2013 Honeywell Users Group Americas Kevin Brown and Chris Stearns Operations and Alarm Management Reap the benefits of a healthy alarm system 1
Agenda Alarm Management Effective best practices How can Honeywell tools help? Roadmap Next steps into operations management Effective best practices How can Honeywell tools help? Roadmap Questions 3
What is Alarm Management? Process by which alarms are engineered, monitored and managed to ensure safe, reliable operations 4
Phase 1 Phase 2 Phase 3 Phase 4 Real results from a customer the approach Bad actor clean up Rationalization Reprioritize Rename Consolidate Document Revisit Alarm Limits No action, No alarm Smart Alarming Shelving First out alarming Mode dependant suppression Offline suppression ASM Graphics S? CCXXXX PR 5
Alarm rates BEFORE and AFTER bad actor cleanup 6
7 Alarm rates BEFORE and AFTER rationalization
Post Phase 1 ownership & tools to sustain benefits 8
Operator best practice shift review Review Standing Alarm Report 9
Operator best practice shift review Review safety related alarms and actions 10
Operator best practice shift review Review shelved alarms 11
Weekly Maintenance / Operation Meeting Review Chattering Alarm Report Assign responsibility Discuss repeat offenders on the list 12
Weekly Maintenance/Operation Meeting Review Most Frequent Alarms Report Assign responsibility Discuss repeat offenders on the list 13
Control Engineer best practice Review Most Frequent Interventions and Intervention Count Over Time Tuning issues Valve stiction Exceeding output limits Control design 14
Control Engineer best practice Review what the operator is changing 15
HAZOPs, LOPAs & Incident Investigations Number one cause of alarms after a rationalization Teams consist of the resources required for rationalization Topics covered during review Causes Consequences Alarm required Topics needed to be added Corrective actions Severity Priority 16
Process Engineer best practice Review alarm rates looking for: Alarm rate changes during product changes Alarm rate changes during shift change 17
Process Engineer best practice Review alarm rates looking for: Alarm rate changes during product changes Alarm rate changes during shift change Oscillations 18
Summary Initiatives require a systematic approach Alarm management is ongoing Can improve reliability Make part of culture Assign accountability Identify goals and implement methods Tools necessary to achieve the results Incorporate alarm management tasks into workflow PHILOSOPHY IDENTIFICATION RATIONALIZATION DETAILED DESIGN IMPLEMENTATION OPERATION MAINTENANCE MANAGEMENT OF CHANGE MONITORING & ASSESMENT AUDIT ANSI/ISA-18.2-2009 Alarm Management Lifecycle 19
What s next? Operations Management! Alarms protect equipment and personnel Operations Management adds protection for efficiency and profitability Difficult without a healthy alarm system and associated work processes Unplanned Downtime Safety Technology Costs / Effort Production Dependability 21
Operations management best practices Communication Know your limits and plan Capture deviations and context Capture operator observations Effective shift handover 22
Know your limits and plan Operators Specialists Capture Limits Design, Corrosion, Environmental, Safety, Alarms, etc. 23
Know your limits and plan Limit Repository Operators Specialists Design, Corrosion, Environmental, Safety, etc. Capture Limits 24
Know your limits and plan Planners Plan Operators Specialists Validate Design, Corrosion, Environmental, Safety, etc. Capture Limits 25
Know your limits and plan Planners Operating Instructions Plan Operators Specialists Validate Design, Corrosion, Environmental, Safety, etc. Capture Limits 26
Capture deviations and context Planners Plan Operators Specialists Validate Monitor Design, Corrosion, Environmental, Safety, etc. Capture Limits 27
Capture deviations and context Planners Intuition Operations Monitoring Plan Operators Specialists Validate Monitor Design, Corrosion, Environmental, Safety, etc. Capture Limits 28
Capture operator observations Gain context not found in event journals for investigation activities Satisfy regulatory requirements Knowledge capture Supports an effective shift handover 29
Effective shift handover The most common causes of incidents related to shift handover include poor logbook design and poorly conducted shift handovers. Approximately 80% of industrial operations lack a structured approach to shift handovers In 1988, 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. 30
Effective shift handover Reduces risk that critical information is not communicated during shift changes Ensures accurate and consistent understanding of the plant situation is shared from shift to shift 31
Summary Alarm management is imperative Operations management builds on your alarm management investment Improves uptime Improves reliability and production dependability Increases safety Reduces cost/effort from technology staff to achieve with home built tools Best practices and effective tools deliver results 32