2013 Honeywell Us ers Group Americas

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Operations and Alarm Management – Reap the benefits of a healthy alarm system

Alex Botek and Chris Stearns

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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

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What is Alarm Management?

Process by which alarms are engineered, monitored and

managed to ensure safe, reliable operations ”

“

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Real results from a customer – the approach Ph

ase

1 Bad actor clean up

Phas

e 2 Rationalization

• Reprioritize • Rename • Consolidate • Document • Revisit Alarm

Limits • No action, No

alarm

Phas

e 3 Smart Alarming

• Shelving • First out alarming • Mode dependant

suppression • Offline

suppression

Phas

e 4 ASM Graphics

S?

CCXXXX

PR

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Alarm rates BEFORE and AFTER bad actor cleanup

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Alarm rates BEFORE and AFTER rationalization

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Post Phase 1 – ownership & tools to sustain benefits

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Operator best practice – shift review

• Review Standing Alarm Report

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Operator best practice – shift review

• Review safety related alarms and actions

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Operator best practice – shift review

• Review shelved alarms

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Weekly Maintenance / Operation Meeting

• Review Chattering Alarm Report • Assign responsibility • Discuss repeat offenders on the list

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Weekly Maintenance/Operation Meeting

• Review Most Frequent Alarms Report • Assign responsibility • Discuss repeat offenders on the list

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Control Engineer best practice

• Review Most Frequent Interventions and Intervention Count Over Time – Tuning issues – Valve stiction – Exceeding output limits – Control design

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Control Engineer best practice

• Review what the operator is changing

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• 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

HAZOPs, LOPAs & Incident Investigations

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Process Engineer best practice

• Review alarm rates looking for: – Alarm rate changes during product changes – Alarm rate changes during shift change

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Process Engineer best practice

• Review alarm rates looking for: – Alarm rate changes during product changes – Alarm rate changes during shift change – Oscillations

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Summary

PHILOSOPHY

IDENTIFICATION

RATIONALIZATION

DETAILED DESIGN

IMPLEMENTATION

OPERATION

MAINTENANCE

MANAGEMENT OF

CHANGE

AUDIT

MONITORING

& ASSESMENT

ANSI/ISA-18.2-2009 Alarm Management Lifecycle

• 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

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Patch Releases Not Included – All Content Subject to Change – Consult for Revisions – Disclaimer – This Document Expires 2013-Jun-30

2H 1H 2H 1H 2H 1H 2H

Alarm Management Product Roadmap

2014 2015 2016 2013

AMS R100 • Best of MTK + HON • AM A&E + ACM + UA • System independent • Trend with Events

AMS R110 • Customizable KPI

dashboard • View multiple reports • New dashboard UI &

mobile compatibility

AMS R230 • New user interface • Escalations support

for alerts

DCS R430 HPS Product

Inter-dependency

AMS R120 • Overhaul all metric reports • Ability to create custom reports • Mobile compatibility

AMS R220 • Advanced rationalization tools • Improved alarm help • Mobile workflow

AMS R200 • Enhanced rationalization

tools • web user interface for ACM /

mobile compatibility

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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 Production Dependability

Technology Costs / Effort

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Operations management best practices

Communication

Know your limits and

plan

Capture deviations

and context

Capture operator

observations

Effective shift

handover

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Know your limits and plan

Capture Limits Design, Corrosion,

Environmental, Safety, Alarms,

etc.

Specialists

Operators

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Know your limits and plan

Capture Limits Design,

Corrosion, Environmental,

Safety, etc.

Specialists

Operators

Limit Repository

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Know your limits and plan

Capture Limits Design,

Corrosion, Environmental,

Safety, etc.

Specialists

Plan

Validate

Planners

Operators

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Know your limits and plan

Capture Limits Design,

Corrosion, Environmental,

Safety, etc.

Specialists

Plan

Validate

Planners

Operators

Operating Instructions

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Capture deviations and context

Capture Limits Design,

Corrosion, Environmental,

Safety, etc.

Specialists

Plan

Validate

Planners

Operators

Monitor

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Capture deviations and context

Capture Limits Design,

Corrosion, Environmental,

Safety, etc.

Specialists

Plan

Validate

Planners

Operators

Monitor

Intuition Operations Monitoring

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Capture operator observations

• Gain context not found in event journals for investigation activities

• Satisfy regulatory requirements • Knowledge capture • Supports an effective shift handover

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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.”

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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

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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

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Patch Releases Not Included – All Content Subject to Change – Consult for Revisions – Disclaimer – This Document Expires 2013-Jun-30

2H 1H 2H 1H 2H 1H 2H

Operations Management Product Roadmap

2013 2014 2015 2012

Intuition Applications

Intuition Operations Suite

Operations Monitoring R100

Operations Logbook R100

Operations Suite R100

Operations Monitoring R110

Operations Suite R110

Operations Logbook R110

2013 Honeywell Us ers Group Americas

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Questions?