DYNAMO ALARM MANAGEMENT

Transcription

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

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: 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.

7 Alarm Management: 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.

8 Operational Integrity Building Blocks 7 Alarm Management Reduce alarm noise Clarity over remaining alarms Operator guidance in abnormal situations Rationalize Alarms Incremental Value Compliance to industry standards and best practices Predict abnormal situations Return to normal, safe control - faster Operations Management Operate within safe limits Protect equipment Stay within efficient operating windows Secure shift handovers Reduce Risk Minimize Abnormal Situations Maximize Performance

9 Honeywell s Approach to Operational Integrity 8 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

10 Operational Integrity: A New Industry Focus 9 By integrating alarm Human Error Equipment Failure management with operations Other management reduces one of largest causes of incidents in the process industry today: abnormal situations caused Causes of Abnormal Situations 40% of Abnormal Situations caused by Human Error 40% caused by Equipment Failure by operator error - 75% of those failures caused by operating outside of equipment limits - API Required Practice 584 for Integrity Operating Windows

11 Operational Integrity: A New Industry Focus 10 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 Causes of Abnormal Situations Other, 20% Equipment Failure, 40% Human Error, 40%

12 11 Identify the Problem

13 Identify the Problem 12 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

14 Impact of Good Alarm Management ASMC June 2014 QRM 13 Alarm and Operations Management Good Alarm Management Poor Alarm Management

15 14 Alarm Management Risk Reduction

16 Alarm Management Risk Reduction 15 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

17 16 Step 1: Benchmark and Track Alarm Performance

18 17 Step 2: Identify Assets Most at Risk from Alarm Flooding

19 18 Step 3: Assess Operator Console Workload

20 19 Step 3: Assess Operator Console Workload

21 20 Step 4: Unlock the Knowledge and Drive the Improvement

22 21 Step 4: Unlock the Knowledge and Drive the Improvement

23 22 Step 5: Don t Forget the Last 20-40%. They Make all the Difference

24 23 Operator Guidance Risk Reduction+

25 Embedded Operator Guidance 24 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

26 Embedded Operator Guidance 25 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

27 Deliver it Directly to the Operator 26

28 Next Step to Operational Integrity ASMC June 2014 QRM 27 Alarm and Operations Management Good Alarm Management

29 28 Operations Management Maximizing Safe and Profitable Performance

30 The Building Blocks of Operations Management 29 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

31 A Typical Shift Trend Operating between the alarm limits 30 alarm limit process alarm limit

32 What About Those Other Limits How safe and productive are we really? 31 equipment damage alarm limit fouling process planning target economic feasibility planning target alarm limit

33 Before Alarm and Operations Management How safe and productive are we really? 32 High Risk of Safety Incidents and Equipment Damage equipment damage alarm limit fouling process 35% Optimal Performance Per Shift planning target economic feasibility Sub-optimal Performance planning target alarm limit

34 After Alarm and Operations Management Stay within the plants limits for increased safety and production 33 equipment damage alarm limit fouling process planning target economic feasibility planning target alarm limit

35 After Alarm and Operations Management Stay within the plants limits for increased safety and production 34 Significantly Reduced Safety and Equipment Risk equipment damage alarm limit fouling process 95% Optimal Performance Per Shift planning target economic feasibility Reduction of Alarms and Abnormal Situations planning target alarm limit

36 35 Step 1: Operate Within Safe Limits. On Every Shift.

37 36 Step 2: Identify Excursions from Safe Operating Windows

38 37 Step 3: Document Deviations and Secure Shift Handover Processes

39 The Third Step to Operational Integrity 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 The Third Step to Operational Integrity 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 40 Process Safety Analytics Unlocking the knowledge behind the noise

42 Process Safety Analytics Shutdown Cause and Effect Analysis 2. Safety Valve Integrity Analysis 3. Intelligent Alarm Delay Analysis

43 42 Step 1: Shutdown Cause and Effect Analysis (Planned and Unplanned)

44 43 Step 1: Shutdown Cause and Effect Analysis (Planned and Unplanned)

45 44 Step 2: Real-time Risk Analysis for Process Safety Elements

46 45 Step 3: Intelligent Alarm Delay Analysis for Optimal Deadband Settings

47 46 Summary

48 Operational Integrity Achieved 47 Alarm Management Reduce alarm noise Clarity over remaining alarms Operator guidance in abnormal situations Rationalize Alarms Incremental Value Compliance to industry standards and best practices Predict abnormal situations Return to normal, safe control faster Operations Management Operate within safe limits Protect equipment Stay within efficient operating windows Secure shift handovers DynAMo Alarm Management DynAMo Process Safety Analytics DynAMo Operations Management