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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?