DYNAMO ALARM MANAGEMENT Product Director 28 September … · The Secret to Unlocking Operational...
Transcript of DYNAMO ALARM MANAGEMENT Product Director 28 September … · The Secret to Unlocking Operational...
The Secret to Unlocking Operational IntegrityDYNAMO ALARM MANAGEMENTTyron Vardy
Product Director28 September 2017
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Defining Operational Integrity1
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.
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Defining Operational Integrity2
To secure a process plants integrity is to reducethe risk to its people, its process and its assets;
to maximize performance and to minimize the impact of abnormal situations.
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Defining Operational Integrity3
To secure a process plants integrity is to reducethe risk to its people, its process and its assets;
to maximize performance and to minimize the impact of abnormal situations.
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
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Defining Operational Integrity
To secure a process plants integrity is to reducethe risk to its people, its process and its assets;
to maximize performance and to minimize the impact of abnormal situations.
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Alarm Management: Unlocking Operational Integrity5
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.
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Alarm Management: Unlocking Operational Integrity6
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.
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Alarm Management
Reduce alarm noise
Clarity over remaining alarms
Operator guidance in abnormal situations
Rationalize Alarms
Operations Management
Operate within safe limits
Protect equipment
Stay within efficient operating windows
Secure shift handovers
Operational Integrity Building Blocks
Incremental Value
Compliance to industry standards and best practices
Predict abnormal situations
Return to normal, safe control - faster
Reduce Risk Maximize PerformanceMinimize Abnormal Situations
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Alarm Management
Reducing alarm noise and operator error through effective
alarm management
Honeywell’s Approach to Operational Integrity
Operations Management
Driving informed decisions and operational compliance through
safe and profitable operating practices
DynAMo® Suite
Process Safety Analytics
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Human Error
Equipment Failure
Other
Causes of Abnormal Situations
• 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
Operational Integrity: A New Industry Focus
By integrating alarm management with operations management reduces one of largest causes of incidents in the process industry today: abnormal situations caused by operator error
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Causes of Abnormal Situations• 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
Operational Integrity: A New Industry Focus
Human Error, 40%
Equipment Failure, 40%
Other, 20%
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Identify the Problem
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• 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
Identify the Problem
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ASMC June 2014 QRM13
Poor Alarm Management
Good Alarm Management
Alarm and Operations Management
Impact of Good Alarm Management
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Alarm Management
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Risk Reduction
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Alarm Management Risk Reduction15
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
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Step 1: Benchmark and Track Alarm Performance
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Step 2: Identify Assets Most at Risk from Alarm Flooding
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Step 3: Assess Operator Console Workload
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Step 3: Assess Operator Console Workload
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Step 4: Unlock the Knowledge and Drive the Improvement
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Step 4: Unlock the Knowledge and Drive the Improvement
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Step 5: Don’t Forget the Last 20-40%. They Make all the Difference
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Operator Guidance
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Risk Reduction+
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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
Embedded Operator Guidance
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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
Embedded Operator Guidance
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Deliver it Directly to the Operator
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ASMC June 2014 QRM27
Good Alarm Management
Alarm and Operations Management
Next Step to Operational Integrity
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Operations Management
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Maximizing Safe and Profitable Performance
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Console Operation PlanningEnsuring 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 LimitsEnsuring 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 PlanTrack 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 ProcessAdopting a best practice for automated shift handover and takeover processes.Ensuring all deviations, critical alarms, safety bypasses etc. are effectively captured and communicated
The Building Blocks of Operations Management
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A Typical Shift TrendOperating between the alarm limits
alarm limit
alarm limit
process
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What About Those Other LimitsHow safe and productive are we really?
alarm limit
alarm limit
process
alarm limit
alarm limit
fouling
equipmentdamage
planning target
planning target
economicfeasibility
process
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Before Alarm and Operations ManagementHow safe and productive are we really?
alarm limit
alarm limit
process
alarm limit
alarm limit
fouling
equipmentdamage
planning target
planning target
economicfeasibility
process
Sub-optimal Performance
35% Optimal Performance Per Shift
High Risk of Safety Incidentsand Equipment Damage
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After Alarm and Operations ManagementStay within the plants limits for increased safety and production
alarm limit
alarm limit
process
alarm limit
alarm limit
fouling
equipmentdamage
planning target
planning target
economicfeasibility
process
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After Alarm and Operations ManagementStay within the plants limits for increased safety and production
alarm limit
alarm limit
process
alarm limit
alarm limit
fouling
equipmentdamage
planning target
planning target
economicfeasibility
process
Reduction of Alarms and Abnormal Situations
95% Optimal Performance Per Shift
Significantly Reduced Safety and Equipment Risk
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Step 1: Operate Within Safe Limits. On Every Shift.
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Step 2: Identify Excursions from Safe Operating Windows
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Step 3: Document Deviations and Secure Shift Handover Processes
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Alarm Management
Reducing alarm noise and operator error through effective
alarm management
The Third Step to Operational Integrity
Operations Management
Driving informed decisions and operational compliance through
safe and profitable operating practices
DynAMo® Suite
Process Safety Analytics
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
39
Alarm Management
Reducing alarm noise and operator error through effective
alarm management
The Third Step to Operational Integrity
Operations Management
Driving informed decisions and operational compliance through
safe and profitable operating practices
DynAMo® Suite
Process Safety Analytics
Honeywell Proprietary - © 2017 by Honeywell International Inc. All rights reserved.
Process Safety Analytics
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Unlocking the knowledge behind the noise
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Process Safety Analytics
1. Shutdown Cause and Effect Analysis2. Safety Valve Integrity Analysis
3. Intelligent Alarm Delay Analysis
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Step 1: Shutdown Cause and Effect Analysis (Planned and Unplanned)
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Step 1: Shutdown Cause and Effect Analysis (Planned and Unplanned)
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Step 2: Real-time Risk Analysis for Process Safety Elements
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Step 3: Intelligent Alarm Delay Analysis for Optimal Deadband Settings
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Summary
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Alarm Management
Reduce alarm noise
Clarity over remaining alarms
Operator guidance in abnormal situations
Rationalize Alarms
Operations Management
Operate within safe limits
Protect equipment
Stay within efficient operating windows
Secure shift handovers
Operational Integrity… Achieved
Incremental Value
Compliance to industry standards and best practices
Predict abnormal situations
Return to normal, safe control – faster
DynAMo® Alarm Management
DynAMo® Operations Management
DynAMo® Process Safety Analytics