Statoil SnowWhite LNG process plant northern Norway ThomasChristian

Statoil Snow-White, LNG process plant, northern Norway Thomas-Christian Skovholt, Product Manager ABB Alarm Lifecycle Management Managing the human factor © ABB December 1, 2020 Slide 1

Introducing the human factor Control room operator behavior “I think with my spine. ” © ABB December 1, 2020 Slide 2

Overwhelmed operators may not react quickly or correctly In the process automation industry, up to 90% of accidents are attributable to human error. © ABB December 1, 2020 Slide 3

Imagine this scenario There’s an unusual situation Your pulse starts racing Then, alarms start ringing and keep ringing In this situation, operators are supposed to perform a full safety and process evaluation before performing the corrective actions. And all of this needs to be completed in a limited amount of time. * *Normally, this is performed by teams of experts—not just one operator. © ABB December 1, 2020 Slide 4

Not just an imagined scenario anymore What has happened • Excessive number of alarms in emergency situation (85% were defined as high priority) • Reduced operator response effectiveness • Resulted in explosion and fire Milford Haven © ABB December 1, 2020 Slide 5 • “Had the alarm sounded properly as the blowdown drum was flooding, it could have alerted operators to the emergency situation. ” • Resulted in fatal explosion— 15 killed, 170 injured Texas City • “At the heart of this tragedy is the fact that the stall alarms were ignored” and the situation was misinterpreted • Resulted in a downed airplane, killing 228 on board Air France 447

The automation paradox “. . . the more reliable and greater the scope of automation, the greater the demand on the operator when it fails. ” § Users are being pacified. § Important clues are overlooked or misinterpreted. Modern digital control systems hide most of the process from the operator and alarms are required to direct the operator’s attention as well as annunciate problems. © ABB December 1, 2020 Slide 6

How digitization has impacted operators Too many alarms implemented without formal review No understanding of the subsequent operator burden Operators are overloaded beyond their design limit Pre-digitization (1960) = 100 alarms per operator Digitized (2000+) = 4, 000 alarms per operator © ABB December 1, 2020 Slide 7

How you can help operators Enable § Use alarms as a toolset to help perform correct actions and direct attention appropriately Involve § Operators notes (via Alarm Helper) act as feedback to alarm reviews We need to manage and design alarm systems with the operators in mind. © ABB December 1, 2020 Slide 8

Make an alarm management strategy Low hanging fruit: focus on top 10 alarms Complete redesign and alarm rationalization Continuous bi-weekly reviews Bulk updates Evolution Revolution Both approaches may be used, at different points in time © ABB December 1, 2020 Slide 9

Plan for success from the start Every digital automation control system* needs an alarm management solution And the relevant services to ensure adoption * Let’s start with 800 x. A © ABB December 1, 2020 Slide 10

Reference case Gas processing, Egypt § Problem § Too many alarms / safety issue Numerous plant shutdowns led to lost production § ABB lead alarm diagnosis, alarm rationalization and implementation of new design § Alarm rates reduced Solution § Benefits Figure 1. Alarm rate reduction over time § Improved plant uptime § § Slide 11 From 25 6 shutdowns/yr Higher production per year § © ABB December 1, 2020 400 8 alarms/10 min Estimated USD 2 M/yr

Reference case Power generation, United Kingdom Problem § § § Solution § § § Figure 2. Sudden alarm rate reduction when DCS was bulk updated with new alarm design from alarm rationalization Benefits § § © ABB December 1, 2020 Slide 12 Operators missing key alarms Safety compromised Alarm system redesign and rationalization Chaired by ABB consulting Bulk update of DCS controllers Alarm rates significantly reduced § Operators able to proactively identify and prevent problems from escalating Improved plant uptime Improved focus on safety

Reference case Heavy oil production, Canada Problem § § Solution § § Figure 3. Continuous alarm rate reduction. Spikes due to new sections coming online. Benefits § © ABB December 1, 2020 Slide 13 Too many alarms Missing operator response texts Installed Alarm. Insight® software Started continuous alarm optimization process Used Alarm. Insight to detect bad actors and manage process Alarm rates significantly reduced § Operators able to proactively identify and prevent problems from escalating Operator response help available

Alarm Lifecycle Management benefits Move from reactive to proactive © ABB December 1, 2020 Slide 14 § Compliance with industry standards and good practice § Improved safety and environmental performance § More efficient plant operation § Increased production and equipment availability § Smoother start up and shutdown § Operational human factors improvements § Reduces operator stress § Enables operators to be proactive

Enabling efficient alarm management Lifecycle approach to alarm management “My alarms are under control and I want to ensure they stay that way. ” Sustain “I know what my problem is and I need help fixing it. ” Implement “I don’t know what my problem is. ” Consulting Services and Alarm. Insight Software Diagnose Alarm benchmarking services © ABB December 1, 2020 Slide 15 Continuous and/or periodic support services

Overview Complete offering Diagnose § Basic Benchmarking Service Implement § Kick Start Service Sustain § § Standard Alarm Rationalization Service Full Alarm Rationalization chaired by ABB, setting alarm priorities and operator response, input for Alarm Helper and DCS bulk updates (using ART) § Continuous Alarm Optimization Periodic reviews and support to ensure adoption of Alarm. Insight Software and alarm management processes Training, alarm philosophy, basic alarm logging/reporting and nuisance alarm management Extracting only alarm and events data for benchmarking reports and recommendations § Alarm System Maintenance Periodic health checks, product support Advanced Alarm Rationalization Service Grouping, state-based alarming and suppression (using ART, Expert Tool Alarm Analysis) § Alarm. Insight Software Installed on-site, IT project delivery, enables efficient alarm management throughout the lifecycle of the plant Analyze alarm system performance metrics and manage the alarm system according to EEMUA 191, ISA 18. 2, IEC 62682. © ABB December 1, 2020 Slide 16

Basic Benchmarking Service Predefined package Customer DCS Alarm log dump 1 month of data (or similar) © ABB December 1, 2020 Slide 17 ABB Services Alarm data analysis Making use of Alarm. Insight Expert Tool or similar Customer Predefined report: - Alarm Benchmarking Report -Recommendations Comparing customer alarm rates with best practices and recommending next steps

Alarm. Insight Software for the entire alarm management lifecycle Alarm. Insight® § Alarm performance monitoring and nuisance alarm management § Bulk alarm rationalization § Real-time alarm information for operators Software is integrated and proven with 800 x. A today and in the future. © ABB December 1, 2020 Slide 18

Alarm. Insight Software overview Alarm monitoring and analysis Alarm management Real-time information Basic and enterprise data logging Lifecycle management Per site / for control room operator § Alarm. Helper (AH) § KPI-Report/. pdf (KPI) § § § Manually set filters, analyze and generate reports Event. Log Viewer (EL) § § Automatically generated KPI reports: daily, weekly, monthly Alarm Rationalization Tool Alarm. Analysis (AA) § § § Manually set filters, find root cause and sequence of events Expert Tool (ET) § Service tool for ad-hoc , deep-dive analysis supporting improvement work: used in all phases (client) § Alarm Rationalization and Continuous Alarm reviews, Management of change/ Master Alarm Database (SQL) § Input for Alarm Helper and DCS bulk updates § Both a services tool and on-site server implementation § Operator support: How to react to an alarm and collect feedback from operators § Context-sensitive presentation of input from Rationalization, design and modification work Alarm Change Recorder (ACR) § Monitor changes to alarm attributes/ values in the distributed control system § Track changes during operation and modifications Basic: Logging and alarm KPI reporting , log collection from multiple sources Enterprise features: Multi-site alarm consolidation, office network reports, large datasets © ABB December 1, 2020 Slide 19

Alarm. Insight Real-time information LAH – 123456 Flare Knock Out Drum – High level Called up directly from the alarm list on 800 x. A control panel Alarm Help for operators: 1. What does the alarm mean and how to remedy the issue 2. Capture operator feedback (for future alarm reviews) Can include change recorder historical alarm attribute values Populated/updated via Alarm. Insight Alarm Rationalization Tool 5 min © ABB December 1, 2020 Slide 20

Alarm. Insight Alarm reporting Monitor and benchmark alarm performance through predefined KPI Report, including collection of historical data Web based © ABB December 1, 2020 Slide 21

Alarm. Insight Analysis and drill down I Find most frequent alarms, longest standing alarms, etc. , and plan improvement activities with Alarm Analysis/Expert Tool Ad–Hoc reports, manual filter settings, and historical data Web based © ABB December 1, 2020 Slide 22

Alarm. Insight Analysis and drill down II Exclude alarms already identified for rationalization and drill down further to find the next set of bad alarms “Preview” impact (on KPIs) of “fixing” a particular nuisance alarm © ABB December 1, 2020 Slide 23

Alarm. Insight Lifecycle Alarm design, rationalization and optimization Document the alarm settings in the master alarm database Use the Alarm Rationalization Tool to efficiently rationalize alarms and optimize alarm settings and operator response texts throughout the lifecycle Web based © ABB December 1, 2020 Slide 24

Alarm. Insight Alarm Change - Mo. C Alarm system audits and alarm setting enforcement Monitor changes to alarm attributes directly from 800 x. A. Add references to work orders Web based © ABB December 1, 2020 Slide 25

Alarm. Insight Alarm Rationalization Workflow Meetings chaired by ABB Manual work Alarm Document Philosophy DCS • Alarm attributes data dump file from controllers • Transform data file into ART format (Excel) 800 x. A © ABB December 1, 2020 Slide 26 AI ART • Import data • Rationalize Alarms • Mo. C/store records in DB • Export data Alarm. Insight Alarm Rationalization Tool DCS Bulk upload or implement manually into DCS • New alarm Priority and attributes • Operator response texts Alarm. Insight Alarm Helper population

Sustain Continuous improvement 1 Consider: Plant conditions and equipment are in a constant state of flux It is a continuous job to monitor and optimize 2 Processes change over time 4 Equipment wear and tear 3 New extensions or upgrades within the plant Alarms should change as the plant changes. © ABB December 1, 2020 Slide 27 Change of equipment that affects alarm settings

What customers say about ABB Services § UK North Sea: § § Rashid Petroleum Company (Egypt): § © ABB December 1, 2020 Slide 28 “A number of shutdowns have been avoided due to the low level of alarms the operators now have to deal with, which enables them to react in a more timely and proactive manner. Several instances of savings in the region of USD 0. 2– 0. 5 M in lost production have been recorded. ” “This is what success looks like. WDDM alone had only 6 trips in 2008 compared to 25 in 2007, and 17 in just the second half of 2006. This has significant business value. ”

What customers say about ABB Alarm. Insight software © ABB December 1, 2020 Slide 29 Calgary, Canada: Houston, United States of America: “Alarm. Insight Alarm. Analysis is far beyond competitors capabilities. ” “The future Alarm Analysis capabilities and Master Alarm Database are all very interesting to us. ” Calgary, Canada: Oslo, Norway: Burlington, Canada: “This is what we are looking for–we are interested in the whole package. ” “The alarm exclusion feature will be really useful to us. ” “This is a great package. ”

Consulting services references Highlights BP § § § Aberdeen/North Sea § Support to alarm improvement and rationalization projects § Benchmark assessments § Alarm strategy documents Projects, Aberdeen/GPO § § © ABB December 1, 2020 Slide 30 Alarm rationalization reviews (Quad 204, SCPX and SD-2 projects) Corporate, Sunbury § Preparation and delivery of global alarm management training program § Alarm management consulting support § Alarm rationalization reviews Sharjah § Benchmark assessment § Alarm rationalization reviews Azerbaijan § Alarm management FEED scoping studies § Customized operations and maintenance training § Full lifecycle alarm rationalization and offshore implementation BG Group, Aberdeen, Egypt and Tunisia § Full lifecycle alarm rationalization and management § Benchmark assessment § Alarm philosophy documents § Alarm managementoring and coaching § Continuous improvement services § Periodic audits § Alarm flood management services

Consulting services references Highlights § § Huntsman, UK § Full lifecycle alarm rationalization and management § Continuous improvement support ICI Polyurethanes, Wilton, UK § § Conoco. Phillips, Norway § § © ABB December 1, 2020 Slide 31 Trip and alarm design, full lifecycle alarm rationalization and management Alarm management support § Britannia Operator Ltd, UK – Alarm management health check § Chevron, UK – Alarm management health check § Exxon. Mobil, UK, NO – Training § Maersk, DK – Training § Nexen, UK – Alarm management health check § Shell, UK – Alarm management assessment § TAQA – Alarm management health check § E. ON, UK Conoco. Phillips, Aberdeen § Benchmark assessment § Full lifecycle alarm rationalization and management support § Alarm management software installation and support § Customized alarm management training § ADCO, Abu Dhabi – Benchmark assessment and software § Gasco, Abu Dhabi – Benchmark assessment and software § Glaxo. Smith. Kline, Singapore – Benchmark assessment § Apache, AU – Alarm Rationalization reviews § QGC/BG, AU – Alarm Rationalization § Blue. Scope Steel, AU – Alarm management strategy and benchmark

System installation references Various options of Alarm. Insight – current versions North America Europe § Exxon. Mobil Hebron (KPI, AA, EL, BL, AH- CA/) § Conoco. Phillips J-Block (AA, EL, ET - UK) § Exxon. Mobil Pt. Thomson (AA, BL, EL, ACR, AH - USA) § E. ON Benelux Maasvlakte (NL) § Devon Energy Jack. Fish 2 (AA, EL, ACR, AH– CA) § Indaver Antwerp (BE) § Devon Energy Jack. Fish 3 (AA, EL, ACR, AH– CA) § Indaver Doel (BE) § Indaver Ijmuiden (BE) § Nexen Buzzard platform (UK) Asia § Maersk Oil Qatar Al Shaheen platform, Loc A § Petroplus Antwerp (BE) § Maersk Oil Qatar Al Shaheen platform, Loc B § Talisman Energy Inc. Fulmar platform (UK) § Gasco Habshan complex § E. ON UK § Takreer Ruwais Refinery Holford Gas Storage (EC, ET, KPI, UK) § BP Sangachal Terminal – ACG Azerbaijan (AA, EL, ET, KPI – UK) Australia © ABB December 1, 2020 Slide 32 § Visy Tumut Brisbane § Queensland Gas Company Chinchilla, Queensland

System installation references Various options of Alarm. Insight – current versions Denmark Norway § Amerada Hess South Arne platform § Shell Ormen Lange (ACR, AH, BL) § Aarhus Karlshamn Århus § Statoil Snøhvit (BL, EL, AA) § Dalum Papir Odense § Statoil Sleipner (ACR, AA, EL, BL) § DONG E&P Siri platform § Statoil Gudrun (ACR, AA, EL, BL) § Energinet. dk Ll Torup § Statoil Aasta Hansteen (AA, KPI, EL, BL, ACR, AH) § IS Vestforbrænding Glostrup § Shell Draugen (AH, ACR, EL, BL) § Haldor Topsøe Frederikssund § Maersk Vincent (AA, EL) § Maersk Oil & Gas AS Dan B Platform § Conoco. Phillips Ekofisk (KPI, BL) § Maersk Oil & Gas AS Dan F platform § ENI § Maersk Oil & Gas AS Dan FG platform Goliat (AA, EL, AH, ACR, BL, not commisioned) § Maersk Oil & Gas AS Dan Utility § Statoil Kårstø § Maersk Oil & Gas AS Esbjerg § BP Ula (EL, AH) § Maersk Oil & Gas AS Gorm platform § BP Valhall (EL, BL ) § Maersk Oil & Gas AS Halfdan platform § Statoil Sture (BL) § Maersk Oil & Gas AS Harald platform § Statoil Heimdal (KPI, EL) § Maersk Oil & Gas AS Rolf platform § Teekay Knarr (BL, KPI) § Maersk Oil & Gas AS Skjold platform § Statoil Grane (EL, BL) § Maersk Oil & Gas AS Tyra East platform § Hess Sedje Ceiba (AA, EL, BL, ACR ) § Maersk Oil & Gas AS Tyra SE platform § Dana WIDP (planned) § Maersk Oil & Gas AS Tyra West platform Sweden § © ABB December 1, 2020 Slide 33 Korsnäs AB Gävle

Learn more Watch “Getting Alarm Management Right First Time” webinar by Colin Bartliff https: //www. youtube. com/watch? v=-Yp 1 u. U 4 p 5 t 8 Watch “Alarm Management in the Regulatory Spotlight” webinar By Joan Evans https: //www. youtube. com/watch? v=2 r. Ct-sl. Gm 30 Visit the “Human Factors” blog by Tony Atkinson www. tinyurl. com/humanfactorsblog http: //uk. inside. abb. com/cawp/seitp 202/db 362514 c 262 e 753 c 1257 bce 004 f 4347. aspx http: //new. abb. com/docs/librariesprovider 53/about-downloads/human-factors-in-the-workplace. pdf? sfvrsn=2 Additional training courses and seminars http: //new. abb. com/uk/about/our-businesses/process-automationdivision/consulting/training-events © ABB December 1, 2020 Slide 34

Contact information © ABB December 1, 2020 Slide 35 Product manager: Thomas C Skovholt Contact and support: NO-Alarm. Insight. Support@abb. com Software Orders: ogp. products@no. abb. com Alarm Services Link abb. com Software Link

Evolution and experience Started in late 1990 s with the realization that spreadsheets could not handle the large amounts of alarm configuration data 1990 s © ABB December 1, 2020 2003 Slide 37 Redeveloped in 2012 to focus on Alarm Reviews as a follow on to work ABB undertook on EEMUA 191 revision 3 2012 Integrated into Alarm. Insight 2015

Insight® portfolio Insight® Alarm. Insight® Manage and monitor the alarm system • © ABB December 1, 2020 Slide 38 Analysis and reporting • Real-time alarm information • Managing alarm settings • Safety. Insight® Operation. Insight™ Manage and monitor the safety system Manage the day-to-day operations in the control room Provide reports and documentation on safety functions • Listing of blocked, forced and suppressed alarms • Record and share shift information

Alarm. Insight Architecture Office: Make reports available outside the «factory» / control network All components and database on one physical or virtual server Client installation Expert tool KPI reports Alarm Analysis Change Recorder Event Log OPC-DA Event Consolidation Database (SQL) Alarm Helper 800 x. A Aspect/web Alarm Rationalization Tool Block. Log (OI) (Master) Alarm Database (SQL) OPC-AE PLANT NETWORK CONTROL NETWORK Collect data from various sources Third-party DCS 800 x. A History 800 x. A Some components are also available in the System 800 x. A pricelist as: 800 x. A History and reports 800 x. A Alarm operations © ABB December 1, 2020 Slide 41

Alarm. Insight Small standalone architecture All components and database on one physical server Installed on a PC Transfer data to AH vi Excel DCS controllers updated manually Alarm Helper (800 x. A only) KPI reports Event Consolidation db Alarm Rationalization Tool (incl. SQL Express) Alarm Helper db PLANT NETWORK CONTROL NETWORK 800 x. A History Collect data from various sources 800 x. A Third-party DCS Some components are also available in the System 800 x. A pricelist as: 800 x. A History and reports 800 x. A Alarm operations © ABB December 1, 2020 Slide 42

800 x. A and Alarm. Insight How to choose software (1) Monitor, Manage and Optimize Manage the Alarm System (Near real time or offline, historical data) or Use the Alarm System 800 x. A control room interface real time © ABB December 1, 2020 Slide 43

800 x. A and Alarm. Insight How to choose software (2) With only 800 x. A, • • Cannot complete ad-hoc queries or dill downs Must configure everything in advance 800 x. A alarm handling The alarm system core 800 x. A Wait at least two plus weeks for your first report Cannot look at extend time intervals (only what’s available via 800 x. A memory © ABB December 1, 2020 Slide 44 With alarm management software: 800 x. A Operations 1. Grouping 2. Shelving Alarm lists 3. Pre-defined alarm analysis (KPIs) 4. Alarm. Insight Alarm Helper Manage the alarm system • Comply with international standards 800 x. A History & Reports • Gain deeper insight and analysis • Deeper drill down and filters for alarm analysis • Manage change easier (i. e. configure new installations) Alarm. Insight Deeper Insight + Lifecycle Management 1. Alarm Analysis 2. Event. Log Viewer 2. ART 3. Expert Tool 6. Alarm Change Recorder Monitoring 1. Alarm. Insight KPI reports 2. Alarm. Insight Event Consolidation Database (historical alarm data)

Comparison Software enterprise options Onsite Server PC expertise Additional Front-End web Server (all applications) IT project delivery: - Cyber Security - Network Office network Plant network 800 x. A Operations Expert Tool Alarm Helper Alarm Rationalization Tool 800 x. A Operations + 800 x. A History&Reports Alarm. Insight full scope Alarm. Insight Office network access Alarm. Insight Consolidation – multiple sites Alarm. Insight 3 rd party DCS Alarm Helper KPI Reports KPI Reports Event. Consolid DB Alarm Analysis Event. Log Viewer Alarm Change Recorder Alarm Rationalization T. IT project delivery: -IIS web server -SQL maint. (Index, defragmentation etc) -backup -HW/OS/remote access Control network 800 x. A © ABB December 1, 2020 Slide 45 800 x. A Smart Logger integration DCS w/ OPCAE, Seriel, Print DCS / event flow understanding