Using Assessments to Improve System Availability

Transcription

1 Honeywell.com 2014 Honeywell Users Group Americas Using Assessments to Improve System Availability Chris Peters 1 Document control number Honeywell Proprietary

2 Agenda Operational excellence How is an audit performed Data Collectors & Files Why do this The Assessments The typical process The benefits Starting the process

3 Operational Excellence What leads to operational excellence? Systems management Preparedness Risk reduction Comprehensive analysis and planning How can you achieve a holistic view of these activities? 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.

4 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

5 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

6 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

7 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

8 The Assessments Cyber Security Vulnerability Assessment Network Assessment Wireless Integrated Automation Assessment (IAA) System Performance Baseline (SPB) System Migration Definition

9 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

10 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

11 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

12 Integrated Automation Assessment (IAA) Support status Open systems hardware System software Cyber protection Alarm system Control loops Backup & Restore

13 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)

14 IAA Report Structure 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 CONFIGURATION FTE Netw ork Installation and Configuration Security Updates & Antivirus Verification Controller Status Operating System Performance EPKS Client Server Configuration Verification of Graphics Performance Back Up and Recovery Assessment SYSTEM PERFORMANCE CONTROL LOOP PERFORMANCE

15 IAA - Assess Your Control Performance Loop Attainment First Quartile Second Quartile Third Quartile Fourth Quartile 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

16 System Performance Baseline (SPB) For TPS and EPKS Baseline Status After upgrade Identify critical issues Key observations Recommendations Planning Changes over time

17 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

18 SMD Typical Deliverables 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 Actual Deliverables based on your need and specified in the SMD Proposal

19 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

20 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

21 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!

22 Starting the process 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

23 Honeywell.com 2014 Honeywell Users Group Americas Questions 24 Document control number Honeywell Proprietary