DYNAMO ALARM MANAGEMENT Product Director 28 September … · The Secret to Unlocking Operational Integrity. Tyron Vardy. DYNAMO ALARM MANAGEMENT. Product Director. 28 September 2017

The Secret to Unlocking Operational IntegrityDYNAMO ALARM MANAGEMENTTyron Vardy

Product Director28 September 2017

Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.

Defining Operational Integrity1

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.



To secure a process plants integrity is to reducethe risk to its people, its process and its assets;







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Defining Operational Integrity




Alarm Management: Unlocking Operational Integrity5

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.


Alarm Management: Unlocking Operational Integrity6


• 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.


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Alarm Management

Reduce alarm noise

Clarity over remaining alarms

Operator guidance in abnormal situations

Rationalize Alarms

Operations Management

Operate within safe limits

Protect equipment

Stay within efficient operating windows

Secure shift handovers

Operational Integrity Building Blocks

Incremental Value

Compliance to industry standards and best practices

Predict abnormal situations

Return to normal, safe control - faster

Reduce Risk Maximize PerformanceMinimize Abnormal Situations


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Alarm Management

Reducing alarm noise and operator error through effective

alarm management

Honeywell’s Approach to Operational Integrity


Driving informed decisions and operational compliance through

safe and profitable operating practices

DynAMo® Suite

Process Safety Analytics


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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

Operational Integrity: A New Industry Focus

By integrating alarm management with operations management reduces one of largest causes of incidents in the process industry today: abnormal situations caused by operator error

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


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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

Operational Integrity: A New Industry Focus

Human Error, 40%

Equipment Failure, 40%

Other, 20%

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


Identify the Problem

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• Eliminate the 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 QRM13

Poor Alarm Management

Good Alarm Management

Alarm and Operations Management

Impact of Good Alarm Management


Alarm Management

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Risk Reduction


Alarm Management Risk Reduction15

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

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Step 2: Identify Assets Most at Risk from Alarm Flooding

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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 Guidance

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Risk 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 action Time to Respond

CFE Charge Pump A Suction Strainer PDAH 10kPa Suction strainer plugged

Reduced flow, possible pump damage

Switch to standby pump, initiate strainer cleaning procedure > 15 min

FSD Feed Surge Drum LAL 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

FSD Feed Surge Drum LAH 80%

Upstream 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

CFE Charge Pump B Suction Strainer PDAH 10kPa Suction strainer plugged



Embedded Operator Guidance


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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 action Time to Respond

CFE Charge Pump A Suction Strainer PDAH 10kPa Suction strainer plugged



FSD Feed Surge Drum LAL 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

FSD Feed Surge Drum LAH 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

CFE Charge Pump B Suction Strainer PDAH 10kPa Suction strainer plugged



Embedded Operator Guidance


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Deliver it Directly to the Operator


ASMC June 2014 QRM27

Good Alarm Management

Alarm and Operations Management

Next Step to Operational Integrity



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Maximizing Safe and Profitable Performance


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Console Operation PlanningEnsuring 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 LimitsEnsuring 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 PlanTrack 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 ProcessAdopting 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 TrendOperating between the alarm limits

alarm limit

alarm limit

process


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What About Those Other LimitsHow safe and productive are we really?

alarm limit

alarm limit

process

alarm limit

alarm limit

fouling

equipmentdamage

planning target

planning target

economicfeasibility

process


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Before Alarm and Operations ManagementHow safe and productive are we really?

alarm limit

alarm limit

process

alarm limit

alarm limit

fouling

equipmentdamage

planning target

planning target

economicfeasibility

process

Sub-optimal Performance

35% Optimal Performance Per Shift

High Risk of Safety Incidentsand Equipment Damage


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After Alarm and Operations ManagementStay within the plants limits for increased safety and production

alarm limit

alarm limit

process

alarm limit

alarm limit

fouling

equipmentdamage

planning target

planning target

economicfeasibility

process


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After Alarm and Operations ManagementStay within the plants limits for increased safety and production

alarm limit

alarm limit

process

alarm limit

alarm limit

fouling

equipmentdamage

planning target

planning target

economicfeasibility

process

Reduction of Alarms and Abnormal Situations

95% Optimal Performance Per Shift

Significantly Reduced Safety and Equipment Risk


Step 1: Operate Within Safe Limits. On Every Shift.

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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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Alarm Management


alarm management

The Third Step to Operational Integrity




DynAMo® Suite



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Alarm Management


alarm management

The Third Step to Operational Integrity




DynAMo® Suite




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Unlocking the knowledge behind the noise


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1. Shutdown Cause and Effect Analysis2. Safety Valve Integrity Analysis

3. Intelligent Alarm Delay Analysis


Step 1: Shutdown Cause and Effect Analysis (Planned and Unplanned)

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Step 1: Shutdown Cause and Effect Analysis (Planned and Unplanned)

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Step 2: Real-time Risk Analysis for Process Safety Elements

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Step 3: Intelligent Alarm Delay Analysis for Optimal Deadband Settings

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Summary

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Alarm Management

Reduce alarm noise

Clarity over remaining alarms

Operator guidance in abnormal situations

Rationalize Alarms


Operate within safe limits

Protect equipment

Stay within efficient operating windows

Secure shift handovers

Operational Integrity… Achieved

Incremental Value

Compliance to industry standards and best practices

Predict abnormal situations

Return to normal, safe control – faster


DynAMo® Operations Management

DynAMo® Process Safety Analytics

Documents

DYNAMO ALARM MANAGEMENT Product Director 28 September … · The Secret to Unlocking Operational Integrity. Tyron Vardy. DYNAMO ALARM MANAGEMENT. Product Director. 28 September 2017