2012 Honeywell Pacific Users Group. Sus tain.ability.

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1 2012 Honeywell Pacific Users Group Sus tain.ability. 1

2 2012 Honeywell Pacific Users Group Sus tain.ability. Nico Oosthuizen Effective Alarm and Operations Management 2

3 Topics Overview What is the problem? Why solve the problem? How to solve? Alarm Management Why is it needed? Product details and roadmap Operations Management Why is it needed? Product details and roadmap Summary Questions and Answers 3

4 What is the problem? Cause? Cause? Cause? Event Operating outside the envelope Effects Equipment reliability is not at industry norms/design expectations or necessary levels for production plans Unacceptable incident rate Operations plans rarely met 4

5 Why solve the problem? 20% - 80% (50% average) reduction in Unplanned Downtime Complete program can reduce the number and cost of incidents by 50% Other benefits 3% better capacity utilization 5% better energy utilization 5% better mechanical availability 5

6 How is the problem solved? Mixture of work processes and technology Develop Alarm Philosophy Work Practices for reviewing existing boundary and alarm information Work Practices for alarm Management of Change (MOC) Work Practices for alarm system monitoring and review Master repository of boundary, limit, alarm and alert information Operator performance analysis Mode-based alarming and alarm suppression Alarm system performance analysis Tools to offload the alarm system Incremental Change Big Bang not required! 6

7 Alarm Management: Background Remember when Alarms were indicators on panels Physically wired to instruments Cost was prohibitive Physical layout drew operators directly Now More process units under centralized control More alarms configured for fewer operators 7

8 Alarm Management: The Problem Too many alarms Overloaded operators Moving away from what alarms are suppose to do Alert the operator to a change in normal operation Inform the operator about the change Guide the operator to take corrective action (Key!) 8

9 Alarm Management: The Problem EEMUA 191 ANSI/ISA-18.2 Oil & Gas PetroChem Power Other Average alarms per day <144 (up to 288 may be manageable) ~150 (~300 may be manageable) Average standing alarms <10 <5 per day Peak alarms per 10 minutes < Average alarms per 10-minute interval 1 ~1 (~2 may be manageable) Distribution % (low/med/high) 80/15/5 80/15/5 25/40/35 25/40/35 25/40/35 25/40/35 9

10 Alarm Management: Why fix the problem? Shell Shearwater, North Sea, UK High standing alarm quantities and alarm floods during start-up, operating & plant trips Over 20,000 alarms configured with some having no priority 1,200 alarms per hour Solution Applied Alarm Configuration Manager to track alarm configuration and design Enforcement of design values back to DCS Key Benefits Reduced alarm rate from 1,200 per hour to just 288 per day Reduced number of trips per year Improved operator effectiveness, operators can concentrate on high priority alarms 10

11 Alarm Management: Why fix the problem? Kestrel Coal (Operator), Bowen Basin, Australia Maximum number of alarms exceeded EEMUA guidelines Existing alarm management system essentially useless (audible alarms disconnected and alarm page not used by operators) Solution Applied Alarm Manager power by Matrikon Honeywell alarm management expertise (consultants) Key Benefits 97% reduction in average daily alarm count Increased safety as high priority alarms clearly defined The root cause of alarms identified, providing the ability to focus maintenance and reducing plant downtime 11

12 Alarm Management: Why fix the problem? Irving Oil Refinery, Saint John, New Brunswick Too many configured alarms within the alarm system No definition of alarm philosophy and rationalization processes Operator overwhelmed with alarms during plant upsets Solution Applied Alarm Configuration Manager to manage alarms with daily enforcements UserAlert to offload some of the alarms from the DCS Key Benefits 35% reduction in the number of configured alarms Average daily alarm rate decreased by 45% Improved operator effectiveness, operators can concentrate on prioritized alarms Copyright 2011 Irving Oil 12

13 Alarm Management: Solution Tools Techniques and Procedures Standards and Guidelines Alarm Manager Alarm Configuration Manager Safety Reliability Efficiency Sustainability 13

14 Documentation and Rationalization Products Alarm Manager MOC Web-based application Monitors control systems and changes to any control system configuration Notifies appropriate people Automate your Configuration Tracking Automatically create an audit trail of all changes, and who made the changes 14

15 Documentation and Rationalization Products Alarm Configuration Manager (ACM) Context Sensitive Operator Alarm Help Audit and Enforcement of Alarm Settings Mode Based Alarm Handling (dynamic configuration settings) Boundary Management operate within the constraints Capture complete alarm rationalization data Enterprise-wide web viewer 15

16 Metrics and Reporting Products Alarm Manager A&E Seamlessly collect and store alarm and event data from any data source Automatically generate web-based, standards-compliant key performance indicator reports for an accurate snapshot of current alarm system performance Identify problem areas & compare against industry standards Quickly identify the highest ROI changes to your automation system 16

17 Metrics and Reporting Products Alarm & Event Analysis (AEA) Measure alarm system performance Follow up and fix root causes Extensive pre-configured reports that can be ed to a distribution list periodically Analyze alarm system performance against industry benchmarks 17

18 Monitoring and Notification Products UserAlert Keep operators well informed under normal conditions without being overwhelmed during process upsets Decrease alarm flooding Early detection of abnormal situations Combination alerts Keep users informed of situations unrelated to alarms Integrated with Experion Alert Summary Display 18

19 Alarm Manager Developments AM MOC Additional filtering options in discrepancy report and audit trail Tolerance threshold for engineered vs. DCS values Updated platform support for OS, Java, IE, SQL Server AM A&E 440 ISA 18.2-based KPIs Improved performance of standing alarm reports Web report enhancements Honeywell OPC A&E private key enabled 19

20 AAM Developments AAM (ACM, AEA and UserAlert) R320 Support for Experion R410 and TPS R420 ACM Alarm Help integrated with Experion R410 Updated platform support Improved ACM enforcement robustness Enhanced ACM support for Honeywell s Blending Movements Automation (BMA) ACM maintenance improved Shelved alarm tracking on Experion R310 or later Verification of standing alarm list with control system 20

21 Alarm Management Roadmap Suites Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 (Honeywell) Advanced Alarm Management R3xx Maintenance Release Minor enhancements Honeywell Alarm Manager R100 R200 R210 Common user interface Base functionality Standards compliance Extend features Complete integration Market driven enhancements (Matrikon) Alarm Manager Patch releases not shown A&E R440 Web report enhancements New KPIs A&E R441 MOC 306 Maintenance Release Minor enhancements IO Subject to Change

22 Building on Alarm Management Effective alarm management is imperative Safety, Environmental, etc. Does operating within alarm limits avoid all problems/effects? 22

23 OM Pro Operating Instructions Define and communicate the operating plan & targets ACM Define, enforce proper alarm limits Operations Monitoring Monitor all process limits, report on, and explain violations Boundary Management Manage safe operating limits & consequences UserAlert Monitor selected process limits and raise alerts to operators Operations Logbook Shift reporting and stewardship; record/explain happenings AEA Capture, analyze, and report on alarm metrics 23

24 Limit Repository Define the operating envelope Provides a comprehensive view of limits from many applications, making it possible to see limits together and in context, regardless of source single data model of the limit space (variables, boundaries, constraints, operating limits, modes) enables limits to be consistently managed (storage and retrieval) Used to integrate the OM Pro applications Can be used with other applications HI FSC Trip HI Safety Constraint PVHH HI Environmental Constraint HI APC OP Clamp 24

25 25 Limit Repository Operator View

26 Operating Instructions Helps business planner define daily/weekly operating targets Improved systematic communications between planning and operations Provides a work process for creating, validating, approving, and activating instructions Sets complete operating plans, not just key drivers Ensures targets are within boundary limits (e.g. flows, temperatures, pressure, corrosion, etc.) 26

27 Operations Monitoring Systematically monitor thousands of process variables Boundaries, planning targets, other limits Highlight problem areas Collect notes and observations, and assign follow-up 27

28 Did You Know? Approximately 80% of industrial operations lack a structured approach to shift handovers In 2002, a pipefitter was exposed to toxic chemicals at an undisclosed facility due to poorly documented tank maintenance procedure. The most common causes of incidents related to shift handover include poor logbook design and poorly conducted shift handovers. In 1968, a fire and explosion on the Piper Alpha offshore platform was attributed to poorly documented valve status. A fire and explosion at the BP refinery in Texas City, TX, in 2005 resulted from the failure to log shift startup procedure which, in turn, led to a flammable liquid overfill condition. 28

29 Operations Logbook Create shift handover reports Records shift notes and reports in one place Include alarms, deviations, instructions, and other highlights Use for shift orientation and shift team meeting Manage the shift handover process Creation, submission, approval, re-use Communicate shift information to managers and engineers 29

30 OM Pro Roadmap Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 OM Pro R400 OM Pro R320 OM Pro R310 OM Pro R300 OM Pro R Subject to Change

31 OM Pro R400 Development Programs Program R100 Program Monitoring R100 R110 R110 Program Logbook R100 Program R100 Instructions R100 Program R100 Alarm Management R100 Program R100 R200 Program R200 OM Pro R400 R400 Program R Subject to Change

32 Summary Improving the effective operations of your facility can be achieved by properly managing limits and the communication of those limits Can be involved and look overwhelming Start small, engage experts Alarm Management is an obvious, manageable starting point Expand to address comprehensive limit management Honeywell s OM Pro is unmatched in the industry! 32

33 33 Questions?

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