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1JANUARY 2015 Process Solutions Issue No. 158
The GUARDIAN newsletter is published for, and proprietary to,
customers worldwide with a current Benefits Guardianship (BGP)
contract. To visit our website, go to
http://www.honeywellprocess.comand select Login. If not yet
registered, complete registration on login page (access will be
provided within 24 hours of registration.)
In this issue of the Guardian Newsletter:
Application Service News
New Year Greetings . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .1
Blending and Movement Automation
Did you know that . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .1
Use of Triggers in BMA Movement Automation . . . . . . . . . . .
.1
UniSim Operations Suite
UniSim Operation R430 Support of CDA Protocol
for Safety Manager Simulation . . . . . . . . . . . . . . . . .
. . . . . .2
Safety Manager CDA UI . . . . . . . . . . . . . . . . . . . . .
. . . . . . . .3
UniSim Training Courses . . . . . . . . . . . . . . . . . . . .
. . . . . . . .4
Operator Training Simulator Software Updates available . . .
.4
UniSim Operations Suite R430 Patch Releases . . . . . . . . . .
.4
UniSim Operations Suite R410 Patch Releases . . . . . . . . . .
.4
UniSim Design Suite
Using Excel to set compressor curves in
UniSim Design model . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . .5
Operations Excellence
Intuition Operations Logbook . . . . . . . . . . . . . . . . . .
. . . . . . .5
Courses . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .10
Current & Upcoming Product Releases . . . . . . . . . . . .
. . . .11
Contact Information . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .11
Application Service News
We wish to extend New Year Greetings and to wish all of our
AdvancedApplication Benefit Guardianship Program (BPG) customers
continuedsuccess in 2015. The New Year will bring new challenges
for everyone andHoneywell will continue to look for opportunities
to grow and improve theproducts and services we provide to our
valued customers.
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Blending and Movement Automation
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Did you know that trigger elements in Movement Automation can be
usedto start or stop sequences automatically? Triggers are a
special type ofBlending and Movement Automation (BMA) element. They
are used to monitorconfigurable conditions and when those
conditions are satisfied, the triggercommands the associated task
sequence to perform a path state transition(e.g. lineup, throttle
flow, full flow, gravity flow, stop flow, closeout).
Use of Triggers in BMA Movement Automation
Triggers are Blending and Movement Automation (BMA) equipment
elements;they are an equipment type of their own because they
fulfill the unique functionof monitoring configurable conditions,
and when these conditions aresatisfied, the triggers are able to
command path state transitions. Theyrepresent internal software
entities, instead of physical equipment in the field.
Trigger elements are designed to mimic the behaviour of task
monitoringconditions, with some differences. Conditions including
Date/Time, TankLevel, Tank Volume, Tank Limit, Stop Gauge Level or
Volume, Task Status, andmore, may be configured on a trigger
element. The conditions Task, Operator,Target Volume and Target
Flow, that may be assigned to tasks and sequences,do not apply to
triggers.
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2Triggers are associated with task sequences, either manually
during ordercreation or through association with other elements in
the piping network.In both cases the triggers appear as associated
elements on the path as soonas path selection has been
completed.
There is no limit to the number and type of possible triggers
that can beassociated to a path. Multiple simultaneous conditions
are supported. A pathcould for example have a single start full
flow trigger and several stop flowtriggers.
Trigger monitoring occurs at the same time as the sequence start
and stopcondition monitoring. The first condition that is met will
be acted upon. Forexample, say that a sequence is configured with a
stop condition that willstop flow at a specific date and time, and
the same sequence includes atrigger that is configured to stop flow
on a high tank level. If the identifiedtank reaches its high level
before the stop condition date and time, thesequence is
stopped.
In the same manner as in task monitoring, where individual
monitoringconditions can be set up as non-persistent (once off) or
persistent (repeatedlytriggering on every rising edge of the
condition becoming true) triggers canbe persistent or
non-persistent.
Non-persistent trigger conditions monitor until a rising edge is
followed bya falling edge. The trigger is set to MET at the rising
edge and set toNOTMET at the falling edge, as shown in Figure 1
below. A non-persistenttrigger can be restarted by clicking the
START button on the Trigger Detailor change zone.
Figure 1 Edge Triggering of Triggers and the Effect of
ConfiguringPersistence
Triggers can be preconfigured as part of the normal Movement
Automationconfiguration procedures.
They can also be fully reconfigured from the Trigger Detail -
Conditions tab,if access is provided. Standard Experion Asset based
security determineswho can see and access a trigger's
configuration.
For more information on triggers, or any of the BMA
applications, please
Blending and Movement AutomationBlending and Movement
Automation
Continued Back to TOCContinued Back to TOC
contact your Honeywell Account Manager or your local Application
Supportoffice.
Application Support Contact Information:
The Americas: [email protected]
Europe, Middle East and Africa:
[email protected]
Asia Pacific: [email protected]
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UniSim Operations Suite
UniSim Operation R430 Support of CDA Protocol for Safety
ManagerSimulation:
Since UniSim Operations R430, the Safety Manager emulation
supportsconnecting to Experion Server and Experion simulation
controllers throughCDA protocol for display, peer to peer and
notifications via CEE adapter. CDAprotocol support provided in
emulation will be similar to the support providedby real Safety
manager controller:
To configure the adapter model for both the CEE Interface and SM
CDA, it isnecessary to merge the contents of DCS adapter file
generated by SafetyManager Toolkit with the DCS adapter file
generated by CEE Toolkit.
The value of the CDACommunication should be set to SMandCEE in
theDCS adapter file.
Note that by default Safety manager translation will set
theCDACommunication to SMOnly, when used along with CEE interface,
thisvalue has to be changed to SMandCEE
Following are the possible values:
SMOnly Adapter model is used only for SM CDA protocolsupport,
CEE interface features will not be enabled
CEEOnly Adapter model is used for CEE interface only, SM
CDAfeatures will not be enabled
SMandCEE Adapter model is for both CEE interface and SM CDA If
entry is not configured, system will consider as CEEonly by
default.
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3Alarm Type Filter:
Select the required alarm type and choose the required
filtername. For example, Select Filter type as Off Normal Priority
andFilter Name as All to filter all DI points configured with Off
NormalAlarms. Choose Filter name as High to view all Off Normal
alarmsconfigured with High priority:
Alarm Type Filter
Block Name Filter:
This filter is to filter the points by its name. Block name
filter canbe combined (AND) with Point type and Alarm priority type
filtersalso.
For example, entering *BO00* in Block Name field will filter all
thepoints containing BO00.
Selecting filter type as point type and filter name as AI will
list outall AI point types. If Block name field is entered as
*BO00*, it willlist out the all AI points containing BO00 in block
name.
Block Type Filter
UniSim Operations Suite
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An example CEE adapter configuration file containing entries CEE
interfacesupport and multiple SM emulations is displayed below:
Safety Manager CDA UI
The adapter UI will display the current values and alarm
configuration detailsof the points. Alarm configuration such as
Trip points, priority can be changedusing the UI.
Trip point change will get effected immediately and alarm
priority change willget effected in the next alarm generation. If
the Model contains multiple safetymanager emulations, each safety
manager will be represented in one tab.Filters available in UI and
points can be filtered by point types, alarm prioritiesand block
name. Also sorting can be done columns Block name, Point typeand
Forced.
Point Type Filter:
Select the filter type as Point type and choose the required
filtername. For example choose filter name DI to view all DI
points:
Point Type Filter
UniSim Operations Suite
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Note: Safety Builder application is needed for setting CDA
protocolsupport. A Safety Builder license must be purchased
separately and it isnot part of UniSim Operations. Please refer to
the Safety Manager FSCToolkit Guide for further references.
For further details on CDA Protocol for Safety Manager please
contact yourlocal OTS Support Team.
Article submitted by Andrea Mancini, OTS ATS EMEA Team Lead
UniSim Training Courses:
The following UniSim training courses are provided through
HoneywellsAutomation College:
UniSim Design:
PDS-4526: Fundamentals - Process Modelling Using UniSim
Design
PDS-4527: Advanced - Process Modelling Using UniSim Design
PDS-4528: Fundamentals - Dynamic Modelling Using UniSimDesign
Suite
UniSim Operations:
OTS-0001: Fundamentals - UniSim Instructor Operation
OTS-0002: Fundamentals - UniSim Configuration Implementation
OTS-0003: Fundamentals - UniSim Run Time Graphics UsingHMIWeb
Implementation
OTS-0004: Fundamentals - UniSim System Manager
Administration
OTS-0006: Fundamentals - UniSim Experion ImplementationFor
schedules and more details about these training courses on
simulationor other Honeywell products, go
tohttps://www.honeywellprocess.com/en-US/training/Pages/default.aspx.
Under some conditions, UniSim training courses can also be
provided atthe customers site as appropriate.
Operator Training Simulator Software Updates available
Operator Training Simulator Software Updates are now available
forcurrently
UniSim Operations Suite R430 Patch Releases...
UniSim Operations Suite R430 patch 3 was released on Sept 15,
2014.
The main corrections are described below for the different
functions:
DCS and PLC:
CentumVP DCS - events converted to scenario corrected.
CL execution sequence in USO revised.
CS3000 FFAO GCB PV, RSV, MV, and OUT registers with CSV
valueupdated.
Dual Centum VP interfaces encountering snapshot load errors
beenresolved.
Support SIMFFD blocks in CEE Toolkit and adapter.USO:
Allow ShadowPlant models to load a customizedDsmDllWithSlibs.dll
revised.
Confirmation message displayed when exiting USO underSimulation
Server mode added.
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UniSim Operations Suite
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UniSim Operations Suite
Crash when activating multiple evaluations
simultaneouslyresolved.
Load specific version of USD when launching an OTS been
added.
R430 installed on a machine that previously contained R410
patch11 been fixed.
RTG shows out-of-memory error after running for 22
hoursresolved.
SCADA: Parameter is from STATION not captured in USO
eventmonitor when scenario is played.
Simulation Server download fails if download takes more than
5minutes been corrected.
Simulation Server doesn't not show any models or exercises
forcertain users resolved.
USO Toolkits:
CS3000 interface fails to start due to unavailability of DLLs
fixed.
DeltaV: Translation when Serial IO Card has a Device definition
butno DST been corrected.
Delta V: AI point missing in the output files corrected.
Diasys Netmation Adapter Toolkit Implementation.
SCADA: Toolkit Engine Execution been fixed.LMS:
SCORM activeX requires DCOM dynamic port.
SCORM: Reduce security risk by removing this dependency.
SCORM: Error when new user first downloads a simulation from
thesimulation server.
SCORM LMS can't contact USO dispatcher from ActiveX
control.UniSim Operations Suite R410 Patch Releases...
UniSim Operations Suite R410 patch 16 was released on Sept 29,
2014.The main corrections are described below for the different
functions:
DCS and PLC:
ProSim Bridge Step takes longer after saving a snapshot.
Modify MarkVI Adapter to support MarkVIe controllersUSO:
Not possible to change SPHILM/LOLM from DCS resolved.
XNODE CIMPP revised.USO Toolkits:
Centum VP Translation fails when TagRef and FcsRef databaseshave
a mismatch.
Modify MarkVI to support MarkVIe controllers.For information on
UniSim Operations, please contact your Honeywellaccount
representative or email your regional UniSim / OTS Support
centre
OTS Support addresses:
[email protected] for North America & South America
regions;
[email protected] for Europe, Middle East region,
andAfrica regions;
[email protected] for Asia Pacific region.
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5UniSim Design Suite
Also, UniSim Design Type Library and OLE Automation must be
selectedfor the link between UniSim Design and Excel to function
properly. This isachieved by opening the Visual Basic window under
the Developer tab,and then selecting Tools->References, as seen
below. The Developer tabmay need to be activated in Excel Options
from the file menu. The availablereferences are not sorted
alphabetically and may require searching for itwithin the list. If
the UniSim Design Type Library is not available in the list,simply
add it by clicking on the Browse button and searching for the
filenamed unisimdesign.tlb in the path similar to the one provided
below. Asseen below, RXX0 represents the UniSim Design version
installed on yourmachine and may vary.
C:\Program Files (x86)\Honeywell\UniSim Design RXX0
Once these settings are configured, the setup is complete and we
are readyto create a Compressor UnitOp and set the curves by
executing the macro.Simply, press Go button and the data is then
transferred to UniSim Designcase by creating a new compressor named
Stage 1 in the Main Flowsheetenvironment. If a compressor with the
name Stage 1 already exists in theMain Flowsheet, the macro
overrides any curves with the data from the Excelfile.
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UniSim Design Suite
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Using Excel to set compressor curves in UniSim Design
model...
When working with a single stage compressor for a basic
simulation model,entering compressor curve is a very straight
forward process. However, whenthe model grows in complexity with
multiple compressors system in multipletrains, the process becomes
cumbersome and time consuming.
This months article looks at a solution of linking UniSim Design
to MicrosoftExcel using OLE Automation and setting the compressor
curves. The purposeof this solution is to illustrate an example of
automating the steps of enteringthe compressor curves while
reducing human errors. It can be very usefulwhen new set of
compressor curve data are provided by the vendor and themodel needs
to be updated; thus, increasing overall efficiency andproductivity.
The solution can be customized according to the userspreferences
and requires knowledge of VB(A) and OLE Automation.
The solution macro illustrated in this article may be found in
Solution 311 inthe UniSim Design Knowledgebase,
UniSim Design Simulation Case
The UniSim Design application must be open for this solution to
work. Onemay start with a previous model or simply create a blank
simulation case.
Once a case has been opened, the Excel macro handles rest of the
process.When the solution macro is downloaded on the local hard
drive, open theExcel file.
Excel and UniSim Design Interface
In order for the Excel file to run macro embedded in the
solution, securitysettings must be configured to enable the macros,
if not already set by default.If macros are disabled when the file
is opened, a security warning is displacedon top left section of
the screen. A screenshot is provided below to show howmacros are
set to enable from the Options button.
UniSim Operations Suite
Newsletter Articles
We aim to provide articles of interest to the UniSim Operations
usercommunity. If you have any feedback or have suggestions for
topics tocover here please feel free to contact us; we value your
input.
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UniSim Design Suite
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We invite any feedback through the normal support channel.
For information on UniSim Design, please contact your Honeywell
accountrepresentative or email the ATS UniSim Support
Team:[email protected]
Also visit the UniSim Design Suite Web Page or the UniSim Design
SuiteSupport Centre.
Newsletter Articles
We aim to provide articles of interest to the UniSim Design user
community.If you have any feedback or have suggestions for topics
to cover here pleasefeel free to contact us; we value your
input.
Sub-flowsheet Functionality
If desired, a simple modification to code allows setting the
compressor curvesin a Sub-flowsheet environment. First, create a
Sub-flowsheet in the UniSimDesign simulation case and then
implement the below code. Please note thata complete validation of
the code may be required; however, the key codefor this objective
is presented below.
Create a Sub-flowsheet in the simulation case (make sure to
usethe Sub-flowsheet Tag instead of Name when modifying with
theoptional macro)
Declare another variable in Visual BasicDim usdSubFlwSht As
UniSimDesign.Flowsheet 'Declare an object
Find the code and modify (Sub-flowsheet Tag is TPL1 in
thisexample)
Set usdSubFlwSht = usdCase.Flowsheet.Flowsheets.Item("TPL1")Set
usdComp = usdSubFlwSht.Operations.Add(strCompName,"Compressor")
Article submitted by Sumit Pandya, UniSim Design NA Support
Teamwith acknowledgement to James Martin, Team Lead, UniSim
DesignEMEA Support Team
Note:
This Automation example has been created by Honeywell as an
example ofwhat can be achieved through the object architecture of
UniSim Design. Thisexample is provided for academic purposes only
and as such is not subjectto the quality and support procedures of
officially released Honeywellproducts.
Users are strongly encouraged to check performance and results
carefullyand, by downloading and using, agree to assume all risk
related to the useof this example.
UniSim Design Suite
6
Operations Excellence
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Intuition Operations Logbook ..
Executive Summary
Shift handover is a common source of revenue loss and safety
incidents inprocess plants. Catastrophic accidents around the world
have been attributedto discontinuity of tasks and personnel
following operator shift changes. Botheconomic and regulatory
pressures demand substantial improvement in theshift handover
process.
In the operation of an industrial site, a large number of events
must bedocumented, together with the operator actions performed.
This kind ofdocumentation is obligatory in many plants, and is
typically referred to as anoperator shift log book. Still, today,
it is often a paper document or page in abook filled out manually
by the operator during or near the end of his or hershift.
Even with ad hoc or standalone logging techniques such as
spreadsheets,retrieval of information about past shift events is
very time-consuminganddetailed analysis of data for optimizing
operations, workflows and safetymeasures is nearly impossible.
A new breed of electronic operations shift logbook is now
bringing reducedrisk, greater effectiveness and substantial savings
to the process industries.This tool helps personnel across the
plant work together to achieve greateroperational reliability. The
electronic log consolidates information fromdifferent sources to
provide a consistent and up-to-date view of key processdata,
problems, operating plans and the shift log.
Background
The industrial world has long recognized that discontinuities of
shift handoverare among the most common and potentially serious
sources of problems.These can range from minor impacts on
operational efficiency to the mostserious safety incidents; all
incur corresponding levels of economic cost.
Shift handover occurs when one team of operators goes off duty
and an
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Operations Excellence
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Todays Operating Challenges
Ideally, the pre-defined sheet of an operations logbook ensures
consistentdata collected at defined, scheduled times. Too often,
however, the logbookis a collection of disparate data and notations
maintained by a supervisor ormanager, with little or no ability to
share information up and down the chainof command within the
organization (See Fig. 1).
Plant information relevant to the shift handover process can
include:
Permit to work status
Alarm defeat logs
Emergency shutdown device (ESD) defeat logs
Controller mode status
Sample logs such as lab results
Defective equipment log
Night order book
Unit and factory standing instructions/orders
Work order log
Shutdown job folders
Operating instructions
Material handling guides
Production, operations, and safety incident logs
Besides content for shift handover logs, there is also
contextwhat datashould be included in daily reporting? Ideally,
clear boundary lines should bedrawn between different units within
a plant containing several product lines.
Figure 1. Operations logbooks are often a collection of
disparate data andnotations maintained by a supervisor or
manager.
Problems with Existing Approaches
Most process plants already have a shift handover logging
application ofsome sort, but they frequently make use of ad hoc or
standalone data loggingtools such as spreadsheets, e-mail or custom
databases. Ad hoc tools mayprovide only limited access to daily
operating information for the rest of theorganization, or be
inconsistently applied. In addition, homegrown solutionscan be
difficult to keep up-to-date when the process changes. And such
toolsmay not be suited to following through on problems once
identified.
incoming team takes ownership of the plant for the following
shift. Duringthis period, the incoming shift must be made fully
aware of the plants status,including any incidents. A comprehensive
view of the process will includemany different kinds of
information, such as safety logs, operational records,lab
information, etc. The necessary transfer of information can be
performedboth by a review of the shift handover log, or,
preferably, a face-to-facemeeting between outgoing and incoming
shift workers.
Based on reports from high-profile incident investigations,
coupled withAbnormal Situation Management (ASM) Consortium research
on effectiveshift handover, failures of communication or
misunderstanding at shifthandover are to blame for many industrial
accidents. Incidents often takeplace during maintenance work or in
the implementation of changes. In manycases, they occur within the
first hours after the next shift has started.
The ASM Consortium has identified the need for a more
comprehensiveapproach to shift handover in plants with complex
operations and processes.Information in manually prepared shift
logs often is limited in usefulness, andas a result, whiteboards,
post-it notes and change sheets are common waysof enhancing
communicating and coordinating across shifts. However,
thesecommunication mechanisms suffer from a lack of structure and
permanence.
Examples of Industrial Accidents
Several industrial incidents emphasize the importance of
effective loggingand shift handover. On July 6, 1988, a large fire
and explosion on the PiperAlpha offshore platform killed 165 and
destroyed the facility. A relief valveon the platform was removed
for service and a blank had been looselyinstalled in its place.
This information was not recorded in the control roomor maintenance
logs. During shift handover, the status of the pump work
wasdiscussed, but no mention was made of the relief valve work.
Upon restart,the pump leaked, producing a flammable hydrocarbon
cloud.
A more recent incident occurred at a refinery in Texas City,
Texas, on March23, 2005. Fifteen people were killed and over 170
injured as the result of afire and explosion in the plants
isomerization unit. The explosion occurredwhen a flammable vapor
cloud formed following liquid overflow from theblowdown stack
during operation of the raffinate splitter. Among the rootcauses of
the accident were a failure to log pertinent information, as well
asan informal and unstructured shift handover process
Collectively, these and other incidents suggest there is a need
for a moreefficient way to guarantee the next shift gets the
information needed forshared situational awareness. Crucial data
and insights may be obtained fromlaboratory results, managers,
engineers, supervisors, field operators,maintenance personnel,
business planners and schedulers.
In addition to safety considerations, the details of
work-in-progress are notalways accurate conveyed during shift
handover, and thus tasks are oftenrepeated from the beginning. This
results in wasted time and material. Assuch, effective tools for
shift handover are also needed to help with executingoperational
tasks.
Operations Excellence
7
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that puts advanced operations logging capabilities within the
reach of alltypes of end usersfor both large and small
implementations. It is part of acomprehensive operations management
suite currently under developmentby Honeywell.
Provided on a new, streamlined platform, this control
system-independentapplication builds on Honeywells experience in
the operations managementarena and can be tightly integrated with
additional tools for plant operationsmonitoring, setting daily
operating instructions and analyzing alarmperformance.
Intuition Operations Logbook helps industrial facilities
transition from labor-intensive legacy spreadsheets, word documents
or paper logbooks to anautomated and standardized system for
facility-wide data collection, analysisand reporting. Employing
versatile Microsoft SQL Server technology, thesoftware can be used
to keep a detailed record of events during an operatorshift. It
delivers user-configurable shift summary reports to enable
effectiveshift handover and an intuitive, blog-style interface to
capture operatorcomments and notes about daily operations,
replacing ad hoc paperwork andspreadsheets.
Intuition Operations Logbook provides operations staff with a
common,browser-based window to access and enter information related
to variousplant operations. Information from a wide range of data
sources, includingplant databases, process historians, maintenance
management systems andMES/ERP systems, is automatically brought
together to give operators,supervisors and engineers a consistent,
up-to-date view of key operatingdata, problems, operating plans,
the shift log and more. The software canalso be integrated with an
alarm management system to provide an overviewof alarm activity
during a shift.The operations logging tool is designed toaddress
questions such as:
What comments and observations were recorded today or duringthe
last shift?
What comments and observations have been recorded about atopic
such as environmental issues for a particular unit?
What happened during a shift and what does the incoming teamneed
to know in order to operate safely and effectively during thenext
shift?
What are the safety, process, design and environmental limits,
andare these limits being honored when operating plans are
drawnup?
What did the operators observe while executing the plan?
Honeywells software lets operators enter comments and prepare
shiftsummary reports, often used to facilitate an effective,
structured shifthandover. It allows comments or notes to be entered
from a variety of places.The system automatically records the name
of the user who entered or lastedited a comment and the time of the
change.
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Operations Excellence
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Because personal spreadsheets are generally not subject to the
same rigidcontrol standards as other IT applications, errors and
omissions can occur,impacting the accuracy of information used to
implement shift handoverprocedures. Without a central data
repository, different individuals may applydifferent data as the
basis for reporting and decisions.
In a typical scenario, a plant relies on a manual system to
manage its shifts,using hand-written reports logged in hardcover
books. This process is notonly time-consuming, but it can be
unreliable, with readings for criticalprocesses such as tank levels
and ratios often not recorded accurately. Issueslike defeated
alarms and details on plant status and situations can also
bemissed. Plus, the logbook may not always be accessible between
shifts, andbeing manual, it has no backup in the event of loss or
damage, so the riskof data loss is high.
Some shift handover logs are no more than simple notebooks that
operatorscomplete during their shift. These have obvious and
serious limitations, suchas illegible handwriting, the difficulty
of searching through a mass of entriesacross numerous books to find
a particular entry, and the inability to identifyor correlate
common or recurring issues.
More advanced shift handover systems use some type of electronic
logbook,which overcomes the illegibility problem and can provide
limited searchcapabilities. However, these are generally
stand-alone applications, whichdo not enable information to be
shared across networks or used as a corporateresource. Search
provisions are often simple text-matching functions thatcannot
access the latent intelligence in the accumulated
information,inhibiting the ability to identify related problems or
recurring issues.
The requirements for an effective operations logging solution
include: openconnectivity with plant information systems, real-time
process datareconciliation and validation, an efficient and
friendly user environment, lowmaintenance requirements and full
automation capability.
Finding a Better Solution
Improving operational reliability requires a team effort by
operators, engineersand various specialists in a process plant.
These people will benefit fromsoftware tools that help ensure the
facility is always operated within the rightlimits and each new
team of operators fully understands what is happening,and what
activities remain to be done.
Leading automation suppliers like Honeywell Process Solutions
havedeveloped a new breed of tools to enable an effective shift
handover processat modern industrial sites. These solutions,
designed to capture andaggregate key data from across the plant and
make it available through aweb-based user interface, enable
efficient and reliable shift handover workprocesses to reduce
errors, avoid incidents and improve operationaleffectiveness.
Honeywells Intuition Operations Logbook is powerful and
versatile software
8
Operations Excellence
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Operations Excellence
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Benefits for Process Facilities
The new generation of electronic operations logbooks can
substantiallyeliminate the deficiencies of current shift handover
management systems,and deliver significant economic benefits in
operational efficiency and riskreduction. The advantages available
to process plants come from a varietyof sources, including:
Reduced number and severity of incidents
Lower operating and maintenance costs through increased
assetreliability
Better safety and environmental compliance
Increased production through learning from and avoiding
incidents
Automatic documentation of the state of the plant for
shifthandover
Reduced time for analyzing disturbances
Easier evaluation of messages for diagnosis and
optimizationpurposes
Simple collection and maintenance of plant know-how
Better identification of weak points and opportunities
foroptimization
Even experienced operators can make mistakes if the information
they haveis incomplete or difficult to understand. A well-designed
electronic logbookhelps solve this problem by enabling a structured
shift logging and handoverprogram. Operators record what they do,
and everyone can see what reallyhappened in the plant.
IT professionals will also appreciate how tools such as
Intuition OperationsLogbook work as part of an integrated plant
information system. They helpsatisfy a number of crucial IT
requirements:
Minimizes administration costs with a web user interface
Reduces costs by taking advantage of built-in integration with
otheroperations-related applications
Accesses process data from plant historians
Implements a robust, role-based security mode
Summary
Todays advanced operational logbook tools are designed to
capture andmake data accessible across an industrial organization
to a wide variety ofusers. They can replace the myriad of paper
logs, spreadsheets and disparatedatabases and integrate information
from many different sources in onelocation. Providing a sound
structure for operator logging, based on keycategories of
situational information, is the answer to optimizing
theeffectiveness of shift handovers.
Many key benefits result from a structured shift handover
solution. Theseinclude:
Ability to quickly find relevant information (e.g., comments
logged
Figure 2. Intuition Operations Logbook provides a common,
web-basedwindow to access and enter information related to various
plant
operations.
Typical Plant Application
A common objective in the process industries is to improve
reliability, andreduce the number and severity of incidents. In
addition, plants are seekingto extend asset life and increase
margins through better fidelity to theoperating plan. Solutions
such as Honeywells Intuition Operations Logbookcan assist control
room and field personnel by providing quick access to ahost of
valuable information from all corners of the operation.
For example, using the electronic log, an operator reviews the
highlights ofa shift just ending with another operator. The
outgoing operator brings up theshift report he recently filed via
the logbook application. He points to acomment about a pump repair,
and another notation about a feedstock changeplanned for the next
shift. He looks to the instruction, where flow andtemperature
target changes are highlighted, and sees the planner wrote thata
lineup change is needed.
The operator returns to the shift report and points out the key
operatingparameters for the unit, and how they have been stable for
the day. He thenshows the result of the last alarm enforcement
report, which indicates theoutgoing operator changed some alarm
limits for the pump that was repairedwith a note the limits should
be changed back when the repair is complete(See Fig. 3).
Figure 3. Using the electronic log, an operator can review the
highlights ofa shift just ending with another operator.
Operations Excellence
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Operations Excellence
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by an operator dealing with the same situation in the past);
Saved time in terms of capturing data and pulling
informationtogether for the shift summary report;
Improved reliability/reduced downtime; enhanced
communicationsacross all organizations at the site, not just
operations;
Improved regulatory compliance (where applicable) givenautomated
recording and archiving of reports in a format that is
noteditable;
Consistent situational awareness for all users; and improved
datafor process improvement activities and incident forensics.
References
1. Plocher, T., Shanqing Y., Laberge, J., Thompson, B., Telner,
J., EffectiveShift Handover, Engineering Psychology and Cognitive
Ergonomics. Web.2011.
2. Nimmo, I., Effective Shift Handover Is No Accident, Chemical
Processing.Web. 28 June 2006.
3. Intuition Operator Logbook- Whitepaper.pdf
Support Services
Intuition Operations Logbook comes with worldwide, premium
supportservices through our Benefits Guardianship Program (BGP).
Helping improveand extend the benefits applications deliver, BGP
safeguards your softwareinvestment.
For More Information
Learn more about how Honeywells Intuition Operations Logbook can
helpimprove your operational effectiveness, visit our
websitewww.honeywellprocess.com/software or contact your Honeywell
accountmanager.
Honeywell Process Solutions
Honeywell 1250 West Sam Houston Parkway South Houston, TX
77042
Honeywell Control Systems Ltd, Honeywell House Skimped Hill
LaneBracknell RG12 1EB
Shanghai City Centre, 100 Junyi Road Shanghai, China 20051
www.honeywellprocess.com
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