nvrb & honeywell symposium - pss 21-11-18 rb0 · honeywell’s process safety suite automates...
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Process Safety Suite - WorkbenchNVRB & HONEYWELL SYMPOSIUMRudi Bott
21-11-2018
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Process Safety Suite
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Seamlessly Connecting the Safety Lifecycle Inside One System
Today the key information in the Process Safety Lifecycle is
handled through many manual
and disconnected steps.
Honeywell’s Process Safety Suite automates this lifecycle helping
to reduce errors, lower costs,
continuously monitor operations for hazard conditions and
provide safety alerts in a timely
fashion.
Compliant with ISA-84 / IEC 61511
SafetyBuilder
Figure 1. Data Model Enabling “Loop-backs”PSA1st
UAS2nd
CMMS
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Process Safety Suite Overview
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Single Source of Truth for Process Safety
One enterprise-level software to manage the entire process safety lifecycle
Centralize & Synchronize Data flows consistently from one system to the next to eliminate errors and inconsistencies
Higher quality with fewer resourcesImprove productivity of expensive/scarce design resources in the FEED process after the PHA
Monitor performance to Minimize RiskUse data from Historian to validate designs or flag issuesUp to date Dashboard of Risk Today
Seamlessly Connecting the Safety
Lifecycle Inside One System
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
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Data all in a single “model”. No manual transfer from step to step
Hazard Identification
Risk Analysis � Solutions
Solution Details Install, ValidateOperate & MaintainToday
PHA Report LOPA ReportSRS with Calcs. Investigations
Fault &
Success
Test Reports
Refresh Site Risk Assessments
Automated Data Transfer
Manual Data Transfer
Test
Plans
Design & Engineer
Logic diagrams & Safety Builder programming
Manager
Safety C&E Matrix
Validation Report
Process Safety
SuitePHA
Report
LOPA
Report
SRS
Report
C&E
MatrixInvestigations
Fault &
Success
Test Reports
Refresh Site Risk AssessmentsAutomated Data Transfer
Manual Data Transfer
Test
Plans
Design & Engineer
Manager
Safety Validation
Report
Hazard Identification
Risk Analysis � Solutions
Solution Details Install, ValidateOperate & Maintain
Automating the Process Safety Lifecycle
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
• Single enterprise solution
• IEC 61511 / ISA-84 Compliant
• Seamless data transfer
• Single point of data entry
• Concurrent users and projects
• Unlimited users (multiple EPCs)
• Company standards and libraries
• Save man-hours by utilizing templates
• Manage competencies with user permissions
• Revision controls to support stage/gated process
Reduce man-hours - Drive consistency - Ensure functional safety
Process Safety SuiteCompliant with ISA-84 / IEC 61511
SafetyBuilder
Figure 1. Data Model Enabling “Loop-backs”PSA1st
UAS2nd
CMMS
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Start anywhere!
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Better Analysis at Reduced Cost. Improve safety of operations
There are several logical places to get started:
1. Process Hazard Analysis (PHA) / Layers of Protection Analysis (LOPA) � Whether it’s the Initial project PHA or the Five year Revalidation
� Transfer your current PHA from all major tools into PSS Workbench
2. Confirming or redoing your SIL calcs.� Build your SRS in Process Safety Suite Workbench. Save time and
money and set yourself up for step 3
3. Confirm your systems are working as intended� Compare actual plant results using PSA with intentions from PHA, LOPA
& SRS
OPERATESAFELY
30+ years
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Monitor & Sustain
Process Safety Design Data
ANALYTICS ENGINE
Daily Operating Data
BIG DATA
Real-time Instrument
Data
Real-time Maintenance
Data
PHD & PSA
Intelligent Business Decisions
BENCHMARK
89%Operating Data
Design Basis
Contributing Factors Source Impact
Excessive Bypassing PHD 4% ↑
Excessive Demands PHD 2% ↓
Late Testing CMMS 5% ↑
Frequent Failures CMMS 3% –
Process Safety Suite
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Typical Architecture7
• Safety Instrumented Systems• Fire & Gas Detectors• DCS based IPLs• Control Valves• Other edge devices
Plant 1 Plant 2 Plant 2
Honeywell Cyber Secure Network
Process Safety Workbench
Cloud Historian
Safety Lifecycle Analyzer
Process Safety Analyzer – to be moved to Cloud
Asset Sentinel
Customer 1 Customer 2
.
.
Customer N
Process Safety Suite
Sentience/ MS Azure
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Process Safety Suite Components
• Process Safety Workbench (Works with Safety Builder)
Consolidates all the tools, synchronizes the information for seamless transfer and revision control, and represents the single source of truth for your process and functional safety data.
• Process Safety Analyzer (part of DYNAMO)
Is an advanced software that automates tracking, analysis and reporting on operation of shutdown systems and safety elements, to promptly detect issues and continuously ensure process safety
• Safety Lifecycle Analyzer
Interfaces with operating data such as process historians and maintenance management systems provide the insight required to make better business decisions regarding testing, planned outages, safety system performance, and future capital project spend
• Process Safety Services
Encompass the total safety lifecycle and are designed to help our customers improve and extend the usage of their applications and the benefits they deliver, ultimately maintaining and safeguarding their advanced applications.
8
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
9
• Streamline Audits and FSA’s
• Supports Bypass Management
• Management of Change
• Functional Testing
• Incident Investigations
• Excessive Demands Tracking
• Excessive Bypass Tracking
• On-Time Testing Monitoring
• Failure Collection
• Spurious Trip Identification
• Manage Failure Rate Library
• Three Layers of Voting
• Calculate PFD, RRF, & MTTFs
• Test and Diagnostic Coverage
• Partial Stroke Testing
• Common Cause Factors
• Accounts for IEC 61511 “Shalls”
• What If’s / Option Engineering
• Graphical Architecture
• Multiple Logic Solvers
FunctionalSafety
Operations & Maintenance
• PHA/LOPA Tightly Integrated
• Cause or Consequence Based
• Flexible Library Settings
• Recommendation Tracking
• Cause Summing
• Data Migration Tools
• Multiple Risk Matrices
• Complete Reporting
• Gap Assignments
• Configurable Checklists
Process Safety
Process Safety WorkbenchCompliant with ISA-84 / IEC 61511
SafetyBuilder
Figure 1. Data Model Enabling “Loop-backs”PSA1st
UAS2nd
CMMS
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Greenfield - Reduced Hours
Reduce man-hours - Drive Consistency
SILVerification
SRSDocuments
C&E Matrices
TestProcedures
Savings up to ¹ 45%
¹ Using templatization features within Process Safety Workbench
2 Assuming 35% copy factor & $6M Functional Safety Engineering
Hours per SIF
Traditional Workbench
On a typical $10Bn Facility Engineering savings calculated to be
$2.7M+ 2
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Key Software Features
• Concurrent users
• Simultaneous projects
• Enterprise solution
• Competency management
• Version control
• Status reporting
• Multiple installation options
• Varying support packages
• Numerous training courses
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Safety Builder separate pricing
12
• Safety Builder engineering tool provides full support of the Safety Manager platform (Planning & Design, Installation & Upgrades, Engineering, Operations and Troubleshooting & Maintenance).
• IEC 61508 & 61131 compliant Configuration Management & Audit Trail logs.
• TÜV approved logic library and approved online modifications.
• Graphical layout with easy drag-and-drop hardware and software configuration.
• Multi-layer password protected access with configurable time-out.
• System Information screens provide detailed information on performance, usage of system and application variables and diagnostic log files.
• Online documentation and help screens.
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Process Safety Suite Components
• Process Safety Workbench (inc. Safety Builder)
consolidates all the tools, synchronizes the information for seamless transfer and revision control, and represents the single source of truth for your process and functional safety data.
• Process Safety Analyzer (part of DynAMo)
is an advanced software that automates tracking, analysis and reporting on the operation of shutdown systems and safety elements, to promptly detect issues and continuously assure process safety
• Safety Lifecycle Analyzer
Interfaces with operating data from DynAMo PSA or process historians and maintenance management systems to summarize risk status “today”. Enable better business decisions regarding testing, planned outages, safety system performance, and future capital project spend.
• Process Safety Services
encompass the total safety lifecycle and are designed to help our customers improve and extend the usage of their applications – like Process Safety Suite - and the benefits they deliver, ultimately maintaining and safeguarding their safe performance.
13
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Process Safety Analyzer (PSA)
• PSA automates the process of validating shutdown systems and safety elements.
• It continually examines the Event Journal1, looking for issues
- High demand?
- Performance of the SIFs
• PSA flags problems like:
- A safety system is in Bypass
- Possible overdue inspection(e.g. valve supposed to be stroke-tested annually but hasn’t moved in 35 months)
- Valve is moving slowly (possible “sticktion”)
- SIF101 has been activated 1/month on average vs design = 1/year
• Uses Cause & Effects Matrix for what should happen
• Feeds data back to PS Suite Workbench & Lifecycle Analyzer
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Analytics to find and display Weak Links using Data you already collect
1 From any vendor
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
PSA - Shutdown Analyzer
• Detect and flag issues to Operations & Maintenance
• Opportunity to reduce planned shutdowns by using unplanned
• Reduced time and effort for validation
• Validated record of safety operations
• Complies with Good Engineering Proactices ISA-S84/IEC-61511
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
• Improved Safety- Continuous validation using planned AND unplanned operations
- Early identification of issues
- Excellent input to Reliability and to PHA teams during revalidation
• Increased Uptime- Faster restarts after unplanned shutdowns, through faster validation
- Reduce unplanned shutdowns through early fault detection
• Efficient work processes- Simplified / automated verification of SIS/PSD/PCS & final elements
- Exception based safety inspection & testing
- Helps identify root causes & nested shutdowns
• RAGAGEP compliance & auditability
PSA – Benefits
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Process Safety Suite Components
• Process Safety Workbench (inc. Safety Builder)
consolidates all the tools, synchronizes the information for seamless transfer and revision control, and represents the single source of truth for your process and functional safety data.
• Process Safety Analyzer (part of DYNAMO)
is an advanced software that automates tracking, analysis and reporting on the operation of shutdown systems and safety elements, to promptly detect issues and continuously ensure process safety
• Safety Lifecycle Analyzer
Interfaces with operating data such as PSA and maintenance management systems like SAP/Maximo to provide the insight. Roll-up KPIs to corporation allow better business decisions regarding testing, planned outages, safety system performance, and future capital project spend – w/o Admin burden
• Process Safety Services
encompass the total safety lifecycle and are designed to help our customers improve and extend the usage of their applications and the benefits they deliver, ultimately maintaining and safeguarding their advanced applications.
17
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Safety Lifecycle AnalyzerWorks with PSA to Validate Design with Operations to Minimize Risk Daily/Weekly/Monthly
Daily activities made simple…
• Device / function testing
• Bypass / override support
• Incident investigations
• Turnaround extensions
• Safety audits and FSAs
• Management of change (MoC)
Corporate roll-up KPIs
• Corporate Hierarchy in the Tool
• Functional Safety Index displayable at any level
• Periodic KPI reports
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Monitor & Sustain
Process Safety Design Data
ANALYTICS ENGINE
Daily Operating Data
BIG DATA
Real-time Instrument
Data
Real-time Maintenance
Data
PHD & PSA
Intelligent Business Decisions
BENCHMARK
89%Operating Data
Design Basis
Contributing Factors Source Impact
Excessive Bypassing PHD 4% ↑
Excessive Demands PHD 2% ↓
Late Testing CMMS 5% ↑
Frequent Failures CMMS 3% –
Process Safety Suite
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Process Safety Suite Components
• Process Safety Workbench (Links to Safety Builder)
consolidates all the tools, synchronizes the information for seamless transfer and revision control, and represents the single source of truth for your process and functional safety data.
• Process Safety Analyzer (part of DYNAMO)
is an advanced software that automates tracking, analysis and reporting on the operation of shutdown systems and safety elements, to promptly detect issues and continuously ensure process safety
• Safety Lifecycle Analyzer
Interfaces with operating data such as process historians and maintenance management systems provide the insight required to make better business decisions regarding testing, planned outages, safety system performance, and future capital project spend
• Process Safety Services
encompass the total safety lifecycle and are designed to help our customers improve and extend the usage of their applications and the benefits they deliver, ultimately maintaining and safeguarding their advanced applications.
20
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Process Safety Services
• Honeywell’s Process Safety Services encompass the total safety lifecycle and are designed to help our customers improve and extend the usage of their applications and the benefits they deliver, ultimately maintaining and safeguarding their advanced applications.
• Honeywell provides a complete portfolio of service offerings to extend the life of your assets and provide a cost-effective path forward to the latest application technology. Honeywell services include:
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Clients choose Honeywell to improve Safety & Performance
• Process Hazard Analysis (PHA) • Layers of Protection Analysis (LOPA) • Reliability Calculations • Safety Requirements Specification (SRS) • Cause & Effects • Functional Test Procedures
• Software installation • On-site engineering • Migration & Scope Expansion Services • Assessment services • Performance baseline and Tuning • Customized training
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.