Secrets to Unlocking Complete Operational Integrity
DynAMo® Alarm ManagementTyron Vardy (Honeywell)
June 2018
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Defining Operational Integrity
1
To secure a process plants integrity is to reduce
the risk to its people, its process and its assets;
to maximize performance and to minimize the impact of
abnormal situations.
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Defining Operational Integrity
2
To secure a process plants integrity is to reduce
the risk to its people, its process and its assets;
to maximize performance and to minimize the impact of
abnormal situations.
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Defining Operational Integrity
3
To secure a process plants integrity is to reduce
the risk to its people, its process and its assets;
to maximize performance and to minimize the impact of
abnormal situations.
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
4
Defining Operational Integrity
To secure a process plants integrity is to reduce
the risk to its people, its process and its assets;
to maximize performance and to minimize the impact of
abnormal situations.
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Unlocking Operational Integrity
5
DynAMo® Alarm Management
• Alarm Management is structured and well defined (ISA, EEMUA, ASM, IEC, API)
• From Alarm Capture, to Alarm Reporting, to Alarm Management, to Situational Awareness
• But there is more to this story.
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Unlocking Operational Integrity
6
DynAMo® Alarm Management
• Alarm Management is structured and well defined (ISA, EEMUA, ASM, IEC, API)
• From Alarm Capture, to Alarm Reporting, to Alarm Management, to Situational Awareness
• But there is more to this story. More potential to unlock greater Safety and Performance.
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
7
Alarm Management
Reduce alarm noise
Clarity to operators for
real alarms
Guiding operations
through abnormal
situations
De-risking the process
Operations Management
Defining safe
operating limits
Staying within those
operating limits
Elevating communication
for safer operations
Protecting people, process
and assets
Operational Integrity Building Blocks
Combined Value
Compliance to industry
standards and best
practices
Predict abnormal
situations
Understand the cause of
an upset to return to
normal, safe control -
faster
Reducing Risk Securing IntegrityMinimize Abnormal Situations
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Industries Approach to Operational Integrity
8
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
9
Causes of Abnormal Situations• 40% of Abnormal Situations caused by
Human Error
• 40% caused by Process Violations
- Operating outside process limits
- Equipment Failure (75% attributed to above)
- API Required Practice 584 for
Integrity Operating Windows
Backed by Research from Global Industry Experts
Human Error, 40%
Process Violations, 40%
Other, 20%
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
10
Human Error
Equipment Failure
Other
Causes of Abnormal Situations
• 40% of Abnormal Situations caused by Human Error
• 40% caused by Equipment Failure
- 75% of those failures caused by operating outside of equipment limits
- API Required Practice 584 for Integrity Operating Windows
Backed by Insights from Global Industry Analysts
By integrating alarm management
with operations management
reduces one of largest causes of
incidents in the process industry
today:
abnormal situations
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
11
Alarm
Management
Reducing alarm noise and operator
error through effective
alarm management
Honeywell’s Approach to Operational Integrity
Operations
Management
Driving informed decisions and
operational compliance through
safe operating practices
DynAMo® Suite
Process Safety Analytics
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Identify the Problem
12
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
13
• Eliminate Areas of Weakness and Greatest Risk
• Operator Role Complexity Analysis (ORCA)
• Operator Interviews and Observations
• Control System Interaction
• Ergonomic Environment
• Operator Workflow
• Process Complexity
• “To help operators make safe decisions in a timely manner”
• Results of ORCA Identify Areas of Improvement
• ASM Graphics, Reduction in Control Room Noise, Lighting
• Improved Alarm Management Practices and Operational Workflow
• Safety Bypass Management, Shift Handover Processes
Identify the Problem
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
ASMC June 2014 QRM14
Poor Alarm Management
Good Alarm Management
Alarm and Operations Management
Impact of Good Alarm Management
14
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Alarm ManagementRisk Reduction
15
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Alarm Management Risk Reduction
16
Primary Risk
• 1250 alarms per day
• Alarms that aren’t really alarms
• What does ‘LC728-1A FAIL’ actually mean?
Secondary Risk
• Non-compliance
• Unplanned downtime
• Slow recovery from abnormal situations
Objective
• Reduce Alarms Noise by 60-80%
• Provide real-time Alarm Help and Operator Guidance
• Provide Situational Awareness and real-time Collaboration
• Give advanced warning of Abnormal Situations
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Step 1: Benchmark and track alarm performance
17
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Step 2: Identify assets most at risk from alarm flooding
18
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Step 3: Assess operator console workload
19
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Step 3: Assess operator console workload
20
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Step 4: Unlock the knowledge and drive the improvement
21
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Step 4: Unlock the knowledge and drive the improvement
22
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Step 5: Don’t forget the last 20-40%. They make all the difference
23
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Operator GuidanceRisk Reduction++
24
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
25
Document (or pre-load) detailed Alarm Help and Operator Guidance to assist the Operators
decision making process. More thinking time equals safer operations.
Asset Service Type Setting Causes Consequence Corrective actionTime to
Respond
CFECharge Pump A
Suction StrainerPDAH 10kPa Suction strainer plugged
Reduced flow,
possible pump
damage
Switch to standby pump, initiate
strainer cleaning procedure> 15 min
FSDFeed Surge
DrumLAL 20%
FIC set incorrectly down stream
feeding the unit above available
feed quantity, feed upset in
upstream unit
Unit trip
Confirm flow of fresh feed from
upstream and flow to the
reactors. Correct imbalance to
stabilize and restore level
< 5 min
FSDFeed Surge
DrumLAH 80%
Upsream unit feed increased
without increasing NHT feed rate,
decreased NHT reactor charge
Full Feed Surge
Drum
Reduce flow into FSD from
upstream unit or increase feed
to NHT after Feed Surge Drum
5 - 15 min
CFECharge Pump B
Suction StrainerPDAH 10kPa Suction strainer plugged
Reduced flow,
possible pump
damage
Switch to standby pump, initiate
strainer cleaning procedure> 15 min
Embedded Operator Guidance
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
26
Document (or pre-load) detailed Alarm Help and Operator Guidance to assist the Operators
decision making process. More thinking time equals safer operations.
Asset Service Type Setting Causes Consequence Corrective actionTime to
Respond
CFECharge Pump A
Suction StrainerPDAH 10kPa Suction strainer plugged
Reduced flow,
possible pump
damage
Switch to standby pump, initiate
strainer cleaning procedure> 15 min
FSDFeed Surge
DrumLAL 20%
FIC set incorrectly down stream
feeding the unit above available
feed quantity, feed upset in
upstream unit
Unit trip
Confirm flow of fresh feed from
upstream and flow to the
reactors. Correct imbalance to
stabilize and restore level
< 5 min
FSDFeed Surge
DrumLAH 80%
Upsream unit feed increased
without increasing NHT feed rate,
decreased NHT reactor charge
Full Feed Surge
Drum
Reduce flow into FSD from
upstream unit or increase feed
to NHT after Feed Surge Drum
5 - 15 min
CFECharge Pump B
Suction StrainerPDAH 10kPa Suction strainer plugged
Reduced flow,
possible pump
damage
Switch to standby pump, initiate
strainer cleaning procedure> 15 min
Embedded Operator Guidance
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
27
Deliver it Directly to the Operator
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
ASMC June 2014 QRM28
Good Alarm Management
Alarm and Operations Management
Next Step to Operational Integrity
28
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Operations ManagementSecuring Integrity through Safe Operations
29
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
30
Console Operation
Planning
Ensuring operations know
exactly what planners,
schedulers and optimizers
need for that shift.
Effective communication
of operating plans to
produce what the
business actually needs
Operating within
Safe and Defined
Limits
Ensuring Operations
deliver on the plan
and operate to that
plan within safe
operating limits.
Protecting the
people, the
equipment, and the
process
Tracking and Validation
of the Operating Plan
Track shift performance
against defined plans.
Highlight and document
deviations from operating
plans.
Deviations lead to process
risk, damaged equipment,
and poor performance
Secure Shift
Handover Process
Adopting a best practice
for automated shift
handover and takeover
processes.
Ensuring all deviations,
critical alarms, safety
bypasses etc. are
effectively captured and
communicated
The Building Blocks of Operations Management
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
31
A Typical Shift Trend
Operating between the alarm limits
alarm limit
alarm limit
process
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
32
What About Those Other Limits
How safe are we really operating?
alarm limit
alarm limit
process
alarm limit
alarm limit
fouling
equipment
damage
planning
target
planning
target
economic
feasibility
process
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
33
Before Alarm and Operations Management
How safe are we really operating?
alarm limit
alarm limit
process
alarm limit
alarm limit
fouling
equipment
damage
planning
target
planning
target
economic
feasibility
process
Sub-optimal Performance
35% Safe Zone Operation
High Risk of Safety Incidents,
Equipment Damage and Abnormal Situations
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
34
After Alarm and Operations Management
Stay within the plants limits for safer operations
alarm limit
alarm limit
process
alarm limit
alarm limit
fouling
equipment
damage
planning
target
planning
target
economic
feasibility
process
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
35
After Alarm and Operations Management
Stay within the plants limits for increased safety and production
alarm limit
alarm limit
process
alarm limit
alarm limit
fouling
equipment
damage
planning
target
planning
target
economic
feasibility
process
Sub-optimal Performance
95% Safe Zone Operation
High Risk of Safety Incidents,
Equipment Damage and Abnormal Situations
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Step 1: Operate within safe limits. On every shift.
36
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Step 2: Identify excursions from safe operating windows
37
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Step 3: Document Deviations and Secure Shift Handover Processes
38
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
The Power of Integration
39
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Reduce Alarms Secure Integrity Reduce Risk
Stale and Standing Alarms
Safety Bypasses and Inhibits
Critical Alarm Limits
Boundaries and Constraints
Limit Deviations
Excursions from Safe Operations
Windows
Secure Shift Handover Process
40
The Power of Integration
40
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Alarm and Limit Documentation Visualized in Experion
41
The Power of Integration
41
Direct to Where the Operator Needs It
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
42
Alarm Management
Reduce alarm noise
Clarity to operators for
real alarms
Guiding operations
through abnormal
situations
De-risking the process
Operations Management
Defining safe
operating limits
Staying within those
operating limits
Elevating communication
for safer operations
Protecting people, process
and assets
The Story So Far..
Combined Value
Compliance to industry
standards and best
practices
Predict abnormal
situations
Understand the cause of
an upset to return to
normal, safe control -
faster
DynAMo®
Alarm Management
DynAMo®
Operations ManagementDynAMo®
Alarm and Operations
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Process SafetyContinuous Innovation
43
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
44
Alarm
Management
Reducing alarm noise and operator
error through effective
alarm management
Introducing Process Safety Analytics
Operations
Management
Driving informed decisions and
operational compliance through
safe and profitable operating practices
DynAMo® Suite
Process Safety Analytics
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
45
Alarm
Management
Reducing alarm noise and operator
error through effective
alarm management
Introducing Process Safety Analytics
Operations
Management
Driving informed decisions and
operational compliance through
safe and profitable operating practices
DynAMo® Suite
Process Safety Analytics
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
46
Process Safety Analytics
Latest addition to the DynAMo Suite.
Deployed with or without DynAMo.
Leverages any Alarm and Event Database.
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
47
Process Safety Analytics
1. Shutdown Cause and Effect Analysis
2. Safety Valve Integrity Analysis
3. SIL Analytics for Demand Rate Assessments
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Shutdown Cause and Effect Analysis (Planned and Unplanned)
48
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Safety Value and Final Element Integrity Analysis
49
Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
SIL Analytics for Demand Rate Assessments (Safety Instrumented Functions)
50
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
52
Alarm
Management
Reducing alarm noise and operator
error through effective
alarm management
Operations Integrity….Achieved
Operations
Management
Driving informed decisions and
operational compliance through
safe and profitable operating practices
DynAMo® Suite
Process Safety Analytics
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
53
Alarm
Management
Reducing alarm noise and operator
error through effective
alarm management
Operations Integrity….Achieved
Operations
Management
Driving informed decisions and
operational compliance through
safe and profitable operating practices
DynAMo® Suite
Process Safety Analytics
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
DynAMo® SuiteAlarm Management · Operations Management · Process Safety Analytics
Take the Free 14 Day Test Drive at www.hwll.co/dynamo
Questions?