Honeywell Confidential - © 2017 by Honeywell International Inc. All rights reserved.
Honeywell Oil & Gas Technologies Symposium – Cairo, Alexandria
P.G.Millette
May-2017
Honeywell Process Solutions
INTEGRATED PROCESS SAFETY & PLANT/ PERSONNEL SAFETY
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Safety Moment
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Corporate HSE Drives Operations to Reduce Risk
Risk Assessment Identifies Top Risks…Which Leads to Risk-Reduction Spend
Emergency Response Centers
Process Gas (Fixed & Portable)
PPE
Non-process Fire & Gas (Buildings, RIE’s)
Fire Control & Suppression Systems
Cyber Security
Safety Validation Services
Safety Training
Compliance Monitoring
Thermal Solutions
Physical Security
Safety Shutdown Systems
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2 main areas of activity
Process Safety Plant & Personnel Safety & Security
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Addressing Core Industry Problems – Safety
Key elements of interest
Process Safety Personnel Exposure Compliance
Safety System
Effectiveness
Safety Element
Analysis
IPL Analysis
Hazard Exposure
Tracking
Exposure Risk
Quantification
Operational
Efficiency
Real-time Job
Readiness
PPE Inventory
Tracking
Enterprise-Wide
Compliance
Gains not possible with conventional methods
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The Bow-Tie model - adjusted
People Organization Technology
Short term
dynamic
Long term
dynamicMid term
dynamic
Structural
long term
improvement
Limited (slow)
Long term
improvement
Limited
mid-term
improvement
Safety
CultureNear
miss
Technology
Technology
Organization People
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Safety KPI’s
• Leading & Lagging metrics (CCPS process safety metrics 2010)
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Process Safety Management context
• Industry has adopted a layered approach to separate responsibilities of
independent functions
- Work originates with James Reason’s model - 1990
- A barrier model
Diagram by OGP UK
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Linking hazards to barrier concept…
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Linking the Barrier model to Bow-Tie
http://docplayer.net/6683013-Title-the-role-of-technical-authority-in-managing-asset-
integrity.html
University of Aberdeen – Step Change in Safety
Emmanuel Mbata – Sept 2013
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Capturing measures of Process Safety Management
Incident capture and management
• API RP 574 model
- Lays out 4 tiers of events
- Provides a structured framework from which to capture, categorise, managing work
flow, and reporting in consistently expressed measures
Tier 1, 2 as external, post facto, sharable information
Tier 3, 4 as internal, leading measures
- Challenge to more consistent compliance
Cheaper compliance
Automating some of the information handling
- Tier 3 represent challenges to barriers
Including SIS
Real time captures
- An emerging matter of compliance
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Tying layers of protection to functions:
combined view Operational Excellence & Process safety
3. Capture
alarms, react
5. Manage
Alarms
9. SIS trips
10. Manage SIS ACTUAL
perf – capture challenge
events; Manage IPL/LOPA
testing regime
11. Capture events
from failures -
manually
12. Manage
emergency –
guided process
The vertical slice - Managing a
consistent set of related, but
separate domain barriers as a
holistic, logical set
2. ASM best
practices
1. Operator &
technician
competency mgmt
6. Manage Integrity
Operating Windows -
boundaries for best
efficiency, best
operation; capture
near misses
8. Process & Asset Surveillance:
efficiencies, energy, reliability -
Engineering intervention; safety
health
4. Advanced
Control
Production
Management
Business
Processes
Plant Reliability &
Maintenance
business processes
7.Instrument
health monitoring
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Safety Life Cycle per the standards (IEC61511)
Data
capture:
Automated
analysis
Audit
NEW capabilities
provide automated
capture and analysis
What PSA addresses
Safety Lifecycle elements that need attention
Real time
capture and
alerting of any
degraded
condition:
- LOPA/ IPL
monitoring
Independent Protection Layers – IPL:“A device, system, or action that is capable of preventing a scenario from
proceeding to the undesired consequence without being adversely affected by the
initiating event or the action of any other protection layer associated with the
scenario” AIChE – CPS
• Non-SIF Elements that contribute to mitigating risk
• IPL’s Must be managed throughout the lifecycle process
• Analysis by LOPA
• auditable
SIF health
monitoring
Basic Process Control Systems Non-safety Process alarms
Operator Supervision
PREVENTION
Safety Critical Process Alarms
Safety Instrumented Systems
MITIGATION
Mechanical Mitigation Systems
Fire and Gas Systems
PLANT EMERGENCY RESPONSE
COMMUNITY EMERGENCY RESPONSE
Process Design
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Process Safety Management solutions
Process Safety
Management Solutions
Portfolio of capabilities
Process Safety
Analyzer
Shutdown
Analyzer
Safety (Final)
Element
Scout
SIL
Reports
Uniformance Asset Sentinel – advanced real time & transactional surveillance
platform
Process & Asset
Surveillance: non-safety
related; e,g, Energy
Real Time SIL
– SIF health
monitoring
IPL / LOPA
testing
regime
mgmt
Retrospective
& Documentary
Real Time & Live
historical capture
Transactional
& Real Time +
Documentary
Functionalities
Configured solution
Configured solutions
Sentinel for Instruments:
HART & FF Instrument
Health – diagnostics
capture, categorisation &
history
More Process safety
Better compliance
Reducing manual work
Benefiting from consistent, structured
and analysed real time data
Link to
SAP-PM
Maximo
Meridium
Templated. live logic & calc, Graphics, auto email, XML, URL content linkages Auto pattern matching &
actual function check
Incident capture:
Tier 3 challenges
to barriers
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Process Safety – Multi-Site SIF Analytics
Identify Worst Actors for Improvement
Cloud Analytics
DCS/SIS Process Data
Sequence of Events,
Event Log
Expected SIF Behavior
from Cause/Effects
Device information
Cloud Data
Consolidation
Compare SIF types
across units and sites
Capture proven-in-use
data for SIF elements
Track SIF overrides, bypasses
across units and sites
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Integrated Protective Solutions
Safety Shutdown Systems to
Prevent Process Incidents
Process Fire & Gas Solutions to Detect Leaks and Prevent Fires
Physical Security Solutions to Detect and Respond to Incidents
PJ
On
eW
irele
ss S
olu
tion
s
Ala
rm M
an
ag
em
en
t So
lutio
ns
Ind
us
trial C
yb
er S
ecu
rity S
olu
tion
s
• Consulting services to assess process risks
• Safety Manager to detect potentially dangerous conditions,
shutdown automatically and safely, and provide root-cause
analysis
• Consulting services to deliver performance-based and code-
compliant solutions
• Detector, Control, Alarming and Suppression solutions
• Personnel and location monitoring
• Consulting services for solutions tailored to mitigate specific
risks
• Intelligent Radar/Sonar/Video surveillance,
Intrusion Detection and Alarming
• Access control, mustering, visual process monitoring
• Consulting services to design the most
effective wireless infrastructure
• Wireless network access points and
transmitters
• Portable gas detectors and personnel
location awareness
• Professional field services
• Managed cyber security services
• Cyber security software
• Integrated partner technology
• Complete alarm improvement
service programs
• Analysis and reporting software
• Enforcement of designed alarm
limits
Protecting Process, Plant, People and Environment
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Site
IIoT Applications
OneHoneywell Plant & Personnel Safety Reduces Risk
Completeness of Scope
Connected Worker
HIS
Personnel Safety - Hazardous-Condition
Exposure
Personnel Safety - Organizational
Readiness & Compliance
HPS
Process Safety - Multi-Site Safety
Function Analytics
HIS
HSF 3rd Party
HPS
ICSS
Gas Fire Suppression
Emergency Response
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Fault-Tolerant Ethernet
SafeNet
F&G Logic Solver
Safety Manager (SIL 3)
Battery
Backup
PCS
Experion PKS
Fire & Gas detectors, Manual Call Points Sounders, Beacons F&G MimicPanel
Non-Process Manned Buildings
F&G MimicPanel
F&G OperatorStation
PCS/SIS OperatorStation
Addressable Fire detectors,Modules, Manual Call Points
Honeywell
Digital Video
Server
Digital Camera
SIS
Safety Manager
Plant Wide Historian
Process Unit Areas
Addressable
Fire Alarm Panel
Ethernet
Plant Evacuation System/ Plant Security Center (normally not in F&G Scope )
EBI
Honeywell’s Integrated Fire & Gas Solutions
Seamless integration Simplifies Engineering, Operations and Maintenance
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OneWireless™ Solutions
PCN
XYR6000 ISA100Huawei or Cisco
Access Points
Host Application Servers (e.g. DVM, Experion, Field Advisor, etc. )
Mobile Video & Collaboration
Field Advisor/Mobile
Access
Mobile Station
FlexLine ISA 100
XNX with OW Adaptor
H2S Gas Detection
ConneX1Wireless Portable Gas Detector
LocaXion Anchors
Wireless Beacon
Wireless Fixed gas
detector with ISA 100
Battery-Powered
LA - Dec 2015
IEEE 802.11a/n Backhaul
ISA100.11a, HART
IEEE 802.11 b/g Wi-Fi
RSSI Signal for Location
TCP/IP Ethernet
WDMWLC
Improve safety and reliability with a proven, secure, stable wireless
network
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Extended Boundaries
REMOTE ASSETS
Pipeline/Land/Marine
LIGHTING
Deterrent/Visual
Surveillance
PERIMETER
Deterrent/VisualBoundaries
PERIMETER
Intruder DetectionMonitoring
INTELLIGENT VIDEO
Surveillance &
AssessmentProcess / Security
ACCESS CONTROL
Smart Cards & Biometrics
Accountability
INTEGRATED ENTERPRISE-WIDE
ICSS & SECURITY MANAGEMENT
VISITOR MANAGEMENT
Contractors-Visitors
Contractor
Management
Emergency
Responsiveness
ONE-WIRELESS MESH
LAN/WAN
Experion Industrial Security (EIS)
Coordinate responses to events via process integration
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Honeywell Proprietary - © 2016 by Honeywell International Inc. All rights reserved.
Smart and Connected Operators
Personal Safety Solutions
Safety Communicator
• Visualize where the field
operators are
• See the level of gas
concentrations
• See what type of alarm is
occurring:
- Gas, Panic, Man down
• See location of any gas incident
as it happens and keep historical
dataBLE
BT2.0
Location
Manager(USP)
App – Remote
Monitoring
MicroRae
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Major gas leak ZONE 1
Worker exposed,
alarmed, location and
condition determined
HSE Officer receives alarm and
location; alerts responders
Muster and
automatically
account for
personnel
Operations receives alarms, alerts
and location from system
Worker is rescued and gets back to his family
Personnel Safety SolutionsMonitor personnel for exposure to hazards and rescue safely
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DVM- Digital Video Manager
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Associated PTZ Camera automatically turn to the preset alarm location
Automatic recording is started and includes the events before the alarm (pre-recording)
Alarm Video is displayed on Station Multi monitor
A Gas leak alarm is triggered
Honeywell Experion
System Displays the
alarm
Alarm video
Scenario – with Integrated Video system
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Example integration into Experion Operator Displays
Video + Process Data = increased situational awareness
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Mobile Site Surveillance
• Day/Night PTZ Cameras
Wireless Video Surveillance
• LED Lighting Reducing Running Costs
Security Lighting
• Access Management & Emergency Mustering
Control of Access & Contractors
• Wireless Communication to Central Location
Automated Integrated Solutions
Mobile equipment redeployed upon completion of shutdown activity at the refinery
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Command & Control Suite:
Large touch Screen based user interface integrating security & facility information
Connect, Collaborate, Command and Control with Confidence
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Command and Control Wall
Connect, Collaborate & Control With Confidence
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Honeywell Command Control Suite
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Where does the Command suite fit?
Experion Industrial
Security
Digital Video Manager
Servers
Business
Applications
Digital Video
Manager
Security
Manager Life Safety
Manager
3rd party systems
Industry Open protocol
Command Server
Experion Industrial Security
Station
Command Wall Enterprise Facility Dashboard
Incident Workflow Station
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Incident Commander Vehicle Mounted Camera• Site wide wireless infrastructure
covering process and tank farm
location
• Vehicle mounted camera on top
of Incident Commander
Vehicle
• Handheld Device inside the
vehicle to monitor Video
images from the camera
• Enables HSE to record
incidents
• Able to access any video
camera across the plant in the
future with expansion of
infrastructure
• Better incident management
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Honeywell’s Integrated Solutions for Safety & Security
Enables Unified Plant View – Increased Situational Awareness
Multiple systems monitoring & management on a Single platform
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Summary
• An integrated and holistic approach to protect
the plant, people and environment
• IIoT will further improve the Safety
Instrumented Function performance across
sites, increase Operational Efficiencies and
Measure Compliance
• Encompasses solutions for Risk
Assessment, Process Safety Mgmt,
Safety Shutdown, Process Fire &
Gas, Physical Security, Cyber
Security and Alarm Management
• Enables improved situational awareness and
better, faster response to incidents by all
responsible stakeholders
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Thank You
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Problem Statement 41
Effective Risk Reduction
Effective IPLs
(condition, proper operation,
procedures…)
LOPA
LOPA: Layers Of Protection
Analysis
IPL: Independent Protection
Layer
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Analyze event
log periodically,
in recent
retrospective
time frame
Capture Event
log from SOE,
Event historian,
native time
stamps
Events from
Real time
systems: e.g.
SIS, DCS
Compare
to
expectatio
ns of
safety
actions:
Per Cause
& Effect,
or other
design
SIF – defined causes, event capture and analysis
SIF – Name, reference, type, plant area, event comments, etc
Final Element performance, failure rates captured from actual data
Manage Testing interval from actual operational data
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Example modification procedure model• IEC 61508-1/Ed.2 2008
Safety performance below target
Systematic faults
Incident/accident experience
Operation/production requests
New/amended legislation
Modifications to the EUC
Modifications to the safety requirements
Modification
request
Impact analysis study
Impact analysis report
Modification design
authorization
Modification log
Update
UpdateBack to appropriate
overall safety lifecycle
phase
Hazard and risk analysis
Modification request initiators
(see figure 8)
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Emergency Response with Command & Control Suite
Leadership Has Visibility While ERT Responds Using Automated Workflows
Corp HSE
Leadership
Site Emergency
Response Team
Crisis Manager
EOC
Management Team
Communications
EOC
Management Team
Environmental
EOC
Management Team
Incident Commander
Control Point
Shift Superintendents
Security
EOC
Security Personnel
Decon Team Leader
Control Point
Maintenance Personnel
Entry Team Leader
Control Point
Shift Maintenance
Supervisors
Radiation Safety
Control Point
Health Physics
Personnel
Safety
Control Point
Safety/Utilities
Personnel
Offsite Emergency
Services (Fire, EMS)
Government
Information Release
EOC
Management Team
Media Release
Preparation EOC
Management Team
Records/Boards EOC
Management Team
Control Room Officer
Control Room
FMB Unit Supervisors
Entry Team Control
Room or Control Point
Hazmat Qualified or
Red Hats
Backup Team Control
Room or Control Point
Hazmat Qualified or
Red Hats
Decon Team Control
Point
Hazmat Qualified or
Red Hats
Medical Officer Medical
Office
Laboratory Personnel
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Sample workflows• Interlock testing
• Immediate post shutdown and retrospective analysis
- good function review using SDA;
- identify any bad actors – behaviour not as expected
- generate work request for fix;
- report to authorities;
- in case of all good function; document from SSRS report into format for
authorities – direct printing to PDF so that no manual edit is possible.
• Retrospective analysis of shutdown events in groups, by plant / process
area, by platform etc.
• Pre-shutdown
- Identify any overrides/ blocks/ bypasses etc
- Review expected sequences by plant area
• Regular use of reports to show such as safety bypasses/ inhibits,
blocks/suppresses/overrides (whatever terminology used at site)
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Tier 3 Process incident capture:
challenges to systems
Event
details
shown
here
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From SIF to overall LOPA / IPL
• Barrier model
• Viewing the SIF in the context of the LOPA – other, non
SIF, independent protection layers (IPLs)
- Status of basic controls (as applicable)
- Status of alarms
- Any information about status of relief valves, deluge systems
• Instrument / IPL testing management
- Calibration history for devices
- Manage test history, approvals, capture & link scanned images of test
results etc.
• Links to CMMS
- Work order requests
- Maintenance History (and on non SIF protection layers)
- Inventory of parts for sensors / final elements