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Honeywell Proprietary
Honeywell.com
1
Document control number
2014 Honeywell Users Group Americas
Using Assessments to Improve System Availability
Chris Peters
Agenda
• Operational excellence
• How is an audit performed
• Data Collectors & Files
• Why do this
• The Assessments
• The typical process
• The benefits
• Starting the process
Operational Excellence
– Comprehensive analysis and planning
– Thorough understanding of official/unofficial business processes
• Uncover the “factory within the factory”
• Understand and document how things “really get done”
– Weighing the severity and probability of the various risks/problems
– Establishing priorities and justifying activities to be taken
Through the site assessment process, Honeywell can help you
achieve operational excellence.
What leads to operational excellence?
How can you achieve
a holistic view of
these activities?
– Systems management
– Preparedness
– Risk reduction
How is the Audit Performed?
• Data is collected non-invasively
– Collection performed by local Service team
– Collected from files on the system, or data collected over time
• Data is then transferred to Honeywell data server
– System performance metrics and benchmarking handled
– System architecture compared to current support recommendations
• Report is then presented back to site
– Hard copy of detailed report
– Presentation and discussion over findings
Data Collectors
• Existing collectors are used on the system
– Installed and preconfigured in most cases
– Some installation needed on some sites
– Evolution path to automated data collection • TPC & Experion systems
• Collectors run “behind the scenes”
– Collect system information and diagnostics
– Only loop performance collection requires configuration
• Encrypted files are downloaded onto removable media
Data Files
• Once collected, data files are uploaded to a Honeywell server
– Secure, protected environment
– Anonymized data used
– Honeywell domain engines are used for processing
• Files are processed and collated into report
– Analysis of issues, performance
– Analysis of hardware against support status
– Feedback from audit questions
• Report then reviewed for content, issues and quality
• Feedback presentation then developed
• Cyber security files are highly restricted
Why Do This?
• Verify what is being done well and can be leveraged
• Identifies gaps that could affect production or HSE
• The report clearly shows “How Bad is Bad”
• Simplifies the technology for non-technical managers
• Includes actions you can profit from immediately
• Provides a “Master Automation Plan & Support Strategy”
• Establishes a shared understanding to work from
Creates a meaningful “punch list” of prioritized actions for management
The Assessments
• Cyber Security Vulnerability Assessment
• Network Assessment
• Wireless
• Integrated Automation Assessment (IAA)
• System Performance Baseline (SPB)
• System Migration Definition
Cyber Security Vulnerability (CSVA)
• Provides overall risk assessment
• Provides actionable recommendations to improve security
• Identify regulatory issues (e.g. ISA99, NERC-CIP, ISO/IEC27001, CFATS)
• Optional: Security audits for compliance and regulatory
Network
• Identify possible problem areas in current network
• Performs a “walk-through” of critical PCN and shared business infrastructure
• Provides PCN best practice recommendations
– Security
– Performance
Wireless
• Radio frequency spectrum analysis
– What’s going on in your space
• Map network strength & Identify possible problems / security risks
• Provide wireless best practice recommendations
– Optimal location of towers
– Antenna type
– Integration to PCN
Integrated Automation Assessment (IAA)
•Support status
•Open systems hardware
•System software
•Cyber protection
•Alarm system
•Control loops
•Backup & Restore
IAA - Identified Areas for Attention
• Serious physical and cyber security risks
• Inadequate maintenance procedures
• Environmental maintenance risks
• Insufficient skills/training
• Poor graphic utilization
• Inappropriate spare parts
• Poor data backup procedures
• Outdated disaster recovery plan
• Missing documentation and procedures
• Inappropriate power feed and distribution
• Insufficient UPS capacity
• Obsolete (unsupported equipment in operation)
• Executive Summary
• High level Findings and Recommendations
• Detailed Section Analysis
• Control System
• Configuration Remarks
• Performance Metrics
• Lifecycle status & path forward
• Unsupported products
• Potential Upgrade Scenarios
• Process Control Performance
• Detailed Loop Identifications
• Valve Diagnostics
• Alarm Bench Mark
• Alarm initiation rates
• Identification of “worst actors”
• Comparison to EEMUA requirements
IAA Report Structure
CONTROL LOOP PERFORMANCE
FTE Netw ork Installation and Configuration |
Security Updates & Antivirus Verif ication |
Controller Status |
Operating System Performance |
EPKS Client Server Configuration |
Verif ication of Graphics Performance |
Back Up and Recovery Assessment |
CONFIGURATION
SYSTEM PERFORMANCE
IAA - Assess Your Control Performance
First
Quartile
Second
Quartile
Third Quartile
Fourth Quartile
Loop Attainment
• Control Performance • Poor performing loop prioritization
• Identification of control loop issues
• Resolution plan generation
• Alarm Performance • Alarm initiation rates
• Identification of “worst actors”
• Comparison to legislative
requirement
• Layout of resolution plan
System Performance Baseline (SPB)
• For TPS and EPKS
• Baseline Status
– After upgrade
• Identify critical issues
– Key observations
– Recommendations
• Planning
– Changes over time
Honeywell System Migration Definition
• Modern Method of defining Control System Replacement Projects completed by engineers that understand control systems inside and out.
• Focused on defining the project scope, schedule, and cost to a +/- 10% level with the smallest initial effort and cost
• Deliverables are focused around scope and cost as opposed to delivering detailed drawings which should be moved into the Capitol Project.
• Based on re-termination of existing field wiring or interfacing at marshalling cabinets if possible or new termination options
• Includes a Construction Estimate from a Honeywell approved contractor or a local preferred contractor
• Listing of required Electrical & Instrumentation Engineering deliverables required in the Capitol Project
• Includes System Hardware/Software, Configuration, Field Engineering, Construction, Construction Management, Start-up Assistance, and training.
• Includes enough definition to request bids from other vendors
SMD Typical Deliverables
Actual Deliverables based on your need and specified in the SMD Proposal
DCS/SIS I/O Count Summary Spreadsheet / Database
Dedicated Point to Point Cable Counts Spreadsheet / Database
Multi-conductor Cable Schedule Spreadsheet / Database
Marshalling Cabinet I/O Counts Spreadsheet / Database
Control System Layout Drawing
Control System Power & Grounding Drawing Drawing
Process Control Network & Fiber Drawing Drawing
Process Control Equipment Location Drawing Drawing
Construction Scope of Work Written Description
Site Construction Standards Written Description
DCS/SIS Functional Requirement Overview Written Description
Advanced Controls Overview Written Description
PLC Interface Listings Spreadsheet / Database
DCS/SIS Bill of Materials Spreadsheet / Database
Responsibility Matix Spreadsheet / Database
Preliminary Project Schedule Gantt Chart
Overall Cost Estimate (+/- 10%) Spreadsheet / Database
The Typical* Process
• Contact your local Account Manager
• They will coordinate contact with your assessor
• The assessment process includes: – Pre-site review
– On-site data capture
– Offline analysis / report generation
– Delivery to site with optional on-site review
• Site resource requirements:
– Initial data capture
– On-site interviews and support
– Report review
– Follow-up action implementation
The Benefits
Prioritized focus areas to help get started
Improved system and plant reliability
Increased production / yield
Greater control of operating costs (fewer surprises)
Reduced risk of fines
Specific Examples
• Oil refinery justified adding base skills freeing
up key resources for process optimization
• Paper mill prioritized investment requirements
needed for funding
• Chemical plant improved reliability and safety
by correcting power and wiring issues
Improving Your Results
Get the right knowledge and tools to
the right people to enable them to
improve their effectiveness and
make the right process, and . . .
… execute that process with results!
•Talk to your Account Manager
– Details of what you need
– Details of the systems to be covered
– Timing and detail levels required
• Price based on
– Type of assessment
– Scope
– Existing SESP contracts
Starting the process