Process with Confidence De Risking Your Operations, and Increasing Profit With What You Currently...

De-risking operations and increasing profitability with

Alarm, Operations and Process Safety Management

Process with ConfidenceDan Obrien

Tyron Vardy

Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved.

Process with Confidence

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• De-risking Operations and Increasing Profitability

• Layers of Protection for People, Plants and Processes

• Improve Safety and Abnormal Situation Management

• Ensure Safe Shutdowns and Predict Unsafe Shutdowns

• Protect Plant Uptime, Increase Reliability and Increase Production

• Secure Production Integrity with Proactive Lifecycle Management

• Three Key Focus Areas

• Alarm Management

• Operations Management

• Process Safety Management



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• Three Key Focus Areas

• Alarm Management

• Operations Management

• Process Safety Management


3


• Production Integrity

Management.

Minimizes the risk

faced in operating

plants.

Improves the bottom

line.

By focusing on key

elements in a

programmatically,

joined up way for faster

ROI.


Control

System

Alarm Management

Operations Management

Production Integrity


Alarm Management

4


A Well Understood Process

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Primary Drivers

Compliance

Benchmarking and

Reporting

Alarm System

Improvement

Abnormal Situation

Management

Reduced Operator

Error

Secondary Drivers

Operator Guidance

Increased

Availability and

Reduced Downtime

Root Cause

Analysis for Faster

Recovery Time to

Normal Operations

Enterprise

Assurance


DynAMo Alarm Suite

Standards Compliance and Benchmarking Reporting

6


KPI Dashboards.


Alarm Performance Charts.


Bad Actors, Nuisance Alarms, Flood Analysis.


De-risking Operations

10

Primary Drivers

Compliance

Benchmarking and

Reporting

Alarm System

Improvement

Abnormal Situation

Management

Reduced Operator

Error

Secondary Drivers

Operator Guidance

Increased

Availability and

Reduced Downtime

Root Cause

Analysis for Faster

Recovery Time to

Normal Operations

Enterprise

Assurance


De-risking Operations

11

Primary Drivers

Compliance

Benchmarking and

Reporting

Alarm System

Improvement

Abnormal Situation

Management

Reduced Operator

Error

Secondary Drivers

Operator Guidance

Increased

Availability and

Reduced Downtime

Root Cause

Analysis for Faster

Recovery Time to

Normal Operations

Enterprise

Assurance


Risk Assessment Analytics.


Cause and Effect Analysis.


Operator Guidance and Alarm Documentation.


Embedded into Experion Operator Console

15

De-risk… or No Risk?


Embedded UOP Process Intelligence

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UOP Alarm Help Add-on to DynAMo

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


DynAMo Alarm Suite

Standards Compliance and Benchmarking Reporting…

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DynAMo Alarm Suite

..to Smart, Proactive Alarm System Improvement

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Next Steps to Continual Improvement

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Primary Drivers

Compliance

Benchmarking and

Reporting

Alarm System

Improvement

Abnormal Situation

Management

Reduced Operator

Error

Secondary Drivers

Operator Guidance

Increased

Availability and

Reduced Downtime

Root Cause

Analysis for Faster

Recovery Time to

Normal Operations

Enterprise

Assurance


Next Steps to Continual Improvement

20

Primary Drivers

Compliance

Benchmarking and

Reporting

Alarm System

Improvement

Abnormal Situation

Management

Reduced Operator

Error

Secondary Drivers

Operator Guidance

Increased

Availability and

Reduced Downtime

Root Cause

Analysis for Faster

Recovery Time to

Normal Operations

Enterprise

Assurance



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The Need for Operations Management

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Human Error

Equipment Failure

Other

Causes of Abnormal Situations

• 40% of Abnormal Situations Caused by Operator Error

• 40% caused by Equipment Failure

- 75% of those failures caused by operating outside of equipment limits

• Controlling operating deviations, conforming to safe and integrity operating windows

(API 584), proactive monitoring of your process – drives greater alarm system

improvement

http://www.asmconsortium.net/Pages/default.aspx

http://www.asmconsortium.net/Pages/default.aspx


Increased Safety and Profitability

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Unplanned

Downtime

SafetyProduction

Dependability

Abnormal

Situations

Alarm Limit

Fouling Limit

Energy Efficiency Limit

Planning Limit

• Alarms protect equipment and personnel

- Real-time, safety-oriented, ‘outer-limit’ management

• Operations Management adds protection

for efficiency, profitability, reliability, and preventative ASM

- ‘Inner-limit’ management for all plant limits

- Inside and outside of the control system


DynAMo Suite

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Monitoring of All Plant Limits, Inside and Outside of the DCS.


DynAMo Suite

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From Anywhere in your Enterprise.


DynAMo Suite

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Including Analytics for Operating and Financial Deviation Risks


DynAMo Suite

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DynAMo® Alarm Management

Turning noise into knowledge through effective

Alarm Management

Metrics & Reporting

Documentation & Enforcement

Alerts, Notifications & Collaboration

DynAMo® Operations Management

Driving informed decisions and operational compliance

through safe and profitable operating windows

Operations Monitoring

Limit Repository

Operations Logbook

Reduce Risk Increase Profitability


DynAMo Suite

28

DynAMo® Alarm Management

Turning noise into knowledge through effective

Alarm Management

Metrics & Reporting

Documentation & Enforcement

Alerts, Notifications & Collaboration

DynAMo® Operations Management

Driving informed decisions and operational compliance

through safe and profitable operating windows

Operations Monitoring

Limit Repository

Operations Logbook

Improved Operator Effectiveness and Decision Making


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Management.

Minimizes the risk

faced in operating

plants.

Improves the bottom

line.

By focusing on key

elements in a

programmatically,


ROI.


Control

System

Alarm Management




30



Management.

Minimizes the risk

faced in operating

plants.

Improves the bottom

line.

By focusing on key

elements in a

programmatically,


ROI.


Control

System

Alarm Management




31



Management.

Minimizes the risk

faced in operating

plants.

Improves the bottom

line.

By focusing on key

elements in a

programmatically,


ROI.


Control

System

Alarm Management




32



Management.

Minimizes the risk

faced in operating

plants.

Improves the bottom

line.

By focusing on key

elements in a

programmatically,


ROI.


Control

System

Alarm Management




Process Safety Analyzer

33



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• What is PSA?

• PSA continuously tracks all your plant shutdowns (planned and

unplanned).

• Verifies ESD/PSD systems perform as expected – as designed

• Typically based on Cause and Effect

diagrams.

• PSA also tracks and

analyses all Final Events

e.g. Safety Valves,

function as expected.



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• De-risking Operations?

• Learn from the planned shutdowns to optimize the unplanned shutdowns.

• Validate shutdown elements work as planned.

• Valves close in the allocated time

• Violations are highlighted, investigated and documented.

• Ensure that when the unplanned shutdowns happen, they don’t add additional risk

to the incident.

• Increasing Profitability

• Shorter planned shutdowns –

focus on safety elements

requiring attention.

• Less downtime and man hours

onsite for planned validations.

• Early fault detection and

Recovery back to normal operations faster.


Summary

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37







• Advanced Solutions Suites

• DynAMo® Alarm and Operations Management

• Process Safety Analyzer®



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• Advanced Solutions Suites

• DynAMo® Alarm and Operations Management

• Process Safety Analyzer®

Honeywell Confidential - © 2016 by Honeywell International Inc. All rights reserved. Process with Confidence.

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