Stavros Chrysanthou Madrid DynAMo Alarm Management Secrets to unlocking complete Operational Integrity

Transcription

1 Stavros Chrysanthou Madrid 2018 DynAMo Alarm Management Secrets to unlocking complete Operational Integrity

2 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.

3 Defining Operational Integrity 2 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.

4 Defining Operational Integrity 3 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.

5 Defining Operational Integrity 4 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.

6 Alarm Management s Contribution 5 DynAMo Alarm Management 25 years of progress from Alarm Capture, to Alarm Reporting, to Alarm Management

7 Beyond Alarm Management Plant Limits Short Term Alarm Reduction Alarm Rationalization Profitable Operations Long Term Sustainability Software People Limits Requirements of Operational Integrity Operator Error Reduction Dynamic Alarming Performance Tracking Downtime Reduction KPI s Regulatory Compliance

8 Operational Integrity 7

9 Operational Integrity 8 Alarm Management Reduce alarm noise Clarity to operators for real alarms Guiding operations through abnormal situations De-risking the process

10 Operational Integrity 9 Alarm Management Reduce alarm noise Clarity to operators for real alarms Guiding operations through abnormal situations De-risking the process Reducing Risk 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 Minimize Abnormal Situations Operations Management Defining safe operating limits Staying within those operating limits Elevating communication for safer operations Protecting people, process and assets Securing Integrity

11 Backed by Insights from Industry Analysts 10 Causes of Abnormal Situations 40% of Abnormal Situations caused by Human Error 40% caused by Equipment Failure Human Error By integrating alarm management Equipment Failure with operations management Other reduces one of largest causes of incidents in the process industry today: abnormal situations - 75% of those failures caused by operating outside of equipment limits - API Required Practice 584 for Integrity Operating Windows

12 Backed by Research from Industry Experts 11 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 Causes of Abnormal Situations Other, 20% Process Violations, 40% Human Error, 40%

13 Honeywell s Approach to Operational Integrity 12 DynAMo Suite Alarm Management Reducing alarm noise and operator error through effective alarm management Operations Management Driving informed decisions and operational compliance through safe operating practices Process Safety Analytics

14 Alarm Management Risk Reduction 13

15 Alarm Management Risk Reduction 14 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

16 Step 1: Benchmark and track alarm performance 15

17 Step 2: Identify assets most at risk from alarm flooding 16

18 Step 3: Assess operator console workload 17

19 Step 4: Unlock the knowledge and drive the improvement 18

20 Step 5: Don t forget the last 20-40%. They make all the difference 19

21 Operator Guidance Risk Reduction++ 20

22 Embedded Operator Guidance 21 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 Reduced flow, possible pump damage Switch to standby pump, initiate strainer cleaning procedure > 15 min

23 Embedded Operator Guidance 22 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% 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 Reduced flow, possible pump damage Switch to standby pump, initiate strainer cleaning procedure > 15 min

24 Deliver it Directly to the Operator 23

25 Operations Management Securing Integrity 24

26 A Typical Shift Trend Operating between the alarm limits 25 alarm limit process alarm limit

27 What About Those Other Limits How safe are we really operating? 26 equipment damage alarm limit fouling process planning target economic feasibility planning target alarm limit

28 Before Alarm and Operations Management How safe are we really operating? 27 High Risk of Safety Incidents, Equipment Damage and Abnormal Situations equipment damage alarm limit fouling process 35% Safe Zone Operation planning target economic feasibility Sub-optimal Performance planning target alarm limit

29 After Alarm and Operations Management Stay within the plants limits for safer operations 28 equipment damage alarm limit fouling process planning target economic feasibility planning target alarm limit

30 After Alarm and Operations Management Stay within the plants limits for increased safety and production 29 High Risk of Safety Incidents, Equipment Damage and Abnormal Situations equipment damage alarm limit fouling process 95% Safe Zone Operation planning target economic feasibility Sub-optimal Performance planning target alarm limit

31 Step 1: Operate within safe limits. On every shift. 30

32 Step 2: Identify excursions from safe operating windows 31

33 Step 3: Document Deviations and Secure Shift Handover Processes 32

34 The Power of Integration 33

35 The Power of Integration Reduce Alarms Secure Integrity Reduce Risk Stale and Standing Alarms Safety Bypasses and Inhibits Critical Alarm Limits Boundaries and Constraints Secure Shift Handover Process Limit Deviations Excursions from Safe Operations Windows

36 The Power of Integration Alarm and Limit Documentation Visualized in Experion Direct to Where the Operator Needs It

37 The Story So Far.. 36 Alarm Management Reduce alarm noise Clarity to operators for real alarms Guiding operations through abnormal situations De-risking the process DynAMo Alarm Management 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 and Operations Operations Management Defining safe operating limits Staying within those operating limits Elevating communication for safer operations Protecting people, process and assets DynAMo Operations Management

38 Process Safety Continuous Innovation 37

39 Introducing Process Safety Analytics 38 DynAMo Suite Alarm Management Reducing alarm noise and operator error through effective alarm management Operations Management Driving informed decisions and operational compliance through safe and profitable operating practices Process Safety Analytics

40 Introducing Process Safety Analytics 39 DynAMo Suite Alarm Management Reducing alarm noise and operator error through effective alarm management Operations Management Driving informed decisions and operational compliance through safe and profitable operating practices Process Safety Analytics

41 Process Safety Analytics 40 Latest addition to the DynAMo Suite. Deployed with or without DynAMo. Leverages any Alarm and Event Database.

42 Process Safety Analytics Shutdown Cause and Effect Analysis 2. Safety Valve Integrity Analysis 3. SIL Analytics for Demand Rate Assessments

43 Shutdown Cause and Effect Analysis (Planned and Unplanned) 42

44 Safety Valve and Final Element Integrity Analysis 43

45 Demand Rate Assessments (Safety Instrumented Functions) 44

46 Summary 45

47 Operations Integrity.Achieved 46 DynAMo Suite Alarm Management Reducing alarm noise and operator error through effective alarm management Operations Management Driving informed decisions and operational compliance through safe and profitable operating practices Process Safety Analytics

48 Operations Integrity.Achieved 47 DynAMo Suite Alarm Management Reducing alarm noise and operator error through effective alarm management Operations Management Driving informed decisions and operational compliance through safe and profitable operating practices Process Safety Analytics

49 DynAMo Suite Alarm Management Operations Management Process Safety Analytics Take the Free 14 Day Test Drive at Questions?