Honeywell Process Solutions...•An integrated and holistic approach to protect the plant, people...

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


Safety Moment


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


2 main areas of activity

Process Safety Plant & Personnel Safety & Security


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


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


Safety KPI’s

• Leading & Lagging metrics (CCPS process safety metrics 2010)


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


Linking hazards to barrier concept…


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

http://docplayer.net/6683013-Title-the-role-of-technical-authority-in-managing-asset-integrity.html


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


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


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


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


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


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

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• 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


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


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


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


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


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


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

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


DVM- Digital Video Manager


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


Example integration into Experion Operator Displays

Video + Process Data = increased situational awareness


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


Command & Control Suite:

Large touch Screen based user interface integrating security & facility information

Connect, Collaborate, Command and Control with Confidence


Command and Control Wall

Connect, Collaborate & Control With Confidence

https://youtu.be/aBx_0Y6ElPg

https://youtu.be/aBx_0Y6ElPg


Honeywell Command Control Suite


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


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


Honeywell’s Integrated Solutions for Safety & Security

Enables Unified Plant View – Increased Situational Awareness

Multiple systems monitoring & management on a Single platform


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



Thank You


Problem Statement 41

Effective Risk Reduction

Effective IPLs

(condition, proper operation,

procedures…)

LOPA

LOPA: Layers Of Protection

Analysis

IPL: Independent Protection

Layer


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


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)


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


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)


Tier 3 Process incident capture:

challenges to systems

Event

details

shown

here


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

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