mtk - the real world impact of isa 18.2 on process industries

8/2/2019 MTK - The Real World Impact of ISA 18.2 on Process Industries

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The Real World Impact of ISA 18.2on Process Industries

Kevin BrownMatrikon Inc.


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Agenda

Introduction What is Alarm Management

What is a Lackof Alarm Management

OH&S & Legislation

An Example Plant Incident Demystifying Standards & Guidelines

ISA 18.2 Compliance

Alarm Management Lifecycle

Steps to Compliance Questions

Operators on alert

Operator response, alarmstandards, protection layers

keys to safe plantsIntech, September 2009


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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


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Matrikon Alarm ManagementMatrikon has 20 years experience and is the Global Leader in the deployment of

Enterprise Wide Alarm Monitoring Solutions with the worlds leadingcompanies,innovation, safety, commitment to

value and high ethical standards
http://www.dupont.com/asphalt/http://www.basf.com/


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550 employees 300+ consultants with

extensive domainexpertise

Complete services, fromplanning to execution

GlobalPresence

CompleteSolutionProvider

Company Overview

Consultants275+

R&D100+

Other150+

18 offices 17 Partners

Strong Presence inToronto (25 Consultants)

TSE: MTK


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What is Alarm Management?

Process by which alarms are engineered,monitored, and managedto ensure safe, reliableoperations


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What is Alarm Management?


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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


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What is a Lack of AlarmManagement?


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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/


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Alarm Management: Its about Safety!


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An Example Plant Incident


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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


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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

1stQuestion to Employer: Did you comply with an ISA Standards or Internationallyaccepted Standard?

2ndQuestion to Employer: Did you follow known, good engineering practice?

In recent cases there has been more use of expert witnesses. What wouldan expert witness say in this case?


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Key Features ISA 18.2


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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


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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?MicrositeID=165&CommitteeID=4627


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ISA 18.2 Alarm Performance KPIs


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Industry Benchmarks: Room to Improve!

Other

900

35

180

25/40/35

5

Power

2000

65

350

25/40/35

8

PetroChem

1500

100

180

25/40/35

9

Oil & Gas

1200

50

220

25/40/35

6

ISA

144

5

10

80/15/5

1

Average Alarmsper Day

Standing (stale)

Alarms

Peak Alarmsper 10 Minutes

Average Alarms/

10 Minute Interval

Distribution %(Low/Med/High)


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Philosophy

Audit

Rationalization

Identification

Detailed Design

Implementation

Maintenance

Operation

Managementof Change

Monitoring &Assessment

D

C

E

AJ

B

G

HF

I


Philosophy

Identification

Rationalization

Detailed Design Implementation

Operation

Maintenance

Monitoring & Assessment

Management of Change

Audit


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Entering the Lifecycle - Philosophy

Philosophy

Audit

Rationalization

Identification

Detailed Design

Implementation

Maintenance

Operation

Managementof Change


D

C

E

A

J

B

G

H

F

I

Greenfield orBrownfield sites Objectives of the

alarm system Design it correctlyand keep it there

M it i &


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Philosophy

Audit

Rationalization

Identification

Detailed Design

Implementation

Maintenance

Operation

Managementof Change


D

C

E

A

J

B

G

H

F

I

Entering the Lifecycle - Monitoring &Assessment

Focus onquantitative analysis

to determine gaps FollowMaintenance & MOCpaths to resolve


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Philosophy

Audit

Rationalization

Identification

Design

Implementation

Maintenance

Operation

Managementof Change


D

C

E

A

J

B

G

H

F

I

Audit


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ISA 18.2 Compliance


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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 thatOSHA 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 followedgenerally accepted engineering practice


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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 normativeclauses 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/operatorshall determine that the equipment is designed, maintained, inspected, tested, andoperated in a safe manner.


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Historical Findings

Industry estimate: $10 Billion per year from abnormalsituations

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 >$2.2 Billion

per year due to equipment damage (North America)

ASM Consortium Findings


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Personal Observations.

Many process plants in North America are not doingenough

Alarms form part of your plants layer of protection

There will be more prosecutions for OH&S breaches


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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


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Questions?

mtk - the real world impact of isa 18.2 on process industries

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