Using Process Historian Data to Understand and Assure Barriers

PresentationLike many companies, Honeywell estimates the probability of control system problems and safeguard layer faults using the available reliability data. Probably like others, we have wondered how accurate these “standard numbers” are in our services. In our Advanced Materials division, we have been collecting real-world data on initiating events, Safety Instrumented Functions (SIFs) and other Independent Protection Layers (IPLs) in the data historians at two of our new low-global-warming Hydro Fluoro Olefin (HFO) units. Recently, we began using analysis tools to “mine” this data to see what it could tell us about our actual Initiating Event Frequencies and the Risk Reduction Factors being achieved. In essence, we are comparing the actual performance of our critical safety Layers of Protection with the performance that was intended by the PHA team. In this paper we will describe the results of the Operation and Maintenance phase of the Safety Life Cycle and how we are using the resulting data in several important ways: to indicate the real-time health of active IPLs - watching for events like IPL degrading, and bypassing; to integrate the learnings as Key Performance Indicators (KPIs) to leadership and as inputs to our PHA/LOPA revalidations