Maintenance Technology September 2016 - 29

SAFETY STRATEGIES Reduce Hidden Process-Safety Costs Today's technology means end users no longer must accept every cost associated with validation, verification, and documentation of process-safety equipment and shutdown systems. Special to Maintenance Technology THE PROCESS OF validating and verifying the good function of installed process-safety systems and equipment is driven as a mandatory effort governed by end users and regulatory stipulations across industry. At stake is the protection of people; the environment, property, and equipment; and the economics of preventing unscheduled downtime and lost production. The importance of this validation verification is to ensure that if and when equipment goes to a safe state, good function is established. An expensive problem for end users, according to a white paper, written by Phil Millette, P.Eng, MEI, and principal industry consultant for Honeywell Process Solutions, Houston, has been the hidden costs associated with many practices for confirming and documenting the fact that safety instrumented systems (SIS) are installed and functioning as advertised. Such costs include the actual time to do the work using manual processes and disconnected information sources, not to mention longer planned, and more-frequent unplanned, shutdowns that reduce the operation's revenue opportunity. A key reason for these hidden costs is that, until recently, there were no automated mechanisms to support this critical activity-or formalized approach in industry to conducting it. In his white paper, Millette outlines principles and approaches of a recently introduced capability to perform this function in an automated way-one that results in structured information and shared knowledge, a provable safety state, and benefits from lower costs and greater revenue opportunity. Structuring and automating As the author explains, while the requirements for timeliness and documentation of the completed validation and verification effort are generally expected, the actual mechanisms aren't stipulated-and authorities aren't especially clear on how to perform the task. Thus, with the proliferation of different systems and different generations of technology installed at sites, there's been widespread adoption Real-World Success Application: Offshore field operator, on one of the largest North Sea platforms. Challenges/needs: ■ Establish stringent process-safety regulations. ■ Closely look at Safety Instrumented Function (SIF) demand rate and test intervals for initiators and final elements. ■ Ensure condition of Safety Instrumented Systems (SIS) and Final Safety Elements. ■ Record all safety operations and validate they occurred as expected. ■ Minimize planned shutdown for validation, and unplanned shutdowns for unscheduled testing/maintenance. ■ Automate tracking and validation of safety operations, for implementing an exception- SEPTEMBER 2016 based safety inspection. ■ Maximize personnel effectiveness and efficiency to ensure process safety. ■ Perform hundreds of daily safety operations that would make manual validation too onerous to achieve and prone to error. Solution ■ Process Safety Suite, including Process Safety Analyzer (PSA) Documented benefits (among others): ■ Full shutdown validation and reporting achieved in few hours, minimizing deferred production, fewer personnel on site, lower travel costs, and reduced risk exposure. ■ Full track and validation of partial stroke test, minimizing deferred production. ■ Ability to use unplanned successful safety operations and shutdowns to extend the interval of planned revisions/maintenance, minimizing deferred production. ■ Current and historical view of control overrides and their impact on safety operations. ■ Automation of work that previously required approximately 10 people to semi-manually keep track and validate thousands of safety instrumented features to comply with IEC 61508 and IEC 61511, which requires detailed follow up of all safety-instrumented functions on the facility. For more information, visit honeywellprocess.com. MAINTENANCETECHNOLOGY.COM | 29 http://www.honeywellprocess.com http://www.MAINTENANCETECHNOLOGY.COM

Table of Contents for the Digital Edition of Maintenance Technology September 2016

Editorial
Uptime
On The Floor
Old-School Approach To New-World Technology
Art Meets Reliability Science
Commit To Safety
Robot-Human Interaction Getting Safer
Sanitary, Stainless Conveyors Not The Same
Reduce Hidden Process-Safety Costs
Pace Your Reliability Program
Win The War With 'Lubrication By Design'
SAP Tips And Tricks
Understand Pump Vibration
Select The Right Relay
Bearing Care
Clear Up HOA Confusion
Potato Waste Becomes Clean Water, Energy
Products
Showcase
Ad Index
Final Thought
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - Cover1
Maintenance Technology September 2016 - Cover2
Maintenance Technology September 2016 - 1
Maintenance Technology September 2016 - 2
Maintenance Technology September 2016 - 3
Maintenance Technology September 2016 - Editorial
Maintenance Technology September 2016 - 5
Maintenance Technology September 2016 - Uptime
Maintenance Technology September 2016 - 7
Maintenance Technology September 2016 - On The Floor
Maintenance Technology September 2016 - 9
Maintenance Technology September 2016 - Old-School Approach To New-World Technology
Maintenance Technology September 2016 - 11
Maintenance Technology September 2016 - 12
Maintenance Technology September 2016 - 13
Maintenance Technology September 2016 - 14
Maintenance Technology September 2016 - 15
Maintenance Technology September 2016 - Art Meets Reliability Science
Maintenance Technology September 2016 - 17
Maintenance Technology September 2016 - 18
Maintenance Technology September 2016 - 19
Maintenance Technology September 2016 - Commit To Safety
Maintenance Technology September 2016 - 21
Maintenance Technology September 2016 - 22
Maintenance Technology September 2016 - 23
Maintenance Technology September 2016 - Robot-Human Interaction Getting Safer
Maintenance Technology September 2016 - 25
Maintenance Technology September 2016 - Sanitary, Stainless Conveyors Not The Same
Maintenance Technology September 2016 - 27
Maintenance Technology September 2016 - 28
Maintenance Technology September 2016 - Reduce Hidden Process-Safety Costs
Maintenance Technology September 2016 - 30
Maintenance Technology September 2016 - Pace Your Reliability Program
Maintenance Technology September 2016 - 32
Maintenance Technology September 2016 - 33
Maintenance Technology September 2016 - 34
Maintenance Technology September 2016 - 35
Maintenance Technology September 2016 - Win The War With 'Lubrication By Design'
Maintenance Technology September 2016 - 37
Maintenance Technology September 2016 - 38
Maintenance Technology September 2016 - SAP Tips And Tricks
Maintenance Technology September 2016 - Understand Pump Vibration
Maintenance Technology September 2016 - Select The Right Relay
Maintenance Technology September 2016 - Bearing Care
Maintenance Technology September 2016 - 43
Maintenance Technology September 2016 - Clear Up HOA Confusion
Maintenance Technology September 2016 - Potato Waste Becomes Clean Water, Energy
Maintenance Technology September 2016 - 46
Maintenance Technology September 2016 - 47
Maintenance Technology September 2016 - 48
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Maintenance Technology September 2016 - 50
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Maintenance Technology September 2016 - Showcase
Maintenance Technology September 2016 - Ad Index
Maintenance Technology September 2016 - 55
Maintenance Technology September 2016 - Final Thought
Maintenance Technology September 2016 - Cover3
Maintenance Technology September 2016 - Cover4
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