The Real World Impact of ISA 18.2 on Process Industries Kevin Brown Matrikon Inc. - PowerPoint PPT Presentation

Loading...

PPT – The Real World Impact of ISA 18.2 on Process Industries Kevin Brown Matrikon Inc. PowerPoint presentation | free to view - id: 3b6dcf-NDM0M



Loading


The Adobe Flash plugin is needed to view this content

Get the plugin now

View by Category
About This Presentation
Title:

The Real World Impact of ISA 18.2 on Process Industries Kevin Brown Matrikon Inc.

Description:

The Real World Impact of ISA 18.2 on Process Industries Kevin Brown Matrikon Inc. * * * * * * * * * Who is Matrikon * * * * Continuous lifecycle. Alarm management is ... – PowerPoint PPT presentation

Number of Views:274
Avg rating:3.0/5.0
Slides: 33
Provided by: isaedmont
Category:

less

Write a Comment
User Comments (0)
Transcript and Presenter's Notes

Title: The Real World Impact of ISA 18.2 on Process Industries Kevin Brown Matrikon Inc.


1
The Real World Impact of ISA 18.2on Process
IndustriesKevin BrownMatrikon Inc.
2
Agenda
  • Introduction
  • What is Alarm Management
  • What is a Lack of Alarm Management
  • OHS Legislation
  • An Example Plant Incident
  • Demystifying Standards Guidelines
  • ISA 18.2 Compliance
  • Alarm Management Lifecycle
  • Steps to Compliance
  • Questions

3
Kevin Brown - Introduction
  • Manager North America Alarm Management Team
  • 4.5 years at Matrikon
  • Completed projects from upgrades to 2.8 MM
  • Audits
  • Alarm Philosophy development
  • Facilitate alarm rationalization
  • Spent 20 years in plants in process control
  • Experience with different computer control
    systems
  • Bailey, Taylor, Advant, GE, Allen Bradley, Metso,
    TDC3000
  • Experience with Historians
  • Simsci, MOPS, OSI PI
  • DMZ network design and setup

4
Matrikon Alarm Management
  • Matrikon has 20 years experience and is the
    Global Leader in the deployment of Enterprise
    Wide Alarm Monitoring Solutions with the worlds
    leading companies,innovation, safety, commitment
    to
  • value and high ethical standards

5
Company Overview
Other150
Complete Solution Provider
Consultants275
RD100
  • 550 employees
  • 300 consultants with extensive domain expertise
  • Complete services, from planning to execution

Global Presence
  • 18 offices
  • 17 Partners
  • Strong Presence in Toronto (25 Consultants)
  • TSE MTK

6
What is Alarm Management?
  • Process by which alarms are engineered,
    monitored, and managed to ensure safe, reliable
    operations

7
What is Alarm Management?
8
What is Alarm Management?
  • Alarm Management is a Core Layer of Protection.

COMMUNITY RESPONSE
PLANT EMERGENCY RESPONSE
PHYSICAL PROTECTION / CONTAINMENT
PHYSICAL PROTECTION / RELIEF DEVICES
SIS
ALARM MANAGEMENT
BASIC CONTROLS
PROCESS DESIGN
9
What else is Alarm Management?
  • Continuous lifecycle
  • Plant maintenance/reliability
  • Good process control
  • Outcome of a risk assessment
  • Related to equipment failure
  • A form of Enhanced/Advanced Control
  • Abnormal Situation Management
  • It has been widely ignored for a long time

10
What is a Lack of Alarm Management?
11
(No Transcript)
12
What is a Lack of Alarm Management?
  • Example Texas City Oil Refinery 2005.
  • Precursors
  • - Maintenance cut by 25
  • - Only one Control Room Operator for the whole
    plant
  • - Failed level switches
  • - Level transmitter reading incorrectly no
    alarm
  • - Workers within exclusion zone
  • - Decided against installing safety flares
  • Outcomes
  • - 15 people killed
  • - Could have spent a couple of m but ended up
    costing 1.6b
  • - Oil Refining industry are now relatively
    proactive in AM
  • (Ref.) http//www.texascityexplosion.com/

13
Alarm Management Its about Safety!
Documented financial losses estimated at 1.5
billion
OSHA leveraged fines for this incident exceeded
87MM
14
An Example Plant Incident
15
An Example Plant Incident
  • Plant is unstable, getting towards end of 12hr
    shift
  • Tank containing hot material reaches HH level
  • Trip on HH level interlock was disabled to
    replace the instrument and inadvertently not
    re-enabled
  • Operator misses the alarm because he/she is
    overloaded and there is an alarm flood
  • High level safety switches that trip the incoming
    pump have not been tested for over two years and
    fail to operate
  • Tank overflows and severely burns worker below

16
Possible Outcome
  • Employee Impact
  • Possible Injury
  • Potential Fatality
  • Flow-on Family/Community effects
  • Employer Impact
  • Operational Downtime/Loss of Production
  • Investigation by the relevant authority
  • Expert Witness in Court
  • 1st Question to Employer Did you comply with
    an ISA Standards or Internationally accepted
    Standard?
  • 2nd Question to Employer Did you follow known,
    good engineering practice?
  • In recent cases there has been more use of expert
    witnesses. What would
  • an expert witness say in this case?

17
Key Features ISA 18.2
18
Key Features ISA 18.2
  • Large focus on an Alarm System Lifecycle
  • Clear Alarm System Performance KPIs
  • Section on compliance
  • Alarm Philosophy what must be included
  • Alarm System requirements Specification
  • Identification
  • Rationalization
  • Advanced Methods
  • Less examples are given
  • Complimentary to EEMUA 191

19
Matrikon ISA 18.2
  • Participation
  • Mike Brown
  • Jeff Gould
  • Michael Marvan
  • Alan Armour
  • Section Leadership
  • Operations
  • Maintenance
  • Management of Change
  • Sub-Committees
  • Monitoring Assessment
  • Audit
  • Analysis (Annex)
  • ISAs Committee Website
  • http//www.isa.org/MSTemplate.cfm?MicrositeI
    D165CommitteeID4627

20
ISA 18.2 Alarm Performance KPIs
21
Industry Benchmarks Room to Improve!
22
Alarm Management Lifecycle
23
Alarm Management Lifecycle
  • Philosophy
  • Identification
  • Rationalization
  • Detailed Design
  • Implementation
  • Operation
  • Maintenance
  • Monitoring Assessment
  • Management of Change
  • Audit

24
Entering the Lifecycle - Philosophy
  • Greenfield or Brownfield sites
  • Objectives of the alarm system
  • Design it correctly and keep it there

25
Entering the Lifecycle - Monitoring Assessment

Audit
J
Philosophy
A
Management of Change
I
Identification
B
  • Focus on quantitative analysis to determine gaps
  • Follow Maintenance MOC paths to resolve

Rationalization
C
Detailed Design
D
Implementation
E
Monitoring Assessment
H
Operation
F
Maintenance
G
26
Audit

Audit
J
Philosophy
A
Management of Change
I
Identification
B
Rationalization
C
Design
D
Implementation
E
Monitoring Assessment
H
Operation
F
Maintenance
G
27
ISA 18.2 Compliance
28
Alarm Management is now a Compliance Issue
  • Compliance ANSI / ISA SP18.2
  • Similar to ANSI/ISA S84.01
  • nationally recognized standard
  • qualifies as a nationally recognized standard for
    safety systems such that OSHA recognizes as
    recognized and generally accepted engineering
    practice
  • Not a requirement to meet OSHA 1910.119 PSM
    requirements but bears substantial weight with
    regard to implementing safety/alarm systems
  • burden of proof is on the User to demonstrate
    that they have followed generally accepted
    engineering practice

29
ISA 18.2 Compliance.
  • Section 4.1 Conformance Guidance
  • To conform to this standard, it must be shown
    that each of the requirements in the normative
    clauses has been satisfied.
  • Section 4.2 Existing Systems (Grandfathering
    Clause)
  • For existing alarm systems designed and
    constructed in accordance with codes, standards,
    and/or practices prior to the issue of this
    standard, the owner/operator shall determine that
    the equipment is designed, maintained, inspected,
    tested, and operated in a safe manner.

30
Historical Findings
  • Industry estimate 10 Billion per year from
    abnormal situations
  • Incident costs from 100K-1 Million per plant
    per year
  • Refineries suffer a major incident once every
    three years costing 80M
  • Insurance companies show industry claims gt2.2
    Billion per year due to equipment damage (North
    America)

ASM Consortium Findings
31
Personal Observations.
  • Many process plants in North America are not
    doing enough
  • Alarms form part of your plants layer of
    protection
  • There will be more prosecutions for OHS breaches

32
What Steps Can You Take?
  • Senior Management Sponsorship
  • Purchase ISA 18.02
  • Undertake an audit of your alarm system. Minimum
    do Monitoring and Assessment
  • Prepare a Philosophy Document and then Functional
    Specifications
  • Prepare a Strategic Plan
  • Just Do it

33
Questions?
About PowerShow.com