business process management - fhi · data/experion/uniformance phd prm web server history...

Business Process ManagementHolistic Boundary Management approachOperations Management [OMPRO]Global Asset Management Excellence [Game]Ensured Safe Production [ESP]

Productie Proces Automatiseringsdag4 december 2008

Cor B. GreuterCor B. GreuterAccount ManagerRefining, Energy, HPI

Automation & Control Solutions

[email protected]

Honeywell Process SolutionsLaarderhoogtweg 18NL-1101 EA, Amsterdam Z.O.+31 205 656 219 direct +31 205 656 236 fax+31 653 735 841 mobile

Honeywell Holistic Boundary Management2

Business Process Management why?


Topics

● Holistic Boundary Management

● Limitations of Current Practices

● Introducing Holistic Boundary Management

● How We Can Help

● How Does it Work

● Benefits of the Holistic Boundary Management

● Case Studies & References

● Project Approach

● Summary and Conclusions

Holistic Boundary Management Current Practice

• How is the Operating Envelope typically managed today?

• How does today's practice impact safety, reliability, and efficiency?

• What is the fundamental problem with today's practice?

• Why is the problem getting bigger and bigger?


Let’s Go For a Drive ….

Your Driver.The Road Ahead. The Result.

The Operator.The Process. The Result.


Current Practice● Operating Envelope is Not Managed

● Operating Envelope limited by individual alarms only● No 'other' limits are taken into account

● Alarm limits are static and stuck at some historical value● Limits are not owned, not centrally managed, and not updated

over time● Limits do not change with various modes of operation

● No insight in where the process is with regards to the Operating Envelope● How far can we still push the process? Is any equipment out of

bounds?

● No common, shared, boundary database● Limits not shared between planning, operations, maintenance,

engineering, lab, …

● No structural way of communicating the setpoints and Envelope● Getting planning targets to Operations

● No structural reporting on excursions outside the Envelope● When, how far, and for how long - and why

… 'No Alarm = No Problem'…… 'No Alarm = No Problem'…


Consequences of Current Practice● Reduced Safety

● Abnormal Situations arise that cause incidents/accidents● Abnormal Situations go undetected until they become an operational problem

● Reduced Reliability

● Only tracking/responding to critical limits (alarms)

● Abnormal Situations arise that impact equipment/asset lifetime

● Unexpected equipment failures and downtime

● Reduced Efficiency

● Too many and/or unnecessary alarms

● Disconnects between Business Planning, Production Operations, ProcesscontrolEngineering, Logistics, Quality Lab, Maintenance, Field operations…

● Abnormal Situations must be resolved first (resource drain)

● No visibility towards the Operating Envelope● Remaining capabilities, reduced energy costs, maintenance cost, …

… 'No Alarm ≠ No Problem' !… 'No Alarm ≠ No Problem' !


● The Abnormal Situation Management Joint Research and Development Consortium ('ASM Consortium')

● Group of 15 companies and universities that aims to identify problems during abnormal conditions, and to develop solutions

● ASM Vision

● "Operating teams empowered and enabled to proactively manage their plants, to maximize safety and minimize environmental impact, while allowing the processes to be pushed to their optimal limits"

Researching Abnormal Situations

www.asmconsortium.orgASM

ASM Charter Research the causes of abnormal situations and create technologiesto address this problem

ASM DeliverablesTechnology, best practices, application knowledge, prototypes, metrics

ASM HistoryStarted in 1994;Co-funded by US Govt (NIST);Budget of US$ 16M

ASM Charter Research the causes of abnormal situations and create technologiesto address this problem

ASM DeliverablesTechnology, best practices, application knowledge, prototypes, metrics

ASM HistoryStarted in 1994;Co-funded by US Govt (NIST);Budget of US$ 16M


What Causes Abnormal Situations?

More Than 15 'Serious' Events Per Month(significant damage, deaths)Source: ASM Consortium

40%

40%

20%

Human errorEquipment failureOther

Source: ASM Consortium

Cause of Process Upsets

76%

10%5% 5%

2%

2% Operating out ofrangeImproper design

ImpropermaintenanceNo defect found

Improper installation

Improper material

Presented by N Kosaric at 2005 Defect Elimination Conference

Cause of Equipment Failure

… How Can This Happen …?… How Can This Happen …?


Meaningful Boundaries - Managed!

Target

Operator Intervention

ESD

Control System

Normal

Upset

Shutdown

X = Alarm or Alert

Figure from Campbell-Brown, “Too Much of a Good Thing..” and EEMUA Publication 191

From This …

Alarms and Boundaries without philosophy and rationalisation

Target

Operator Intervention

ESD

Control System

Normal

Upset

Shutdown

… To This!

Alarms and Boundaries with a Philosophy

X

X XX

X

X

X

X

X

X

XX

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

XXX

X

X

X

X

X

X X

X

X

XX X

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

XX

X

XX

X

X

… A Structured is Approach Required …… A Structured is Approach Required …


● Operating Envelope Management Today

● 'No Alarm - No Problem'

Current Practice

One problem in a further perfect day

alarm limit

process

… Another Great Day in Operating History …… Another Great Day in Operating History …

All problems resolved, nothing else to report


● What Operating Envelope Management Should Be

● … Know your limits …

How Boundary Management is Different

alarm limitexcessivefouling

excessive fouling

economicfeasibility

economicfeasibility

planning targetprocess

why is the alarm limit here, anyway?

violating equipment parameters

until now, there has been increased fouling

violating equipment parameters

on-plan, but in-trouble

planning targets not met

planned operation beyond alarm limit

planning targets not met

planning targets changed but nobody knew

economicoperation

… Maybe It Wasn't Such a Great Day After All …… Maybe It Wasn't Such a Great Day After All …


The Problem Grows …

● Plants are Pushed More Than Ever Before

● Economic pressures

● New products, more products

● Increased flexibility, agility

● Fewer People to do More Things

● Tight staffing, people retiring

● Changing job descriptions

● Unstructured Knowledge

● Know-how in people's heads only

● Experience not captured and documented in systems

… Need To Take Action Now …… Need To Take Action Now …

Holistic Boundary Management Introducing the Holistic Approach

• How can we deal with this problem?

• What kind of approach is required?

• How can Honeywell help with this?


Honeywell Holistic Solutions

RegulatoryControl

Human Machine InterfaceAbnormal Situation Manager

Field DevicesAdvanced

Control

Wireless

Manufacturing Execution Systems (MES)

Optimization

Energy Management Solutions

Supply Chain Management

Training SimulatorsAsset Tracking RFID

Corrosion Detection and Monitoring

Process DesignInspection Services

Asset Management Solutions

Reliability Studies

Safety Shutdown Systems CCTV Surveillance

Perimeter MonitoringIntrusion Detection

Access Control

Gas Detection

Fire Detection Systems

Mustering Solutions, Alarms

Digital Video

Process Training

Honeywell Holistic Boundary Management16 Reviews, Reports Execution Decisions

Process Simulation & Design, Equipment & Catalysts

Field Instruments & Control Devices

Safe & Secure Environment

Common Data & Visualisation

Common Limits & Boundaries

Holistic, Integrated Automation


Limits Here, Limits There, Limits Everywhere!

Users of LimitsProceduresOperating alarmsWarning alarmsHAZOP limitsMaintenance limits (RCM, ODR)Environmental monitoringAPC limits and targetsOperational targets'Call-Joe' alarmCorrosion limitTrip settingsEconomic boundaries'Let-Bob-Know' limit

Source of Limits

Safety

Reliabilityxxxyyy

EnvironmentalCorrosion

Location of Limits

… How Do We Manage All These … ?… How Do We Manage All These … ?


● Facilitating and Structuring Work Processes

● Defining, Communicating, and Reporting on Boundaries

report results• performance• deviations• priorities• instructions• metrics• ad hoc

Next Day

record/explain• deviations• problems• things to do• shift handover

Current Shift

operators & engineers

other users

Current Hour

activateinstructions

operators & shift staff

set instructionsand targets

Previous Day

planning & scheduling

What Operations Management Does

Data/Experion/UniformancePHD ● PRM ● Web Server ● History

Operations Management (OMPro) applicationsset standard

operatingconditions

Monthly

planning &supply chain

manage quality data

lab staff

engineers,process experts

planning & scheduling

… Facilitating the Work Processes Around Boundaries …… Facilitating the Work Processes Around Boundaries …


Introducing Holistic Boundary Management

● Operations Management Pro ('OMPro') provides complete Boundary Management

● Comprehensive solution based on Consulting, Engineering, and Software

● Driven By

● Customer Requests - includes majors such as Shell, Exxon

● Existing Institutions & Standards - includes ASM, EEMUA, OSHA

● Honeywell Automation Experience

● Features include

● Ability to manage a (dynamic) master set of limits and boundaries

● Ability to apply limits to alarm enforcement

● Ability to monitor/report violations of any and all limits (incl. alarms)

● Ability to communicate and activate setpoints and boundaries

● Ability to automate and document shift handovers

… OMPro Manages the Entire Operating Envelope …… OMPro Manages the Entire Operating Envelope …


How Can We Help ?

● Assessment & Benchmarking

● Front-end Alarms & Boundaries study and benchmarking

● Boundary Management workshops and consulting

● Review other Operator Effectiveness aspects (Proc-Ops, HMIs, …)

● Alarms & Boundaries Rationalisation

● Workshops and consulting services

● Solution Implementation

● Alarms & Boundary Management solution (OMPro)

● Other Operator Effectiveness solutions

● Training

● Configuration

● Integration

● Benefit Retention

● Review and analysis of performance

● Identify additional improvements

Holistic Boundary Management How Does It Work

• How does OMPro work?

• What are the OMPro components?

• How does each of the components contribute towards Holistic Boundary Management?

• What does OMPro look like from an IT perspective?


OMPro: Complete Boundary Management

● Holistic Boundary Management Solution

● Structural solution for defining, communicating, monitoring, analysing, and reporting on the Operating Envelope


● Standard, Off-the-Shelf Components

● Pre-integrated solution with lifecycle support

OMPro: Solution Components

OM

AEA

Your DCS

ACM EAOI

OL

Your Historian

UAOM PROOM OM PROPRO

EM

LIMSLDI


Define Your Boundaries

● Defining (Managing) Your Boundaries

● Alarm Configuration Manager (ACM)

● Alarm Enforcer

COMMUNICATEDEFINE MONITOR ANALYSE REPORT


Alarm Configuration Manager (ACM)

● Management Tool and Central Repository for all Limits, Boundaries, and Alarms

● Heart of the OMPro solution - all OMPro components refer to this database

● Sharing the Experion Enterprise Model (common equipment definitions)

● Boundaries are controlled; structured; documented● Includes response, priority, consequences, reasons, actions, …

● Dynamic alarm configuration - Mode or State-Based alarming● Per equipment mode (shutdown, startup, idle), or product (grade A, B, transition)● Operator initiated or dynamically detected

● Implements full Management of Change (MoC)● Master Alarm Configuration: In Progress, Proposed, Approved, Released - and why● Control System: Audit, Enforcement, Logging

● Boundaries can selectively be forced down to the DCS (Alarm Enforcer)● Scheduled, or on demand; Defined list of tags, or per group or equipment● Must Enforce, Conditional, Report Only, Ignore; Report

● Secure 'full access' ACM client application, or web-based viewer

● Off-line mode to structure/build/approve definitions


Alarm (Boundary) Configuration Manager

Alarm (boundary) definitions;Full documentation and MoC;Operator Help

Web Viewer

Define equipment;Define constraints;

Map constraints to tags

Selectively enforce alarms in DCS


DEFINE

Communicating Your Boundaries

● Communicating the Operating Envelope

● Operating Instructions

COMMUNICATE MONITOR ANALYSE REPORT


Operation Instructions (OI)

● Controls workflow around setpoints and operating envelope

● Creating, Releasing, Queuing, Approving, Activation of Operating Plan● Can receive instructions from other applications (e.g. Scheduling Solutions)

● All data validation against boundaries in central Boundary Manager (ACM)● New settings also picked-up by User Alert, Ops Monitoring, …

● Structured electronic communication - avoid human error

● Instructions can contain values, notes, …

● Instructions are asset-oriented● Using common Experion Enterprise Model

● Several Instruction can be grouped in Production Orders


Operation Instructions (OI)

Detailed Instruction

List of Instructions


Monitoring Your Boundaries

● Monitoring Boundaries and Alerting Appropriate Personnel

● Operations Monitoring

● User Alert



Operations Monitoring (OM)

● Structural Monitoring of the Operating Envelope

● Monitors based on Operator Instructions and Boundary Manager (ACM)

● Reports deviations from the targets, boundaries, …

● Enter Reason Codes to explain excursions

● Calculate impact and economic consequences of deviations

● Designed to monitor thousands of variables with individual limits

● Suspends monitoring when defined equipment are down● for example, if a process unit is shut down



Entering Reason Codes and free-text comments

Graphical representation of how a boundary is exceeded



Tabular display of monitoring results

List of variables being monitored and their results


User Alert (UA)

● Notification System for the Others

● Personnel Alerts - Non-operator 'alarms'

● Sharing the Experion Enterprise Model (common equipment definitions)

● Early Detection of Potential Problems

● Smart alerts of complex process conditions

● Includes range, bit pattern, digital, boundary, rate of change, frozen, …

● Includes complex evaluations (combinations, and, or, xor, …)

● Improve detection capability by incorporating knowledge into system

● Remove Non-Alarm Conditions

● Offload alarm system

● Reduce operator error by offloading manual operator monitoring tasks

● Reduce operator error by offloading unnecessary 'alarms'

● Alert Appropriate Personnel Automatically

● Public or Personal alerts

● Display, e-mail, pager, SMS, …


User Alert (UA)

Building simple or complex conditions for monitoring

Alerts Explorer

Alerts Display


Analysing Your Boundaries

● Analyse and Review Alarms and Boundaries

● Alarm & Event Analysis (AEA)

● Event Analyst



Alarm & Event Analysis (AEA)

● Determining Metrics of Alarm and Event System

● Performance metrics (rates) - can be leading indicators of process safety!● Age of oldest, no. of standing, alarm rate, time to acknowledge,

priority distribution, bad actor reports, by console, by shift, …● Consistent with ASM guidelines and assessments

● Enforcements (via Alarm Configuration Manager)

● Scheduled (systematic) Reports

● Extensive pre-configured reports that can be customised

● Scheduled for periodic creation - end of shift, weekly, monthly, …

● E-mail to distribution list (.pdf .xls .doc)

● Interactive (ad-hoc) Analysis

● Drill-down to see data at a narrower scope● from Control System to Console to Alarm Group to Tag

● Create and save tailored report setups

● Export data to Excel

● Web-based Interface


Alarm & Event Analysis (AEA)

Title All Data

Last Complete

Month

Last Complete

Week 28 Day 7 Days ShiftDisplayed Alarms By Device Type X X XDisplayed Alarms By Alarm Type X X XAverage Alarm Rates X X X X XBad Actors - Top 20 X X XDaily Alarm Rate X X XDisplayed Alarms Priority Distribution X X X X X XDisplayed Alarms Priority Distribution XMaximum Alarm Rate X X X X X XMedian Alarm Rate XNumber Of Journalled Alarms XPeak Alarm Rate Distribution X X XTotal Repeating Alarms X X X X X XAlarm Duration X X XTime To Acknow ledge X XStanding Alarms X XStanding Stale Alarms X XStanding Disabled And Inhibited Tags XStanding Stale Disabled or Inhibited Tags XConfigured Alarms Priority Distribution XExceptions Summary X X X X XProcess Changes Rate Distribution X X XProcess Changes X X XLong Term Alarm Rate XJournalled Alarms X X X X X

Interactive (ad-hoc) analyses of Alarm & Events Scheduled (systematic)

analyses of Alarm & Events


Event Analyst (EA)

● Combines Continuous and Event Information

● Continuous: Continuous process variables from DCS/Historian

● Event: Discrete alarms and events from DCS/Historian

● Coordinated view of events and history - single display, single time axis

● Investigates Process Events and Their Sequence

● Review process trends, operator actions, alarms, and other events

● Capture, save, and share snapshots of the plant’s operation● Add user notes and comments

● Analyse and improve operating practices - - root-cause analysis

● Illustrate the symptoms of an upset

● Train operators in situation recognition


Event Analyst (EA)

Combining process trends and event data in a single display

Reporting trends and events

Filtering trendsand events


DEFINE

Reporting Your Boundaries

● Reporting (Handing Over) the Operating Envelope

● Operations Logbook

COMMUNICATE MONITOR ANALYSE REPORT


Operations Logbook (OL)

● Documents Shift and Handover

● Electronic log to record of what happens in a shift● Logs can be searched

● Log entries can be automatic and/or manual● Automatic recording of pre-defined events

– Includes information from Ops Instructions and Ops Monitoring

● Ad hoc entry of comments and observations

● To-Do List● Assigns, schedules, and tracks tasks and subtasks

● Prepares shift handover report

● Manages shift handover process● Submitting reports● Approving reports● Locking reports

OI

OM

ACM

Historian;Databases

Applications


Prerequisites

● Distributed Control System (DCS)

● Honeywell suggests you use Experion C300 ….

● .… but OMPro works equally well with non-Honeywell DCSes(1)

● Historian

● Honeywell suggests you use Uniformance PHD ….

● …. but OMPro works equally well with non-Honeywell Historians(1)

● Mindset

● “We know our limits and stay within them all the time”

● …. OMPro does not work without it !

(1) Applies to OMPro's Core Components. Some of the Optional Components require Uniformance PHD and/or Experion DCS


OMPro IT Structure (Example)

Process Historian:PI, Uniformance PHDFirewall

Control Room Workstations

Process Control LAN

OMPro Server 1Oracle / Apps / WebOracle 9i - OM/OI/OL DB- ACM DB

OM/OI/OL Application ServerOM/OI/OL Web ServerIIS 6.0Experion Desktop Server AEA Web ServerCrystal Enterprise ServerCrystal ReportsCrystal Analysis ProACM Manager Web ServiceACM Manager ServerACM Enforcer ProxyACM Web Server

Business LAN

OMPro Server 2SQL / AppsSQL Server 2000- Enterprise Model DB- User Alert DB- AEA DB- Experion Core Services DB- Base Components DB- EAS Event DB

MS Analysis ServicesExperion Application ServerACM Point ServerUser Alert ServerAEA Server

Desktop Clients:OM/OI/OL Web ClientAlert Summary ClientACM Web ClientAEA Web ClientUserAlert Explorer Client

Power User Clients:Same as Desktop and ControlRoom, additionally:ACM Administrator ClientACM Manager ClientAsset Model BuilderOther Configuration Tools

Control Room Clients:ACM Enforcer ClientsAlert Summary Client (EPKS Station)OM/OI/OI Web ClientAEA Web ClientACM Web ClientACM Manager Client (read-only)UserAlert Explorer Client

Enforcer (Proxy) ServerACM Enforcer ServerACM Enforcer Web ServiceACM Manager ProxyIIS 5.x or higherAEA CollectorMatrikon OPC Server

DCSComponents

Holistic Boundary Management Benefits of the Holistic Approach

• What are the benefits from Holistic Boundary Management?

• How does it address the original problem?


Benefits of Holistic Boundary Management

… Know Your Limits - And Stay Within Them - All the Time …… Know Your Limits - And Stay Within Them - All the Time …

vs. That …

This …

Holistic Boundary Management Case Studies & References

• Why and how are other Customers doing this?


World-Wide Implementation at Oil Major

● GAME (Global Asset Management Excellence) Program

● Corporate program affecting some 30 sites and some 20 000 staff● Refining, Oil & Gas, Chemicals

● ESP (Ensure Safe Production) Initiative● "We know our limits and run within them all of the time"

● A Customer Program Facilitated by Honeywell's OMPro, Implemented and Supported by Honeywell

● Multi-year partnership - combined know-how of Customer and Honeywell

● Pre-integrated, end-to-end solution with life-cycle support

● Huge Customer Investment, but Significant Savings Claimed

… Boundary Management as Corporate Initiative …… Boundary Management as Corporate Initiative …

Source: Richie Walker, Shell Global Solutions. Plant Success Conference,April 12, 2007


Consolidation at Chemicals Major

● New Manufacturing Excellence System Initiative ….

● Includes Operator Management and Operator Effectiveness functionality

● … Combined with Existing Alarm Management Initiative

● Includes Advanced Alarm Management Suite

● … Leads to Full OMPro Deployment

● A Customer Program Facilitated by Honeywell's OMPro

● Pre-integrated, end-to-end solution with life-cycle support

… Boundary Management Bringing it All Together …… Boundary Management Bringing it All Together …


Incremental Implementation at Oil Company

● Full Acquisition of OMPro Software Solution …

● … With Gradual Implementation

● A Customer Program Facilitated by Honeywell's OMPro, and Guided by Honeywell

… Boundary Management Applied Incrementally …… Boundary Management Applied Incrementally …

Holistic Boundary Management Project Approach

• Where to start Holistic Boundary Management on your site?

• What can Honeywell bring to the table?


From Vision to Reality

Honeywell Automation Assessment

Section scoreremainingopportunity

Operational Planning 60 40Operational Scheduling 60 40Operating Instructions 20 80Procedure Execution 20 80Process Control 50 50Operator Effectiveness 50 50Asset Effectiveness 50 50Procedure Analysis 10 90Operations Monitoring 15 85Yield Accounting; Allocations; M 50 50Boundary Management 50 50Performance Management 50 50Information Technology; Comm 40 60

… Our Consultants Will Help …… Our Consultants Will Help …

● Honeywell Consulting

● Alarm Management

● Workflow Management

● Procedural Operations

● Ergonomics (HMIs, …)


Standard Methodologies

● Abnormal Situation Management Consortium (ASM)

● Methodologies, standards, recommendations, know-how



The Big Picture

● Operator Effectiveness is More than Boundary Management

● Alarm Management

● Operating Envelope Management

● Managing alarms vs. Managing the plant

● Data vs. Information

● Training & Certification

● Procedural Operations

● Round Automation

● Displays, HMIs


Holistic Boundary Management Summary & Conclusions

• Take-aways from this presentation


Summary & Conclusions

● Holistic Boundary Management is Critical to Improve

● Safety – by avoiding abnormal situations that cause incidents/accidents

● Reliability – by avoiding abnormal situations that cause equipment failures

● Efficiency – by managing and streamlining the workflow

● Our OMPro Solution Enables Holistic Boundary Management

● Includes consulting, engineering, and standard software

● Structure solution with a structured approach

● Deployed and proven as a corporate initiative at major companies

● Honeywell Has Experience Deploying Boundary Management

● Corporate, world-wide programs

● Individual, site-based programs

… Know Your Limits - Stay Within Them - All the Time!… Know Your Limits - Stay Within Them - All the Time!


Frost & Sullivan Award 2008


Now Let’s Go For That Drive ….

Your Driver.The Road Ahead. The Result.

The Operator.The Process. The Result.