nvrb & honeywell symposium - pss 21-11-18 rb0 · honeywell’s process safety suite automates...

Process Safety Suite - WorkbenchNVRB & HONEYWELL SYMPOSIUMRudi Bott

21-11-2018

Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.

Process Safety Suite

1

Seamlessly Connecting the Safety Lifecycle Inside One System

Today the key information in the Process Safety Lifecycle is

handled through many manual

and disconnected steps.

Honeywell’s Process Safety Suite automates this lifecycle helping

to reduce errors, lower costs,

continuously monitor operations for hazard conditions and

provide safety alerts in a timely

fashion.

Compliant with ISA-84 / IEC 61511

SafetyBuilder

Figure 1. Data Model Enabling “Loop-backs”PSA1st

UAS2nd

CMMS


Process Safety Suite Overview

2

Single Source of Truth for Process Safety

One enterprise-level software to manage the entire process safety lifecycle

Centralize & Synchronize Data flows consistently from one system to the next to eliminate errors and inconsistencies

Higher quality with fewer resourcesImprove productivity of expensive/scarce design resources in the FEED process after the PHA

Monitor performance to Minimize RiskUse data from Historian to validate designs or flag issuesUp to date Dashboard of Risk Today

Seamlessly Connecting the Safety

Lifecycle Inside One System


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Data all in a single “model”. No manual transfer from step to step

Hazard Identification

Risk Analysis � Solutions

Solution Details Install, ValidateOperate & MaintainToday

PHA Report LOPA ReportSRS with Calcs. Investigations

Fault &

Success

Test Reports

Refresh Site Risk Assessments

Automated Data Transfer

Manual Data Transfer

Test

Plans

Design & Engineer

Logic diagrams & Safety Builder programming

Manager

Safety C&E Matrix

Validation Report

Process Safety

SuitePHA

Report

LOPA

Report

SRS

Report

C&E

MatrixInvestigations

Fault &

Success

Test Reports

Refresh Site Risk AssessmentsAutomated Data Transfer

Manual Data Transfer

Test

Plans

Design & Engineer

Manager

Safety Validation

Report

Hazard Identification

Risk Analysis � Solutions

Solution Details Install, ValidateOperate & Maintain

Automating the Process Safety Lifecycle


• Single enterprise solution

• IEC 61511 / ISA-84 Compliant

• Seamless data transfer

• Single point of data entry

• Concurrent users and projects

• Unlimited users (multiple EPCs)

• Company standards and libraries

• Save man-hours by utilizing templates

• Manage competencies with user permissions

• Revision controls to support stage/gated process

Reduce man-hours - Drive consistency - Ensure functional safety

Process Safety SuiteCompliant with ISA-84 / IEC 61511

SafetyBuilder


UAS2nd

CMMS


Start anywhere!

5

Better Analysis at Reduced Cost. Improve safety of operations

There are several logical places to get started:

1. Process Hazard Analysis (PHA) / Layers of Protection Analysis (LOPA) � Whether it’s the Initial project PHA or the Five year Revalidation

� Transfer your current PHA from all major tools into PSS Workbench

2. Confirming or redoing your SIL calcs.� Build your SRS in Process Safety Suite Workbench. Save time and

money and set yourself up for step 3

3. Confirm your systems are working as intended� Compare actual plant results using PSA with intentions from PHA, LOPA

& SRS

OPERATESAFELY

30+ years


Monitor & Sustain

Process Safety Design Data

ANALYTICS ENGINE

Daily Operating Data

BIG DATA

Real-time Instrument

Data

Real-time Maintenance

Data

PHD & PSA

Intelligent Business Decisions

BENCHMARK

89%Operating Data

Design Basis

Contributing Factors Source Impact

Excessive Bypassing PHD 4% ↑

Excessive Demands PHD 2% ↓

Late Testing CMMS 5% ↑

Frequent Failures CMMS 3% –


6


Typical Architecture7

• Safety Instrumented Systems• Fire & Gas Detectors• DCS based IPLs• Control Valves• Other edge devices

Plant 1 Plant 2 Plant 2

Honeywell Cyber Secure Network

Process Safety Workbench

Cloud Historian

Safety Lifecycle Analyzer

Process Safety Analyzer – to be moved to Cloud

Asset Sentinel

Customer 1 Customer 2

.

.

Customer N


Sentience/ MS Azure


Process Safety Suite Components

• Process Safety Workbench (Works with Safety Builder)

Consolidates all the tools, synchronizes the information for seamless transfer and revision control, and represents the single source of truth for your process and functional safety data.

• Process Safety Analyzer (part of DYNAMO)

Is an advanced software that automates tracking, analysis and reporting on operation of shutdown systems and safety elements, to promptly detect issues and continuously ensure process safety

• Safety Lifecycle Analyzer

Interfaces with operating data such as process historians and maintenance management systems provide the insight required to make better business decisions regarding testing, planned outages, safety system performance, and future capital project spend

• Process Safety Services

Encompass the total safety lifecycle and are designed to help our customers improve and extend the usage of their applications and the benefits they deliver, ultimately maintaining and safeguarding their advanced applications.

8


9

• Streamline Audits and FSA’s

• Supports Bypass Management

• Management of Change

• Functional Testing

• Incident Investigations

• Excessive Demands Tracking

• Excessive Bypass Tracking

• On-Time Testing Monitoring

• Failure Collection

• Spurious Trip Identification

• Manage Failure Rate Library

• Three Layers of Voting

• Calculate PFD, RRF, & MTTFs

• Test and Diagnostic Coverage

• Partial Stroke Testing

• Common Cause Factors

• Accounts for IEC 61511 “Shalls”

• What If’s / Option Engineering

• Graphical Architecture

• Multiple Logic Solvers

FunctionalSafety

Operations & Maintenance

• PHA/LOPA Tightly Integrated

• Cause or Consequence Based

• Flexible Library Settings

• Recommendation Tracking

• Cause Summing

• Data Migration Tools

• Multiple Risk Matrices

• Complete Reporting

• Gap Assignments

• Configurable Checklists

Process Safety

Process Safety WorkbenchCompliant with ISA-84 / IEC 61511

SafetyBuilder


UAS2nd

CMMS


Greenfield - Reduced Hours

Reduce man-hours - Drive Consistency

SILVerification

SRSDocuments

C&E Matrices

TestProcedures

Savings up to ¹ 45%

¹ Using templatization features within Process Safety Workbench

2 Assuming 35% copy factor & $6M Functional Safety Engineering

Hours per SIF

Traditional Workbench

On a typical $10Bn Facility Engineering savings calculated to be

$2.7M+ 2


Key Software Features

• Concurrent users

• Simultaneous projects

• Enterprise solution

• Competency management

• Version control

• Status reporting

• Multiple installation options

• Varying support packages

• Numerous training courses


Safety Builder separate pricing

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• Safety Builder engineering tool provides full support of the Safety Manager platform (Planning & Design, Installation & Upgrades, Engineering, Operations and Troubleshooting & Maintenance).

• IEC 61508 & 61131 compliant Configuration Management & Audit Trail logs.

• TÜV approved logic library and approved online modifications.

• Graphical layout with easy drag-and-drop hardware and software configuration.

• Multi-layer password protected access with configurable time-out.

• System Information screens provide detailed information on performance, usage of system and application variables and diagnostic log files.

• Online documentation and help screens.



• Process Safety Workbench (inc. Safety Builder)

consolidates all the tools, synchronizes the information for seamless transfer and revision control, and represents the single source of truth for your process and functional safety data.

• Process Safety Analyzer (part of DynAMo)

is an advanced software that automates tracking, analysis and reporting on the operation of shutdown systems and safety elements, to promptly detect issues and continuously assure process safety


Interfaces with operating data from DynAMo PSA or process historians and maintenance management systems to summarize risk status “today”. Enable better business decisions regarding testing, planned outages, safety system performance, and future capital project spend.


encompass the total safety lifecycle and are designed to help our customers improve and extend the usage of their applications – like Process Safety Suite - and the benefits they deliver, ultimately maintaining and safeguarding their safe performance.

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Process Safety Analyzer (PSA)

• PSA automates the process of validating shutdown systems and safety elements.

• It continually examines the Event Journal1, looking for issues

- High demand?

- Performance of the SIFs

• PSA flags problems like:

- A safety system is in Bypass

- Possible overdue inspection(e.g. valve supposed to be stroke-tested annually but hasn’t moved in 35 months)

- Valve is moving slowly (possible “sticktion”)

- SIF101 has been activated 1/month on average vs design = 1/year

• Uses Cause & Effects Matrix for what should happen

• Feeds data back to PS Suite Workbench & Lifecycle Analyzer

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Analytics to find and display Weak Links using Data you already collect

1 From any vendor


PSA - Shutdown Analyzer

• Detect and flag issues to Operations & Maintenance

• Opportunity to reduce planned shutdowns by using unplanned

• Reduced time and effort for validation

• Validated record of safety operations

• Complies with Good Engineering Proactices ISA-S84/IEC-61511


• Improved Safety- Continuous validation using planned AND unplanned operations

- Early identification of issues

- Excellent input to Reliability and to PHA teams during revalidation

• Increased Uptime- Faster restarts after unplanned shutdowns, through faster validation

- Reduce unplanned shutdowns through early fault detection

• Efficient work processes- Simplified / automated verification of SIS/PSD/PCS & final elements

- Exception based safety inspection & testing

- Helps identify root causes & nested shutdowns

• RAGAGEP compliance & auditability

PSA – Benefits



• Process Safety Workbench (inc. Safety Builder)



is an advanced software that automates tracking, analysis and reporting on the operation of shutdown systems and safety elements, to promptly detect issues and continuously ensure process safety


Interfaces with operating data such as PSA and maintenance management systems like SAP/Maximo to provide the insight. Roll-up KPIs to corporation allow better business decisions regarding testing, planned outages, safety system performance, and future capital project spend – w/o Admin burden


encompass the total safety lifecycle and are designed to help our customers improve and extend the usage of their applications and the benefits they deliver, ultimately maintaining and safeguarding their advanced applications.

17


Safety Lifecycle AnalyzerWorks with PSA to Validate Design with Operations to Minimize Risk Daily/Weekly/Monthly

Daily activities made simple…

• Device / function testing

• Bypass / override support

• Incident investigations

• Turnaround extensions

• Safety audits and FSAs

• Management of change (MoC)

Corporate roll-up KPIs

• Corporate Hierarchy in the Tool

• Functional Safety Index displayable at any level

• Periodic KPI reports


Monitor & Sustain

Process Safety Design Data

ANALYTICS ENGINE

Daily Operating Data

BIG DATA

Real-time Instrument

Data

Real-time Maintenance

Data

PHD & PSA

Intelligent Business Decisions

BENCHMARK

89%Operating Data

Design Basis

Contributing Factors Source Impact

Excessive Bypassing PHD 4% ↑

Excessive Demands PHD 2% ↓

Late Testing CMMS 5% ↑

Frequent Failures CMMS 3% –




• Process Safety Workbench (Links to Safety Builder)



is an advanced software that automates tracking, analysis and reporting on the operation of shutdown systems and safety elements, to promptly detect issues and continuously ensure process safety


Interfaces with operating data such as process historians and maintenance management systems provide the insight required to make better business decisions regarding testing, planned outages, safety system performance, and future capital project spend


encompass the total safety lifecycle and are designed to help our customers improve and extend the usage of their applications and the benefits they deliver, ultimately maintaining and safeguarding their advanced applications.

20


Process Safety Services

• Honeywell’s Process Safety Services encompass the total safety lifecycle and are designed to help our customers improve and extend the usage of their applications and the benefits they deliver, ultimately maintaining and safeguarding their advanced applications.

• Honeywell provides a complete portfolio of service offerings to extend the life of your assets and provide a cost-effective path forward to the latest application technology. Honeywell services include:

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Clients choose Honeywell to improve Safety & Performance

• Process Hazard Analysis (PHA) • Layers of Protection Analysis (LOPA) • Reliability Calculations • Safety Requirements Specification (SRS) • Cause & Effects • Functional Test Procedures

• Software installation • On-site engineering • Migration & Scope Expansion Services • Assessment services • Performance baseline and Tuning • Customized training