Case Study: Shell achieves 90% reduction in operator alarm loading and 3–4% reduction in production deferment with Honeywell Forge Alarm Management

Shell - Customer Case Study

Shell’s Sierras Blancas hydrocarbon site in Argentina was overwhelmed by alarm noise—long-term averages of 60–80 alarms per hour per operator and peaks up to 150—far exceeding ISA 18.2 guidance and Shell’s internal target of three alarms per hour. To benchmark, analyze and improve alarm performance, Shell deployed Honeywell Forge Alarm Management from Honeywell Forge to automate data collection, reporting and support the alarm rationalization effort.

Honeywell Forge Alarm Management provided out-of-the-box reporting, documentation and continuous monitoring to drive weekly review meetings, operator training and ongoing improvements. As a result, Shell reduced operator alarm loading from about 80 alarms per hour to three (more than a 90% reduction) and cut production deferment by an estimated 3–4%; Sierras Blancas is now a Shell reference site and continues to use Honeywell Forge to sustain KPI performance.

Shell