DynAMo® Alarm Management - honeywellprocess.com · DynAMo® Alarm Management •Alarm Management is structured and well defined (ISA, EEMUA, ASM, IEC, API) •From Alarm Capture,

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.



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3






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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.


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.


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


Industries Approach to Operational Integrity

8


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%

http://www.asmconsortium.net/Pages/default.aspx


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

http://www.asmconsortium.net/Pages/default.aspx


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


Identify the Problem

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• 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


ASMC June 2014 QRM14

Poor Alarm Management

Good Alarm Management

Alarm and Operations Management

Impact of Good Alarm Management

14


Alarm ManagementRisk Reduction

15


Alarm Management Risk Reduction

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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


Step 1: Benchmark and track alarm performance

17


Step 2: Identify assets most at risk from alarm flooding

18


Step 3: Assess operator console workload

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Step 3: Assess operator console workload

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Step 4: Unlock the knowledge and drive the improvement

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Step 4: Unlock the knowledge and drive the improvement

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Step 5: Don’t forget the last 20-40%. They make all the difference

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Operator GuidanceRisk Reduction++

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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


Reduced flow,

possible pump

damage



Embedded Operator Guidance


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


Reduced flow,

possible pump

damage



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


Reduced flow,

possible pump

damage



Embedded Operator Guidance


27

Deliver it Directly to the Operator


ASMC June 2014 QRM28

Good Alarm Management

Alarm and Operations Management

Next Step to Operational Integrity

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Operations ManagementSecuring Integrity through Safe Operations

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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


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A Typical Shift Trend

Operating between the alarm limits

alarm limit

alarm limit

process


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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


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


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


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


Step 1: Operate within safe limits. On every shift.

36


Step 2: Identify excursions from safe operating windows

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Step 3: Document Deviations and Secure Shift Handover Processes

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The Power of Integration

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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

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Alarm and Limit Documentation Visualized in Experion

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Direct to Where the Operator Needs It


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


Process SafetyContinuous Innovation

43


44

Alarm

Management



alarm management

Introducing Process Safety Analytics

Operations

Management



safe and profitable operating practices

DynAMo® Suite



45

Alarm

Management



alarm management

Introducing Process Safety Analytics

Operations

Management




DynAMo® Suite



46


Latest addition to the DynAMo Suite.

Deployed with or without DynAMo.

Leverages any Alarm and Event Database.


47


1. Shutdown Cause and Effect Analysis

2. Safety Valve Integrity Analysis

3. SIL Analytics for Demand Rate Assessments


Shutdown Cause and Effect Analysis (Planned and Unplanned)

48


Safety Value and Final Element Integrity Analysis

49


SIL Analytics for Demand Rate Assessments (Safety Instrumented Functions)

50


Summary

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52

Alarm

Management



alarm management

Operations Integrity….Achieved

Operations

Management




DynAMo® Suite



53

Alarm

Management



alarm management

Operations Integrity….Achieved

Operations

Management




DynAMo® Suite



DynAMo® SuiteAlarm Management · Operations Management · Process Safety Analytics

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Documents

DynAMo® Alarm Management - honeywellprocess.com · DynAMo® Alarm Management •Alarm Management is structured and well defined (ISA, EEMUA, ASM, IEC, API) •From Alarm Capture,