Sustain.Ability. Alarm Management: Be Pro-active, not Re-active Honeywell Users Group Europe, Middle East and Africa. Tyron Vardy, Honeywell

Transcription

1 Sustain.Ability Honeywell Users Group EMEA 2014 Honeywell Users Group Europe, Middle East and Africa Alarm Management: Be Pro-active, not Re-active Tyron Vardy, Honeywell

2 Agenda Introduction Defining Alarm Management Introducing Operations Management Unified Alarm and Operations Management turns Reactive Operators into Proactive operators Sustainable Improvement Programme 3 pillar approach to sustained improvement Infrastructure and alarm noise reduction Critical Operating Limits and Production Envelopes, Workflow Integration with Secure Shift Handovers Alarm Rationalization Integrated Programme of Improvement Driving Safety, Compliance and Profitability 2

3 Agenda Situational Awareness How Mobility platform delivers enhanced Visibility and Communication One site, or one hundred sites? Scalable Architecture Deployable, Cost Effective Foundation Future Proofing Investment Ensures Enterprise Assurance Every asset is fully compliant Legal, Insurance, Company Goals etc. Grows as you Grow Problem Solving Solution 3

4 4 Alarm Management

5 Process by which alarms are engineered, monitored and managed to ensure safe, reliable operations EEMUA 191 Industry best practice is a combination of good Alarm Management aligned to effective operational workflow. Typically the focus is on alarm and noise reduction, reliable operations is a critical success factor to improvement. 5

6 The Role of an Alarm 40% of Process Upsets due to Human Error Unplanned Downtime Safety Alert, Inform, Guide Alarm Limit Critical Limit Fouling Limit Energy Efficiency Limit Production Dependability Costs/Effort Why wait for the Alarm? 6

7 Alarm Management The Need for Alarm Management Primary Drivers Regulatory Compliance and Alarm Reporting Safety Reduction in Alarm Noise Management of Critical Limits/Safety Bypass/Inhibits Secure Shift Handovers Secondary Drivers Improved Operations Reduction in Trips and Downtime Increased and Sustained Throughput» Operating Envelopes Improved Asset Availability Tertiary Drivers Operator Knowledge Retention, Operator Assistance Reduced Maintenance Costs Insurance 7

8 Alarm Management Additional Benefits Reduced Alarm Stress and Increased Operator Thinking Time Early Event Detection Faster Recovery from Abnormal Situations (i.e. Back to Normal Operations) Standard and Consistent Operator Responses to Alarm Situations Share Operational Knowledge in Ageing Workforce Industry Leaders Reduced unplanned downtime by 50% (up-to 80%) Increased abnormal situation recovery by 80% Minimize Deviations and Predict Abnormal Situations (each operating deviation costs significant $$$$, impacts Safety, Reliability, Quality, Energy) 8

9 9 Alarm Management Solution

10 Alarm Management Alarm Management Solution DynAMo Alarm Management Reporting, Metrics, Improvement Tool Master Alarm Database, Alarm Response Manual Management of Change Dynamic Alarming, Enforcement Honeywell Supporting Services Alarm Philosophy Document Improvement Plan (Alarm, ORCA) Asset Benchmarking and Assessment Alarm Rationalization 10

11 Alarm Management The process by which alarms are engineered, monitored, and managed to ensure safe, reliable operations. PHILOSOPHY IDENTIFICATION RATIONALIZATION MANAGEMENT OF CHANGE DETAILED DESIGN AUDIT IMPLEMENTATION OPERATION MAINTENANCE MONITORING & ASSESMENT ANSI/ISA , Alarm Management Lifecycle 11

12 Alarm Management The Need for Alarm Management Primary Drivers Regulatory Compliance and Alarm Reporting Safety Reduction in Alarm Noise Management of Critical Limits/Safety Bypass/Inhibits Secure Shift Handovers Secondary Drivers Improved Operations Reduction in Trips and Downtime Increased and Sustained Throughput» Operating Envelopes Improved Asset Availability Tertiary Drivers Operator Knowledge Retention, Operator Assistance Reduced Maintenance Costs Insurance 12

13 Alarm Management The Need for Alarm Management Primary Drivers Regulatory Compliance and Alarm Reporting Safety Reduction in Alarm Noise Management of Critical Limits/Safety Bypass/Inhibits Secure Shift Handovers Secondary Drivers Improved Operations Reduction in Trips and Downtime Increased and Sustained Throughput» Operating Envelopes Improved Asset Availability Tertiary Drivers Operator Knowledge Retention, Operator Assistance Reduced Maintenance Costs Insurance 13

14 Alarm Management The Need for Alarm Management Primary Drivers Regulatory Compliance and Alarm Reporting Safety Reduction in Alarm Noise Management of Critical Limits/Safety Bypass/Inhibits Secure Shift Handovers Secondary Drivers Improved Operations Reduction in Trips and Downtime Increased and Sustained Throughput» Operating Envelopes Improved Asset Availability Tertiary Drivers Operator Knowledge Retention, Operator Assistance Reduced Maintenance Costs Insurance 14

15 15 Operations Management

16 Process by which operating practices are engineered to ensure the highest levels of efficiency, safety, and operational risk reduction MIT 16

17 The Role of Operations Management 75% of Equipment Failure due to Operating Outside Limits (ASM) Impact to Safety, Product Quality; Deviating from Limits Active monitoring of critical limits. Alert, inform, guide. Document critical deviations. Enable operators to stay within safe and profitable production envelopes. Capture shift observations. Bad acting alarms, safety bypasses, long term standing alarms and overrides. Secure the Shift Handover (take-over) Align to best practices from ASM, ISA and EEMUA. Embed into daily operations and existing solutions to ensure compliance. 17

18 Operations Management The Need for Operations Management Primary Drivers Regulatory Compliance and Alarm Reporting Safety Reduction in Alarm Noise Management of Critical Limits/Safety Bypass/Inhibits Secure Shift Handovers Secondary Drivers Improved Operations Reduction in Trips and Downtime Increased and Sustained Throughput» Operating Envelopes Improved Asset Availability Tertiary Drivers Operator Knowledge Retention, Operator Assistance Reduced Maintenance Costs Insurance 18

19 Operations Management The Need for Alarm and Operations Management Primary Drivers Regulatory Compliance and Alarm Reporting Safety Reduction in Alarm Noise Management of Critical Limits/Safety Bypass/Inhibits Secure Shift Handovers Secondary Drivers Improved Operations Reduction in Trips and Downtime Increased and Sustained Throughput» Operating Envelopes Improved Asset Availability Tertiary Drivers Operator Knowledge Retention, Operator Assistance Reduced Maintenance Costs Insurance 19

20 Unified Alarm and Operations Management The Need for Alarm and Operations Management Primary Drivers Regulatory Compliance and Alarm Reporting Safety Reduction in Alarm Noise Management of Critical Limits/Safety Bypass/Inhibits Secure Shift Handovers Secondary Drivers Improved Operations Reduction in Trips and Downtime Increased and Sustained Throughput» Operating Envelopes Improved Asset Availability Single Integrated Solution One Project, One Platform, 3 Month ROI Tertiary Drivers Operator Knowledge Retention, Operator Assistance Reduced Maintenance Costs Insurance Alarm Management Operations Management 20

21 Unified Alarm and Operations Management Safety Availability Profitability Throughput 21

22 Complicated to Achieve? Structured Improvement Program 22

23 Improvement Program Alarm System Best Practices Industry Leaders Improvement Program Software Services Operations 23

24 Alarm Management Alarm Management Solution DynAMo Alarm Management Reporting, Metrics, Improvement Tool Master Alarm Database, Alarm Response Manual Management of Change Dynamic Alarming, Enforcement Honeywell Supporting Services Alarm Philosophy Document Improvement Plan (Alarm, ORCA) Asset Benchmarking and Assessment Alarm Rationalization 24

25 Improvement Program Alarm Management Operations Management Alarm Rationalization Dynamic Alarm Suppression Infrastructure (APD, Benchmarking, Plan) Monitoring of Safe and Critical Limits Causes, Consequence, Corrective Actions DynAMo Alarm Management (M&R, MAD, ARM, MOC, D&E) Alarm Rationalization Operating Production Envelopes Secure Shift Handover Alarms v Alerts Smart Alarms Process Pillar 1 Pillar 2 Pillar 3 25

26 Improvement Program Sustainable Improvement is a Continual Process Achieve step-by-step benefits depending on timetable, resource capabilities and current state of alarm management maturity. Phase 1a Phase 1b Phase 2a Phase 2b Alarm Management Infrastructure Operations Management Identify and Eliminate Bad Actors (Alarm Noise) Create an Alarm Improvement Plan Focus on areas of biggest risk and areas of greatest return Integration Alarm Develop Rationalization an Alarm Philosophy Monitoring Generate of EEMUA, Critical ISA Limits compliant and Boundary KPI assessment Management reports Understand Embed KPI Reports the Drivers into Organization and Ensure Buy-in Workflow with Monitor quantifiable and Document deliverables Deviations of Critical Limits and Foundation Deliver Causes, Alarm Consequences, for Help a solid directly Alarm Corrective to System Operator Actions Improvement Stations Programme Dynamic Excursions Fixing Alarm 3 alarms/week Suppression from Plan can equate to a 60% reduction in bad Integrate Is this a Real Alarms Alarm? and Should Operations it be for an Secure Alert? Shift handover Predictive actors Integrate Alarm over into Managementa one Shift month Handovers period Smart Alarming Be Operate sure to within act on Desired the findings Production Envelopes 26

27 Improvement Program Align to Best Practice and Known Standards Pillar 1 Alarm Management Pillar 2 Operations Management Pillar 3 Alarm Rationalization 27

28 28 Improvement in Action

29 Improvement in Action Alarm Management Operations Logbook Operations Monitoring Alarm Reporting Standards Compliance & KPIs Alarm Loading Improvement Master Alarm Documentation Operator Assistance Alarm Suppression, Bypass and Inhibits Secure Shift Handovers Auditable Document of Record Critical Limit Documentation Compliance and Approvals Critical Limit Deviations Excursions from Production Envelopes Functional Limit Ownership PSM Safety Limits 29

30 Pillar 1 Alarm Management 30

31 Improvement in Action Pillar 1: Alarm Management Infrastructure Site Audit to determine the Goals, Issues and Gaps, ORCA Alarm Philosophy Creation Development of the Improvement Plan Alarm Management Metrics & Reporting, Alerts & Notifications EEMUA 191/ISA 18.2 KPI Reporting and Assessment Documentation & Enforcement Master Alarm Database Alarm Response Manual Management of Change 31

32 Alarm Management Enabling Technology The Technology DynAMo Alarm Suite Metrics & Reporting Documentation & Enforcement Alerts & Notifications Captures, stores, measures and analyzes real-time alarms Customizable, role-based dashboard Alarm & event historian Automated alarm assessment Alarm KPI reporting Alarm analysis reports Universal connectivity Vendor neutrality Creates and maintains the master alarm and boundary database for a control system Alarm Help Set-point Enforcement Mode-based alarming Structured Management of Change Framework to assist alarm rationalization Vendor neutrality Monitors and provides alerting of process conditions where notifying operators is useful but alarms are not appropriate Configurable conditions to monitor Notification of Alerts Vendor neutrality 32

33 33

34 34 Identify Weak, Overloaded Units. Don t wait for the Abnormal Situation to Cause Problems. Target greatest returns on time and effort.

35 35 Typical Report to Satisfy Insurance Companies

36 Pillar 2 Operations Monitoring 36

37 Improvement in Action Pillar 2: Operations Management Operations Monitoring Monitoring and Documenting Critical Deviations Alarm Limits, Equipment Limits, Environmental Limits etc. Conformance to Defined Production Envelopes Operations Logbook Alarm Metrics into Daily Workflow Secure Shift Handovers Alarm Help Integration to Operator Panels 37

38 Operations Monitoring Predict Deviations from Plan. Prevent Abnormal Situations. Be Pro-active. 38

39 Operations Monitoring Easy to see deviations from limits any limits, environmental, equipment, safety, optimal production envelopes etc. 39

40 Operations Monitoring Early Event Detection. See units deviating from plan or operating envelope. Each Deviation costs $$$$, or negatively impacts Safety, Reliability, Asset Availability... 40

41 Pillar 2 Operations Logbook 41

42 42 Operations Logbook

43 Operations Logbook Direct automated integration to Operations Monitoring Reports Direct automated integration to Process Historian Automatically populated, reduce operator error, reduce handover time, ensure consistent entries and easy access for knowledge sharing Direct automated integration to Alarm Management Solution Documentation of Inhibits, Bypasses, Safety Alarms IEC62682 Global Standard 43

44 Improvement Programme Alarm Management Operations Management Alarm Rationalization Dynamic Alarm Suppression Infrastructure (APD, Benchmarking, Plan) Monitoring of Safe and Critical Limits Causes, Consequence, Corrective Actions DynAMo Alarm Management (M&R, MAD, ARM, MOC, D&E) Operating Production Envelopes Alarms v Alerts Smart Alarms Secure Shift Handover Process Pillar 1 Pillar 2 Pillar 3 44

45 Unified Suite Drives Real Operations Integration 45

46 Alarm and Operations Management Alarm Management Operations Logbook Operations Monitoring Stale and Standing Alarms Safety Bypasses and Inhibits Critical Alarm Limits Boundaries and Constraints Secure Shift Handover Process Critical Limit Deviations Excursions from Production Envelopes CPM Integration Coming Soon Same platform, same architecture, same interface 46

47 Alarm Help Integration to Experion Integration With Experion R410 New tab in Alarm Summary Details. Alarm Help sourced from DynAMo Server via Experion. More Details calls DynAMo Web where operator can access all related data like settings for different modes. 47

48 Alarm Help Integration to Experion Provides alarm help where the operator needs it Zero integration effort No custom engineering Once invoked, can select other alarms from same point Link for more details 48

49 Want More Operations Integration? 49

50 Operations Performance Management Alarm Management Operations Logbook Operations Monitoring 50

51 Operations Performance Management Consolidate ALL Operations based KPIs into a single Role Based Dashboard Pre-defined metrics for most functional areas Alarm Management Operations Logbook Operations Monitoring 3 rd Party Systems 51

52 Operations Performance Management Intuition KPI Dashboard Shows business performance versus targets. User interface shows values, targets, and status. Track thousands of KPIs, retain history for years. Filter by equipment, categories, and status. Displays your Alarm Metric KPI s. Operations Metrics KPI s Deviations/Excursions Intuition KPI Dashboard 52

53 Scalable Architecture Delivers Enterprise Assurance 53

54 Enterprise Assurance Benefits Global Asset Performance Visibility, Benchmarking Visibility at Local and Corporate Levels Identify Weak Assets before its too late Knowledge sharing and Compliance across the Enterprise Standard Deployments Standard Training Consistent Operator Levels Ensure every Asset is at an Acceptable Level Small IT Infrastructure Intuition Ready 54

55 Gulf of Mexico England Denmark Venezuela Germany 55

56 Mobility Platform Drives Total Situational Awareness 56

57 Mobility Platform (HTML5) Alarm Management Operations Monitoring Operations Logbook 57

58 58 Summary

59 Summary Alarm Management Operations Logbook Operations Monitoring Alarm Reporting Standards Compliance & KPIs Alarm Loading Improvement Master Alarm Documentation Operator Assistance Alarm Suppression, Bypass and Inhibits Secure Shift Handovers Auditable Document of Record Critical Limit Documentation Compliance and Approvals Critical Limit Deviations Excursions from Production Envelopes Functional Limit Ownership PSM Safety Limits 59

60 Summary Every Standard Best Practice Businesss Driver (IEC62682, ISA.18.2) (EEMUA 191 Rev 3, ASM) 60

61 61 QUESTIONS?

62 Sustain.Ability Honeywell Users Group EMEA 2014 Honeywell Users Group Europe, Middle East, Africa Alarm Management: Pro-active, not Re-active Complete System Improvement with Alarm and Operations Suite Thank you.