Conduct of Operations and Operational Discipline: For Improving Process Safety in Industry
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Operational Sustainability LLC believes that intelligent operations requires an integrated solutions platform designed to enhance supporting processes for OpX.
Conduct of Operations and Operational Discipline
Ultimately, an intelligent operations platform supports operational excellence by enabling companies to quickly adopt technology and software advancements, providing the ability to run plants as safely, reliably, and efficiently as possible and react faster to market dynamics. This approach combines disciplines to create process dependencies that improve overall performance.
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To achieve and maintain world-class business performance, many companies find it helpful to create one system of record across diverse applications and data sets. The first steps along the road to intelligent operations are to first identify the key applications, data, measurements, and processes to standardize and then enable those processes with the data needed to optimize processes and assets. According to the company, intelligent operations have the following core elements:.
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Most companies need a significant technology transformation to achieve intelligent operations due to having numerous and often redundant siloed applications. This transformation often involves replacing older software applications with a more agile, standardized platform to support dynamic processes and changes in their business.
Companies also are moving toward software-as-a-service SaaS and relying upon data connectors to simplify integration beyond what traditional on-premise applications allowed. The transformation toward a modern, flexible digital architecture requires making better use of data and analytics to provide all workers with personalized insights, including establishing a digital foundation to share knowledge across the enterprise.
The platform aggregates information to support visualization of the underlying metadata to enable point-and-click drill-down from a facility map or aerial view, all the way to an individual pump. Each site is expected to define an informal and formal evaluation route and train operators on what to look for during the equipment evaluation. In addition, evaluation round sheets should include location of critical bleeders, valve positions and other critical line-ups so that operators check them each time they make their rounds.
As noted, these tools share a common element — a pre-defined Walk the Line checklist. It must be completed and communicated, regardless of whether a change has been made. This repetition helps build the culture of Walk the Line. Figure 3 shows an example checklist for operator shift notes used during shift relief.
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This checklist identifies those activities that lead to changes in line-up. These changes are communicated between and among shifts, with confirmation of review required. Operators returning to duty must give positive verification since the last review. Another class of aids to help operators understand the current operating state of a unit involves design tools. For example, a process to identify critical bleeders will highlight those points in the process that must have a bleed valve shut with a plug to prevent an LOPC incident.
At Celanese, some sites paint these critical bleeders a recognizable color Figure 4 and have the operator inspect them during evaluation rounds. Additional design practices, to name a few, include formal plug and inspection programs, line labeling initiatives, spring loaded valves, and double blocks on some bleeders. Operational Readiness. Experience has taught us that the frequency of incidents is higher during process transitions such as startups.
These incidents often result from the physical process conditions not exactly matching those intended for safe operation.
Thus, it is important that the process status be verified as safe to start. Operational readiness reviews ensure the process is safe to start by examining issues such as:.
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Such reviews of simple startups may involve only one person walking through the process with a straightforward checklist to verify that nothing has changed and equipment is ready to resume operation. More complex reviews or higher risk startup situations may require different tools. Operational readiness tools share some common elements such as defining equipment commissioning steps in standard operating procedures SOPs. A common tool used in industry is independent verification.
It often targets some safety devices such as pressure relief devices but also makes sense for critical line-ups. Celanese uses a risk-based ranking criteria to determine if a task should be considered critical. These tasks are performed with a checklist in hand; the operator verifies each step when completed. After the task is finished, another person independently confirms the steps as complete and accurate.
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Company-wide initiative eliminates operator line-up errors
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