Title: The Real World Impact of ISA 18.2 on Process Industries Kevin Brown Matrikon Inc.
1The Real World Impact of ISA 18.2on Process
IndustriesKevin BrownMatrikon Inc.
2Agenda
- 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
3Kevin 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
4Matrikon 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
5Company 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
6What is Alarm Management?
- Process by which alarms are engineered,
monitored, and managed to ensure safe, reliable
operations
7What is Alarm Management?
8What 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
9What 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
10What is a Lack of Alarm Management?
11(No Transcript)
12What 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/
13Alarm Management Its about Safety!
Documented financial losses estimated at 1.5
billion
OSHA leveraged fines for this incident exceeded
87MM
14An Example Plant Incident
15An 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
16Possible 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?
17Key Features ISA 18.2
18Key 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
19Matrikon 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
20ISA 18.2 Alarm Performance KPIs
21Industry Benchmarks Room to Improve!
22Alarm Management Lifecycle
23Alarm Management Lifecycle
- Philosophy
- Identification
- Rationalization
- Detailed Design
- Implementation
- Operation
- Maintenance
- Monitoring Assessment
- Management of Change
- Audit
24Entering the Lifecycle - Philosophy
- Greenfield or Brownfield sites
- Objectives of the alarm system
- Design it correctly and keep it there
25Entering 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
26Audit
Audit
J
Philosophy
A
Management of Change
I
Identification
B
Rationalization
C
Design
D
Implementation
E
Monitoring Assessment
H
Operation
F
Maintenance
G
27ISA 18.2 Compliance
28Alarm 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
29ISA 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.
30Historical 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
31Personal 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
32What 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
33Questions?