Maintenance Technology September 2016 - 30
SAFETY STRATEGIES
of homegrown tools that involve timeconsuming manual inspection of results
from manpower-intensive tests. In the
process, regular cycles of validation and
verification and labor-intensive manual
work, whether needed or not, have helped
generate the previously referenced
hidden costs.
For example, in the case of processsafety equipment that has been observed
to function well on actual process
demand, the test-interval timer can be
reset, leading to available discount on
the otherwise fixed-test interval. Yet,
this benefit can't be captured without the
necessary structured documentation of
proven good function.
The general result from "own-built"
approaches, Millette laments, has been
the emergence of countless tools that are
used with little consistency throughout
industry. Consider variations, from
one person to the next, in the manual
review of results, which can then lead to
variability in the quality of the analysis
itself. Even worse, "Due to the drudgery
of observing long lists of events from
logs, Sequence of Event Recorders,
Safety Historian functionality of SIS/ESD
systems or even of consolidated process
and safety-event journals," Millette writes,
"the task of such review has often been
handed to more junior engineers. This
may result in a less experienced or critical
eye taken to manual review of event
journals."
A structured approach to this task, he
continues, can provide significant savings
by better targeting a site's validation and
verification efforts. For example, where
verification is an immediate pre-startup,
critical-path activity in planned shutdowns, it's possible to shorten the duration of such events. Reduced downtime,
expressed as less deferred or lost production, can be a significant benefit as well.
When an unplanned shutdown of
part or all of a process area occurs,
the urgent action is to understand the
cause and quickly see if the cause can
reoccur. If, for example, it is momentary
(high or low value to process variation
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30 |
MAINTENANCE TECHNOLOGY
reaching a critical point) or a latched
failure (equipment-repair needed),
engineers need determine the prospects
or the timing of a restart-immediately
following confirmation through observation and engineering conclusions, or after
additional time due to other process-area
effects and verifying a safe-starting point.
The question, according to Millette, then
becomes, "Can we check the actual cause;
did everything happen as it should with
the expected effects and with expected
timing?"
Manually checking the Sequence of
Events or other related event logs might
then be conducted. But that checking may
not flag what is not in the log as "missing
events" unless the engineer has expert
knowledge of the specific sequences.
Moreover, related causes, logical relationships to other effects, or sub-shutdown
levels, may not show up in a manual
analysis-or, at least, they'll take considerable time to discover and may require
expert eyes.
The ability to receive an automated
analysis of how the shutdown occurred
and whether all resultant elements
performed as expected can provide some
critical time saving and relief to detailed
searches across multiple systems. Millette
references a number of ways this type of
automated validation, verification, and
documentation directly supports the
process-safety management function.
Among them:
■ A stored reference cause and effect,
with all relevant event signatures,
timings, and relationships, acts as the
documented, "as-expected" base.
■ Events captured from Level 2 control or
safety system event journals form the
basis of the as-is case to be validated.
■ The automated analysis then carries
out the needed, sequential comparison
between the set of logical relationships
stored, the event signatures with those
observed from the captured event
journals. MT
Phil Millette, P.Eng, MEI, is principal
industry consultant for Honeywell
Advanced Solutions, Houston, part of
Honeywell Process Solutions (HPS). For
more information on referenced capabilities
of the company's Process Safety Analyzer
(PSA), visit honeywellprocess.com.
SEPTEMBER 2016
http://mt.mschem.com
http://mt.mschem.com
http://www.honeywellprocess.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
Maintenance Technology September 2016 - 49
Maintenance Technology September 2016 - 50
Maintenance Technology September 2016 - 51
Maintenance Technology September 2016 - 52
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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