LSS Integrated Automation Report Rev7 - Honeywell · 2012-04-13 ·...

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LSS Performance Services

Integrated Automation Report

September 2011

<< Customer >>

SITE 1

Document : LSS_Integrated_Autom_Report_Customer_Site.Rev 1

Date: Month xxth YYYY

HoneywellHoneywellHoneywellHoneywell Process Solutions

LSS_Integrated_Automation_Report_Rev7Revision History

Revision History

Rev By Date Description

0 1 Safety System Audit included Reference Documents:

Summary of latest Revision:

Approvals:

Technical Content Approved by:

Date:

Quality Control Approved by: Date:


LSS_Integrated_Automation_Report_Rev7Contents i

Contents ABOUT THIS DOCUMENT ................................................................................................................................ 2

EXECUTIVE SUMMARY .................................................................................................................................... 3

AUDIT 1 – CONTROL SYSTEM UPDATE AND PERFORMANCE ASSESSMENT ............................... 6

AUDIT 2 – TECHNOLOGY INTEGRATION .................................................................................................... 8

AUDIT 3 – LIFECYCLE OPTIMAL EVOLUTION PATH ............................................................................. 13

AUDIT 4 – PROCESS CONTROL PERFORMANCE. ................................................................................. 15

AUDIT 5 – ALARM BENCHMARK. ................................................................................................................ 21

AUDIT 6 – SAFETY SYSTEM AUDIT. ........................................................................................................... 23

AUDIT 7 – ENERGY PERFORMANCE AUDIT. ........................................................................................... 28


LSS_Integrated_Automation_Report_Rev7 2

About this Document

Introduction The basis of this report is a set of standardized checks and sampled

parameter status from your process and control system. This will allow us to evaluate the performance of your overall control system performance and to identify areas where there is a potential improvement with respect to reliability, safety and efficiency. We cover the integration of different technologies, the level of security updates and antivirus, and the performance of your human machine interface environment. We provide advice ranging from the best path for your lifecycle installed base to the variability of your process control. The next pages include the summary of our assessment and recommendations in all the areas mentioned; these are supported by a detail analysis available in the complete report.

Data collection procedure

The data collection and checking procedures are designed to be as unobtrusive as possible to the Networks and systems being tested. That is, there are specific collectors designed to collect the parameters to measure such things as the performance of your operating system, the quality of the client server configuration and the performance of your graphics with respect to network traffic generated by those graphics. There is a trade-off between sampling often enough to detect significant events and yet not significantly influencing the values of the parameters being read. There is also the requirement to have enough sample data points to do meaningful statistical calculations.

Document organization

This document has been structured in six sections. Each one contains the audit summary of every control discipline that is being analyzed.

The first audit,Control System Update and Performance, will summarize the most important recommendation regarding control network performance: control software updates status, system configuration, schematics, system security.

The second audit will cover TPS system performance and its integrations with Experion PKS.

The third audit will cover the Installed Base lifecycle.

The fourth audit will address control performance.

The fifth will address Alarm Benchmarking

The sixth audit will analyze the Safety System status.



Executive Summary

Keeping physical assets in proper working order is essential to our organizations. Today, with access to data intensive industrial environments, and condition-based maintenance, we can take performance to the next level of efficiency.

The present report is a result of the assessment of your control systems and applications against our best practices in order to ensure the best performance of your installation.

Within the report you will see our detail observations and recommendations in each of the areas. This executive summary highlights the most significant observations and recommendations grouped by meaningful categories for the plant:

Control System Performance |

Technology Integration |

Lifecycle Optimal Evolution Path |

Process Control Performance |

Alarm Benchmark |

Safety System Audit |

• Control System Performance

o Keeping the security updates and antivirus current is of great importance in protecting your system from contamination that could severely impact the operation of the site. It is highly recommended that you put a maintenance process in place to address that issue.

o We have seen that some custom displays have a significant level of sophistication, exceeding the performance limits, which increased call up times. We consider call up time an important parameter, mainly during periods of transience (e.g., start-up, shutdown) when operators need to respond rapidly to alarms. Consequently, we recommend a rationalization analysis for alignment with ASM best practices.

• Technology Integration

o The Local Control Network performance is being impacted by the high refresh rate of graphics’ parameters, for which we recommend a review of existing configuration in light of our best practices; this will assure the correct response time of the overall system under all



load conditions.

o A general assessment of all LCN nodes that present timeouts is also recommendable, making sure that the resources of all nodes are sufficient to run their associated applications,

• Life Cycle Optimal Path

o Replacement of specific modules of your installed base, including APM controllers or W2K modules, that have been discontinued, is recommended since failure could result a long delivery time.

o Your system exhibits some bottlenecks, in particular on the controller (APM13). Either upgrading the CPU of that controller or optimizing the applications that run on it is highly advisable to ensure correct performance during times of peak alarm loads (including start up, process transience, and shut down).

o Our current technology fully supports the functionality of the old modules and a migration path is available, as indicated in Chapter 4, to extend the life cycle of your system. This will ensure that your system is fully supportable for many years.

• Process Control Performance

o We have detected some significant imbalance among some of the critical loops within your main units. As you can see in the related chapter, usually these loops are your productivity drivers. As a general rule correct tuning could improve the efficiency of the entire unit in the range of 1% to 2%. Consequently, we recommend a detailed benefit analysis for these loops and units.

o In the same way we have detected a significant opportunity to improve the efficiency of your boiler house. In particular, the efficiency of the Boiler F1 could be increased by 10.8%, which would generate savings of approximately 500 K€/year. This could be confirmed by a further feasibility study.

• Alarm Benchmark

o The majority of alarm times fall within the EEMUA guidelines. Nonetheless we have identified ten tags (Bad Actors) that account for 40% of the daily average alarm count. We recommend to go through them and to apply proper alarming criteria, so system performance will not be impacted by them.

• Safety System Audit:

o The most important observation is to implement a preventative process to document the Safety Loops Testing and Inspection



according to TÜV recommendations, in order to maintain the SIL certification.

o There are two safety related signals that need to be configured in order to revise the safety parameter SER to “Yes” according TÜV Safety Best Practices.

o At the earliest possible opportunity, it is highly recommended to replace the safety controller communications cables in the remote site, as these show visible corrosion that could cause “loss of view” of that part of your process.

We will be glad to collaborate with your team in order to work out the technical solutions that best fit the site, as well as a plan that complements our service agreement, in order to address all the above mentioned points.



Audit 1 – Control System Update and Performance Assessment

Control System Highlights Experion PKS System status

FTE Netw ork Installation and Configuration |

Security Updates & Antivirus Verif ication |

Operating System Performance |

EPKS Client Server Configuration |

Verif ication of Graphics Performance |

Back Up and Recovery Assessment |

Experion PKS Health

Observations The Cisco switches did not have the latest qualified version from Honeywell FTE.

The system did not have the latest security updates, which could make it vulnerable to external malware.

The antivirus was not updated to the latest version; anti-virus software is required on all Windows based process control nodes.

The station update rate was not following the Honeywell recommendation of 4 seconds, for the majority of the points, which can have a serious impact on LCN bandwidth.

The disk fragmentation was not properly managed; this could lead to delay in the transfer of data packages through the network. The corrected procedure will provide regular fixes to optimize all system files when they are not in use.

The recommended 20% free hard disk space was not maintained.



Recommendations It is important that every switch should have the latest Honeywell qualified IOS version at the time that a new release of Experion PKS is installed.

Establish a process to check when there are additional updates on Honeywell On Line Support site: http://hpsweb.honeywell.com/Cultures/en-US/Support/SecurityOtherUpdates/MicrosoftSecurityUpdates/ISOImages/default.htm

and proceed with their installation on each specific node.

Having an up to date antivirus is essential on an Experion System, so make certain to follow the latest Antivirus Guidelines; these are located on the OLS/SSOL site (Support – Security Updates – Microsoft Security Fixes – Antivirus Information):

http://hpsweb.honeywell.com/Cultures/en-US/Support/SecurityUpdates/MicrosoftSecurityFixes/AntiVirusInformation/Documents.htm

The latest Antivirus Updates are located on the OLS/SSOL site (Support – Security & Other Updates – Antivirus Information):

http://hpsweb.honeywell.com/Cultures/en-US/Support/SecurityOtherUpdates/AntiVirusInformation/default.htm

The Hard Disk information for both Servers and Stations can be found in ‘Computer Management’ by right clicking ’My computer’ and selecting ‘Manage’. Select ‘Disk Management’ from the left pane. The right pane should then show the total disk space and partition information



Audit 2 – Technology Integration

TPS integration in Experion PKS system and LCN Control Network Assessment Report. LCN Network Health

LCN Node's CPU Free |

Node's Traff ic in parameters/sec |

Nodes memory usage |

Minimum System Heap Memory |

Nodes w ith High Overrun Counts |

Clien Data Access Timeouts |

Nodes Heap Fragmentation |

LCN Network Health

Observations Although the default installation rate is 1 second we recommend using that setting only temporarily to follow up particular events since it can have serious impact on LCN.

It is recommended to set the update rate to 4 seconds (as shown in Figure 2.1) on every ES-T. Also, if Flex Stations are used, their update rate must also be set to 4 seconds. Consequently, we recommend using 4 sec for all stations on steady state. According to the actual data the LCN bandwidth usage looks healthy. The average LCN bandwidth usage= ~38.1%, while the peaks reach ~46.5% for a total of 56 nodes.

• AMs 39 & 41/42 have exceeded the MCVBMAXC limit (maximum memory used so far in current hour).

• HM44 has exceeded the maximum Disk Transfers per

minute (HMSYINFR3), however only 2 infringements are visible out of 251 safety tests

• Timeout records are visible on all client nodes

(PFPSHLDB).



Recommendations Based on the current data we find the present architecture in good condition. We notice that the prior 2007 recommendations were taken into consideration. As a result the condition of overall platform has been improved. Also when comparing to the previous 2007 system performance analysis we detect that the system expanded by 4 nodes while the overall LCN bandwidth usage stayed almost steady and is of no consequence for such a large platform (i.e. previous 2007 data state average LCN usage= ~37.1% & maximum= ~45% for 52 nodes).

• AMs 39 & 41/42 have again exceeded the MCVBMAXC limit. As explained previously this means that the memory allocated for CVB (Current Value Buffer) is close to the limit, indicating that the size configured is not enough to do the requested job. It is user definable, so you should reconfigure to eliminate the nuisance.

• The HM issue is not significant. A few exceeding samples is not cause for concern. These alarms might be due to node checkpoints and/or reload, or heavy engineering work. Avoiding “high load” engineering tasks while checkpoint or node load is in progress should eliminate these alarms.

• Timeouts are yet again impacting the Client nodes. The recorded Data Access Timeouts indicate that these nodes were not receiving data in the requested timeframe, due in most casesother unavailable nodes (i.e. Server nodes).

The responsible node(s) is unknown, but according to the current data we might suspect the UCN as potential source (i.e. APM13). Nevertheless we recommend isolating the nodes from which the impacted nodes most often request their data and improve the availability of the Data Owner(s).



On the other hand, this abnormal behaviour may also indicate a potential problem with hardware or cabling. So for the time being we recommend reloading the impacted nodes at the earliest convenience and following up. If the values are still increasing, and assuming that the functionality of the device is not problematic, then the verification of the hardware and/or cabling should be closely monitored via the PerfMenu.

The NIMs’ loading, in term of Parameters serviced per second, is only given for information and data comparison.



UCN Universal Control Network Assessment Report UCN Network Health

Overall UCN Controllers Loading |

Controllers CPU's free |

Controllers parameters serviced per second |

UCN Network Health

Observations

The overall UCN bandwidth usage is satisfactory (i.e. Communication & Control processor CPUFREE + overall data throughput).

APM13 (U1) has violated the minimum recommended Communication Processor.

CPUFREE (=20%, actual min= ~11% and 19 exceeding samples out of 251 tests).

All controllers have exceeded the Maximum Number of Events generated per second (NEVTMAX= 30). This is provided only for your information.



Recommendations

According to the actual data, except APM13 (U1), all controllers operate satisfactorily within specifications during the SPB data collection time without any apparent issues. In the UCN architecture as well, we detect an obvious performance improvement since APM15 has been upgraded to HPM.

Unfortunately the bottleneck now has simply been moved to another controller. In fact APM13 (U1) was running acceptably during last year’s SPB exercise, but now we see it indicating overruns during some typical process instances. We also discovered that the peak process traffic of this controller has almost doubled vs. 2007 counts (i.e. pps max in 2007= ~100, currently= ~200).

So, as advised in the 2007 report, you should consider either optimizing the controller duties or upgrading to HPM.

You might consider checking if the schematics, alarms generation, Peer-to-Peer strategy and/or CLs are not too negatively impacting the APM Comm CPUFREE and take corrective action(s) accordingly.

The Maximum Number of Events parameter is incremental to the last reload or statistics reset; we suggest resetting the impacted nodes at a suitable time and following up The increased Maximum Number of Events is attributable to process alarms and status changes.

We recommend a check for chattering alarms when the values increase without a valid reason. UCN chattering alarms may also be a responsible for increasing the Maximum Number of Events parameter.



Audit 3 – Lifecycle Optimal Evolution Path

Installed Base Life Cycle Status

Observations

Table with reported lifecycle status per Master Asset System Identification (MSID)

AM (AM-R) AMC AMX APM APM-R APP AxM C200 C300 CB CBRC CEP01 2 0 0 0 0 1 4 0 0 0 0 0 CEP08 0 0 0 0 0 0 2 0 0 0 0 0

Total 2 0 0 0 0 1 6 0 0 0 0 0

HG HLPIU HMON HPM HPM-R LEPIU LLPIU LM MFC NG NIM OPSTA CEP01 6 0 4 0 19 5 0 2 0 0 6 0 CEP08 5 4 3 0 11 2 0 0 0 0 8 0

Total 11 4 7 0 30 7 0 2 0 0 14 0

CG CLM DHEB DHP EC ECRCD EPLCG EST ESVT FSC GPCI GUS H4500 CEP0

1 0 0 0 0 0 0 0 19 4 0 0 9 0 CEP0

8 0 0 0 0 0 0 0 7 4 0 0 7 0 Total 0 0 0 0 0 0 0 26 8 0 0 16 0

PLCG PM PM-R SBHM SM

TPN Bridge UC UCRCD UDHP UHLPIU ULLPIU US UxS

CEP01 0 0 0 0 8 0 0 0 0 0 0 0 1

CEP08 0 0 0 0 12 0 0 0 0 0 0 3 1

Total 0 0 0 0 20 0 0 0 0 0 0 3 2



Recommendations

Advanced Process Manager APM Migration

Technology Refresh Option

Functional Migration

Retaining Existing Field Termination

Rational Migration

Total Replacement

HPM HPM, C200, C300 C300 using PM I/O

C300 c/w series C I/O

Three different options are available for APM migration

Technology Refresh Option Replace APM by HPM, but this will require a different chassis. . It is very difficult to change the chassis on-line. New HPM CPU Racks use existing PM I/O. Functional Migration Retaining Existing Field Termination

The PM I/O family can be used with the C300 and C200 controller. The C300 and C200 supports (2) I/O Link interfaces, and each or both of these can be used with either the PM I/O or the new Series C I/O. PM I/O is supported when an I/O Link is configured as a “PMIO Link”, and the Series C I/O is supported when the link is configured as a “Series C IO Link”. This means that these (2) I/O types cannot be shared on the same I/O Link.

Rational Migration Total Replacement

Using a C300 controller to replace an APM presents low to medium risk: point types are standard enough to be easily transposed. APMCL and Logic Slots are easily replace by standard Experion library items or Sequential Control Modules (SCM). It is unlikely that a Custom Algorithm Block (CAB) would be necessary, but if it were an Advance Control Environment node (ACE) would be also required. Refer to section 7.0 Control Language Migration. The PM I/O family can be used with the C300 controller. The C300 supports 2 I/O Link interfaces, and each or both of these can be used with either the PM I/O or the new Series C I/O. PM I/O is supported when an I/O Link is configured as a “PMIO Link”, and the Series C I/O is supported when the link is configured as a “Series C IO Link”. This means that these 2 I/O types cannot be shared on the same I/O Link.



Audit 4 – Process Control Performance.

Process Control Performance Summary

9% of Loops are Excellent |

13% Loops are Acceptable |

21% of Loops are Fair |

7% of CriticalLoops are Poor |

7% are Open Loops |

32% are Loops Inactive |

10% are Loops Saturated |

Observations

The figure below summarizes the findings of the control loop audit for 150 loops evaluated. The controllers recommended for the tuning improvements fall into several categories of loop improvement, including system oscillation and low performance index.

Given the fact that there are critical loops with poor performance, we recommend beginning with their proper tuning setting, which should improve performance on their associated control function, typically in the range of 1-2% of efficiency.

For inactive loops, we suggest verifying that this inactivity does not correspond to a plant production scheme. Otherwise the causes should be investigated.

Similarly, there are a significant number of saturated loops. It should be distinguished which among these result from a production or design scheme. The causes of remaining saturated should be investigated.

LSS_Integrated_Automation_Report_Rev7

Typical economical impact for

Loop Attainment

Attainment: Function of (Actual Opportunity improvement / Maximum Opportunity Improvement)

HoneywellHoneywellHoneywellHoneywellProcess Solutions


Typical economical impact for regulatory control tuning is 1,5%

Loop Attainment

Attainment: Function of (Actual Opportunity improvement / Maximum Opportunity Improvement)


16

regulatory control tuning is 1,5%



Recommendations

Identify critical loops that have poor performance, and then analyze then in the context of the whole unit. Once these loops are fine tuned and their variability reduced, determine if it makes sense to establish a more appropriate (more economical) set point.

For the Controller PPLC 018, RSXC 550

CPI (Controller performance index) of 0.02. CPI values below 1 indicated a controller settling much slower than the desired benchmark (in this instance is the closed-loop settling time benchmark).

• Closed-loop impulse response went down much more slowly than the desired impulse response of a controller with a four-minute settling time. Again, this sluggish behaviour indicated an under tuning controller.

• Closed-loop frequency response had much greater amplitude at the lower frequencies than the benchmark frequency response, indicating the controller to be significantly under tuned.

Benefits of proper tuning include:

- Reduction in the variance in a process improves process stability. With a more stable process, operators can push the process to new constraints that are more profitable and aligned to production objectives (adjusted throughput and improved quality).

- Reduction in production costs (i.e. energy savings, lower chemical consumption)

To address this, Control Loop Performance Assessment analysis tool will: enable maintenance planners and control engineers to focus on those loops which require attention, assist them by providing insight to the source of the problem, and allow them to trace sequential improvements.



By improving the performance of critical loops, benefits of approximately 1.5% are achievable. A detailed analysis and benefit estimation is recommended.

Control Loop Audit Table

Tagname DCSUnit Description LoopType Performance Opportunity

RSAC_313 RS SH2-2SO2 GAS DE COLA other poor 40PDFC_016 PD F CABEZA HD-V6 A FG flow openloop 16RSAC_513 RS H2S-2SO2 GAS DE COLA other fair 32RSAC_511 RS ANAL. H2S ENTRADA SC other fair 32PDFC_012 PD OFF GAS TOTAL DE HD flow inactive 0CHTC_005 CH CTROL TEMP ENTRADA SHU temperature fair 32RSXC_550 RS CONTROL AIRE PRINCIPAL temperature poor 40RSAC_311 RS Anal. H2S entrada SC other acceptable 8CHFC_008 CH CONTROL H2 LECHOS R-1 flow poor 40CHTC_049 CH ENTRADA A REACTOR HNR2 temperature fair 32RSPC_512 RS VAPOR CONDENS FINAL pressure poor 40CHTC_083 CH ENTRADA REACT SHDS HNR3 temperature fair 32RSLC_311 RS NIVEL CONDENSADOR level inactive 0RSXC_552 RS CURVA TEMP RS-R-505 temperature saturated 0RSLC_554 RS CONDENSADOS V-408 S3 level saturated 0CHTC_044 CH TEMP A SALIDA DE HNE8 temperature fair 32RSFC_551 RS CAUDAL AIRE A SC flow fair 32

309 CH NIVEL ESTABILZADORA HNV8 level acceptable 8CHLC_002 CH NIV BOTELL CARG HN-V-1 level acceptable 8RSLC_312 RS NIVEL AGUA RS-V304 level fair 32RSXC_350 RS CONTROL AIRE PRINCIPAL temperature fair 32CHLC_024 CH CONTROL NIVEL HN-V6 level fair 32PDTC_108 PD T REFLUJ HD-V7 (E11) temperature saturated 0PDFC_014 PD F ENT TOLUEN HD-E9 flow inactive 0PDTC_005 PD T ENT. HD-V3 temperature saturated 0PDTC_006 PD T ENT. HD-V3 temperature saturated 0PDTC_007 PD T SAL HD-E9 temperature saturated 0RSLC_512 RS NIVEL AGUA RS-V404 S3 level poor 40CHLC_037 CH DEPOSIT CONDENSADO HNV10 level fair 32



Control Loop Audit Main Issues

Controllers with Low Service FactorRSAC_313 SH2-2SO2 GAS DE COLA otherPDFC_016 F CABEZA HD-V6 A FG flowRSAC_513 H2S-2SO2 GAS DE COLA otherRSAC_511 ANAL. H2S ENTRADA SC otherPDFC_012 OFF GAS TOTAL DE HD flowCHTC_005 CTROL TEMP ENTRADA SHU temperatureRSXC_550 CONTROL AIRE PRINCIPAL temperatureRSAC_311 Anal. H2S entrada SC otherCHFC_008 CONTROL H2 LECHOS R-1 flowCHTC_049 ENTRADA A REACTOR HNR2 temperatureRSPC_512 VAPOR CONDENS FINAL pressure

Controllers with 100% SaturationPDFC_038 F AGUA A HD-V13 flowPDTC_001 T SAL HD-V1 temperaturePDLC_009 N HD-V8 levelRSXC_352 CURVA TEMP RS-R-305 temperaturePDLC_010 N INTERFAS HD-V8 levelPDPC_018 PLATO 20 HD-V6 SEG pressurePDPC_016 P RECIRC HD-P8 pressurePDOC_004 P DELTA REBOILS HD pressure

Controllers with Valve ProblemsRVFC_046 IMPULSION P15 A FLUSHING flow Valve stictionRHFC_391 HIDROGEN PASO1 H3-H1R1 flow Valve stictionFBFC_450 CARGA LPG LAVADOR-2 flow Valve stictionFLFC_407 ALIMENT. DE LEV2 A DEETA flow Valve stictionFLFC_435 LCN A HDT flow Valve stictionCUPC_060 GAS DE APOYO A CO-B1 pressure Valve stictionRSFC_515 AGUA A RECALENTADOR S3 flow Valve stictionFFFC_210 REFLUJO TPA flow Valve stictionFBFC_457 VAPOR A BPP-E23 flow Valve stictionPDFC_016 F CABEZA HD-V6 A FG flow Valve sizeRSFC_536 GAS ACIDO A LA UNIDAD flow Valve sizeRSXC_550 CONTROL AIRE PRINCIPAL temperature Valve sizeRSFC_315 AGUA A RECALENTADOR flow Valve sizeRSXC_350 CONTROL AIRE PRINCIPAL temperature Valve size



Control Loop Audit Summary (Cont.)

Controllers with tunning problemsCHFC_014 LLCN A TANQUE flowRSFC_515 AGUA A RECALENTADOR S3 flowFLFC_435 LCN A HDT flowCHFC_008 CONTROL H2 LECHOS R-1 flowRSPC_331 VAPOR DE RS-V304 pressureRSPC_512 VAPOR CONDENS FINAL pressureCHFC_007 CONTROL H2 CARGA R-1 flowRSLC_512 NIVEL AGUA RS-V404 S3 levelRSPC_531 VAPOR DE RS-V404 S3 pressureRSXC_550 CONTROL AIRE PRINCIPAL temperatureRSTC_511 SALIDA RECALENTADOR 2 S3 temperatureRSAC_313 SH2-2SO2 GAS DE COLA otherRSTC_539 GAS ACIDO RECALENTADO S3 temperature



Audit 5 – Alarm Benchmark.

Functional Summary

Alarm Performance Benchmark – CUSTOMER <site> (Spain) (pfb)

Area: AREA 10 - LUBES E

EEMUA Benchmark Rank: Very likely to be Acceptable Attainment : 54%

Alarm Activity Benchmarks Number of Operators : 1

Benchmarks

Alarm Activity Metrics AREA 10 - LUBES E

EEMUA (steady state)

Q1 Median

Overall Median

Q4 Median

Manageable Level 94%

(<=1 Alarms per 10 mins) (22 days, 15.8 hrs)

-- 93% 77% 36%

Over-demanding Level 5%

(2-10 Alarms per 10 mins) (1 days, 5.8 hrs)

-- 5% 17% 38%

Excessive Level 0%

Time at Risk Level (steady state)

1st Quartile

(>10 Alarms per 10 mins) (0 days, 2.3 hrs)

-- <1% 3% 29%

Average 0,3 < 1 0,4 1,67 11,7 Alarms per Ten Minutes Maximum 72 < 10 n/a n/a n/a

Alarms 2 < 6 2,4 10,0 70,2 Interventions 0,2 1,7 7,55 18,2 Hourly Average

Intervention to Alarm Ratio 1:11,7 1:1.4 1:1.3 1:3.9

Alarms per Day Average 48,2 <144 57,6 240,5 1684,8

30 Most Active of 134 Points (ten most active contribute 56% of total alarm activity)



The following are the main conclusions from the analysis:

1. The Lubes plant was rated as “Stable” state in July. However, the alarm analysis

period (2 months) may not include all plant modes - normal operation and plant

upset.

2. The alarm priority distribution does not meet the target EEMUA standard, the alarm

priorities need to be reviewed and modified to improve the distribution and match

the target value.

3. In some areas of the Lubes plant, 80% and more of alarms are generated by fewer

than 20 tags indicating a potential for improvement in alarm load.

4. Ratio of operator interventions to generated alarms is approximately 1, although

results vary widely across the areas. Ideally, every alarm should be associated with

an operator action that will allow the alarm to return to its normal value.

5. The majority of the alarms originate from Cracking area.



Audit 6 – Safety System Audit.

Functional Summary

Safety System Audit

Overall Hardw are Condition |

Configuration Safety & Avaliability |

Critical Softw are Update Checks |

Analyze actual & Historical Diagnosis |

The overall conclusion is that the condition and configuration of the Safety systems is OK.

In the following page we analyze the recommendations, with specific points related to configuration, maintenance and documentation.



Observations

Item Conclusion / comment Action by

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RAESD1_1

4.5 ESD1 Second cabinet swing frame hanging, needs to be fastened CUSTOMER

X

4.16 ESD1 First Cabinet Lamp not working CUSTOMER RAESD2_2

3.4 Set Enable and Reset key to SER=Yes 4401XS5501_63N (FORCE-ENABLE) 4401XS5501_63P (FSC-FAULT-RESET)

HON/CUSTOMER

4.2 Correct locking mechanism front right door (move clip down on cabinet)

CUSTOMER X

4.4 Bottom plate RAESD2_2 bend. CUSTOMER X

4.7 SIC cable -IO backplane connection Rack 4 pos 17 SIC cable -IO backplane connection Rack 5 pos 12

CUSTOMER D

4.12 Yellow/Green CAT5 Ethernet cable to tightly fastened (At switch)

CUSTOMER X

RAFGS1_3

4.7

SIC cable -IO backplane connection Rack 4 pos 7 SIC cable -IO backplane connection Rack 5 pos 5 SIC cable -IO backplane connection Rack 9 pos 17

CUSTOMER D

4.7 VBUS -RACK 7 Position 21 not locked CUSTOMER D - Check loop statuses and correct CUSTOMER X

RAFGS2_4

4.7 SIC cable -IO backplane connection Rack 8 pos 8 SIC cable -IO backplane connection Rack 8 pos 4

D

4.14 Fan is not receiving power, Power is not reaching the input of MCB. (temperature is 10 degree Celsius higher then in other cabinets.

CUSTOMER

X

4.16 Lamp is not receiving power, Power is not reaching the input of MCB

CUSTOMER X

4.16 FGS2 First Cabinet Lamp not working CUSTOMER X

- Check loop statuses and correct CUSTOMER X



Conclusion / comment Action by

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RA006_5

3.4 Set Enable and Reset key to SER=Yes 4471XS006P_62N (FORCE-ENABLE) 4471XS006P_62P (FSC-FAULT-RESET)

HON/CUSTOMER

X

4.4 Gaps between bottom plates to be covered X

4.13 Honeywell SMS to provide diagrams how to connect Safety Historian PC

TAC H

- Switch DBM module damaged for both Central Parts. Replace DBM

X

- Provide CUSTOMER with connection diagrams for ODW631 and

TAC H

4.16 Lamp not functioning CUSTOMER X

- Place 10216/A/1 (spare) Rack 6 pos 1 chan 4 (See rack 6 pos 3 chan 4 as an example as this channel is OK)

CUSTOMER

- Why is input "4471HC006P_04B" on Safety Related =Y, while all other inputs are "N"

CUSTOMER

COMMON

5 Implement PN2007-07E

HON/CUSTOMER

X X

- Check spare parts and backup procedures CUSTOMER X



Recommendations • Communication

The configuration for all Safety systems is correct. However it would be advisable to permanently connect a Safety Historian PC to the RA006, in order to capture the event in case of an incident. The FSC-FSC communication issues between EDS2_2 and RA006_5 are described in more detail in the “SR1-884529231 CUSTOMER Visit FSC-FSC communication” document.

• Signal configuration (Safety related Yes/No)

Hardware Tag numbers: configured “not consequent”, see paragraph 3.1 (i.e., some HW tag numbers are not configured according to safety recommendations)

FSC-FSC Tag numbers: not consequent, see paragraph 3.1

• Conditions of system on site

The environmental condition of the FSC systems in the CPP is OK. The FSC system in the remote cluster, however, contains desert sand and corrosion is visible on the communication cables.

• Spare part and Backup Management

To be investigated by CUSTOMER.

• Loop faults

See paragraph 7.5 of the “SR1-884529231 CUSTOMER Visit FSC-FSC communication” document for how to find the loop faults.

• Checklist summary of found items.

In Chapter 9 all items found are listed. This checklist can be used as guidance to get all 5 systems up and running without any fault reported. The goal is to have always “No faults detected” reported in the Extended Diagnostics.



• Force Enable

The #-ForceEnable and the #-FaultReset system marker is not being sent to SOE and Experion for some ESD systems. This should be corrected as it might generate a situation where a safety interlock could be overridden by the operator. It is highly recommended to review existing ESD alarms and improve safety override management.

• Preventive system maintenance scheduling and implementation

For existing RAESD1_1 and RAESD2_2 applications, it is highly recommended to document procedures for Safety Loops Testing and Inspection in order to be compliant with TUV standards.


Audit 7 – Energy Performance A

The objectives of this audit were to:

• Review existing issues

operations, production).

• Define Baseline Furnace Status with the control indicators of furnace

performance.

• Analysis of instrumentation, analyser and control requirements

• Review of current IT infrastructure

F1 Furnace Baseline Performance

The following graphs summarize the performance of furnace F1, based on evaluation of

historical data, plus an check of the efficiency as measured vs. the model’s prediction:

Efficiency Model view



Energy Performance Audit.

The objectives of this audit were to:

Review existing issues for utility boilers and process furnaces

operations, production).

Define Baseline Furnace Status with the control indicators of furnace

Analysis of instrumentation, analyser and control requirements

Review of current IT infrastructure

F1 Furnace Baseline Performance (Typical for other furnaces)




28

for utility boilers and process furnaces (control,

Define Baseline Furnace Status with the control indicators of furnace




Efficiency Model Validation

Histogram Oxygen in Flue gas




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Recommendations

One Oxygen-analyzer needs to be installed to measure current oxygen in flue gas in every

furnace. It must be located close to flue gas output. This measurement will lead to have a

better control furnace combustion and will allow installation of Advanced Regulatory

Control strategies for combustion control.

Some improvements in air/fuel flow meters in some furnaces will lead to tighter control over

associated flows. Adjustment of existing valves for A/F ratio control would be necessary to

have proper values in control set-points (F2).

Some review of dampers will help as well (F1).

Adjustments in existing control strategies will include some operation constraints (ingot time

inside furnace, pressure control, etc..) into the furnace control strategies, resulting in a

improvement in the furnace efficiency..

As shown in figures above, it is confirmed that in general there is a high percentage of

oxygen in flue-gas that is decreasing furnace efficiency.

For improving this situation and advanced combustion controller will optimize the

performance of the furnace, trying to keep oxygen in flue-gas at minimum level in any

possible furnace conditions without compromising furnace safety. The objective is to work

is a maximum excess of oxygen of 3-5%, keeping process variability at minimum and at the

same time maintain Delta-pressure inside the furnace to prevent possible air leakages in the

bottom.

This Advanced Regulatory Controller will optimize combustion by simultaneous control of

A/F ratio (measured air) and furnace pressure (leaking air).

LSS Integrated Automation Report Rev7 - Honeywell · 2012-04-13 ·...

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