarm Flood Console

Root-Cause Graph β€” Alarm #1

GasRegulatordrift detectedBurner 2mod lag Β±4%Zone2_Temp178.4 > 175 Β°CDefectRiskpaint cure impactOp SP Change 13:40172β†’175 Β°Cρ=0.87ρ=0.82β†’ qualitycontributing
AI analysis (87%): Primary cause: Burner 2 modulation lag since 13:52, evidenced by gas flow oscillation Β±4%. Contributing factor (41%): operator SP increase at 13:40 tightened control margin. Recommended: revert SP to 172Β°C and schedule burner inspection.

Alarm Co-occurrence Matrix β€” Last 30 Days

Fraction of times two alarms fire within 2 min. Click a hot cell for drill-down.

Z2 temp-high
GasFlow low
Z2 deviation
AC-03 current
PlantAir low
ECoat pH high
Film-build OOS
Booth hum. low
Orange-peel
Phosphate temp
Z1 temp-high
Z3 temp-high
Z2 temp-high
GasFlow low
Z2 deviation
AC-03 current
PlantAir low
ECoat pH high
Film-build OOS
Booth hum. low
Orange-peel
Phosphate temp
Z1 temp-high
Z3 temp-high
Four alarm dyads account for 68% of co-occurrence volume. Consolidating these into "compound alarms" would cut operator cognitive load by an estimated 28%.

Temporal Causal Chain Explorer

Confidence β‰₯70%
-60m-55m-50m-45m-40m-35m-30m-25m-20m-15m-10m-5mnowGasHeader pressureZ2_PVZ2 temp-high alarmOperator action Z2 SPBPFO vibration AC-03Alarm flood indicatorPaint quality alarmsWO creation eventsBPFO amplitude rise 4.2β†’6.1 mm/s (t=-45m)Gas header pressure 4.3β†’3.9 bar (t=-8m)Flood: 14 alarms in 90s (t=-6m)Low-pressure alarm cascade (3) (t=-4m)WO-10254 created (AC-03 bearing) (t=-2m)Gas header dip to 4.0 bar (t=-35m)Z2_PV climbing 174β†’176Β°C (t=-31m)Operator: Z2 SP 172β†’175Β°C (t=-20m)Z2_PV 177.2Β°C (approaching limit) (t=-12m)Zone 2 temp-high alarm 178.4Β°C (t=0m)Film-build out-of-spec (t=2m)WO-10255 created (burner service) (t=5m)Baseline vibration 3.8 mm/s (t=-55m)Gas header normal 4.5 bar (t=-50m)Z2_PV stable 173.2Β°C (t=-48m)Operator: routine SP check (t=-42m)4 min (91%)Gas dip β†’ Z2 climb β€” lag 4 min, confidence 91%35 min (87%)Z2 climb β†’ temp-high alarm β€” lag 35 min, confidence 87%2 min (85%)Temp alarm β†’ quality impact β€” lag 2 min, confidence 85%37 min (78%)Bearing β†’ pressure dip β€” lag 37 min, confidence 78%2 min (82%)Pressure dip β†’ alarm flood β€” lag 2 min, confidence 82%2 min (76%)Flood β†’ downstream alarms β€” lag 2 min, confidence 76%8 min (72%)SP increase β†’ PV climb β€” lag 8 min, confidence 72%
Two parent causes explain 11 of the 12 recent alarms: (1) gas header pressure dip propagating to Z2 oven, (2) AC-03 bearing degradation propagating to plant air pressure.

Alarm Volume β€” Last 24 h (Raw vs. AI-Consolidated)