MANAGE
INSTRUMENTS
FOR RELIABILITY AND SAFETY :
Effective monitoring and maintenance mitigates
hazards while it raises productivity,
by William Mostia, P..
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The rise of 1S0 55000
Plants can generally achieve significant reductions in op-
erating costs and downtime by implementing an effecti,
asset manageinent strategy (with the key word being “ef
fective”) In 2004, the British Standards Tusttation (eww.
bsigroupcotn) introchiced PAS 55, which was the First pubs
‘ely available standard for management of physical assets
PAS 55 was widely adopted by utilities, tansport, mining,
brocess and manufacturing industries worldwide,
{mn 2006, PAS $5 underwent a substantial revision by 50
organizations from 15 industry sectors in 10 countries, and
served as the hasis for developing the new ISO 35000 se-
ries oF international standards in 2014. ISO 35001 defines
‘quirements for an asset management system in much the
same way as SO 9001 specifies the requirements fora qual
ity managen
TSO $5000 offers a more comprehensive asset manage.
‘ment focus, not focused solely on physical assets, but also
other types of assets including non-physical asets, tangible
nt system,
sand intangible, such as software, experience,
reputation,
brand, intelletual property et. It has a category, Critical
Asset, which would include safety-eritical instrumentation,
Control systems are smart assets
onl and safety tems conain many diferent ype ose
sets" Some of these are traitional physical assets, sch as ser
son, wakes and control components, which would appear on
the accountant ledger in black and white Les ob ous, bat
also important, ae tangible and intangible anes sch ay the
software and is configuration, which help the hardare toon.
tol the proces to make produc, al keep sale your people
Proce expert, engineering expec and process inion,
ge. The sills, capably, knowledge, specific proces expe
tiene of your oman’ petsonnel, and their aby to imple.
‘ment the power af yur contals often are considezed the ssc
that make the dilrence between succes and fle, and it
sakes serie to manage these aswel
With the introduction of microprocesiorbased smart
instments in 1983 and development in the 1990s of dig
ital communication protocols such as HART, Foundation
feldbus, Profibus and their brethren, JAMS have become
increasingly commonplace, They touted to ut operating
and maintenance costs, and reduce downtime while ine
Proving ase efficiency, uptime and reliability. They'e alo
said to improve effectiveness of maintenance and operations
staf and improve the safety of some maintenance activities
to mention afew ofthe claims by [AMS supplies
Experience has aio shown that an AMS ean be of signif
ant benefit during commissioning of smart instrumentation
Another area of bene thts not ahs mentioned is process
safety andthe aspects of elabilty that impact proces se
Asset management's role in process safety
Layers ofprotection analsis(LOPA) identifies independently
B40
ASSET MANAGEMENT
rs of protection (IPL) that ste needed
nlfed risk tothe corpo-
ralerishenferia, Manyofthese aeinstea-
‘mented IPLs that are classified a safety
controls alarms and interlocks (SCAI)
im ANSIMSA-$491.012012—"Identifies-
tion and Mechanical Integrity of Safety
Controls, Alarms, and Interlocks in the
Process Industry” (Figore 1), The safety
instrumented system (SIS). stand,
ANSVISA. $400.01/IEC 61511, require
management of fmetional safety associ
ated with SIS, and also require thal per-
formance ofthe SIS be verified ose the
SIS lifeeyee
Tohelp evaluate the performance of
SIS over ils lieeyele not only requites
collecting file rate and demand rate
data, but also sustaining the effort over
the SIS lifeeyele, whieh ean be 1015
years or more. An TAMS ean provide
a structuce for this effort, and since i's
doubtful that 2 paper system would be
very successful in sustaining this effort
cover changes of administration of the
system, an asset management system.
configured to manage safety critical
instrumentation is a mus
Figure | shows thatthe SIS IPL. isn't
the only possible instrumented safety
function in which we'e interested in
maintaining integrity and assuring re
mS
to reduce the:
liability. There ean be safety-eritieal
alarm IPLs, basic process contol inter
Tock [PLs and other safety-critical sys-
tems, sueh as fre and gas systems and
manual emergeney-shuidown systems.
‘Testing and inspection, equipment re-
lability and management of change
(MOC) are areas where collecting data
and analytes ean help manage and sus-
tain IPL integrity oer its lifecycle
Instrument reliability affects
rocesssolety
Process set cam be stronely affected
by the reliability of ts control and safety
systems. Obviously SIS contributes to
the safety ofa facility, and has a strong,
formal system of standards snd body of
prctice in industry. The area of non
SIS instrumented safely systems is «
byt marie in regards to requirements
There is certainly agrecient on what
the properties of sn IPL should be ne
cluding independence, specifiy, de-
pendability, euditebility, sccurity and.
ranagement of change, Inthe United
States, these instrumented safely sys
tems would come under OSHS PS}
1910.19 and have requirements sim
iar the SIS standards, but with rach
les detail and guides om oto ime
plement the requirements and achieve
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‘SAFETY CONTROLS, ALARMS AND INTERLOCKS SATISFY PROCESS HAZARDS ANALYSIS
Figure The:
ity ofan instrumented safety turcon to fullitsrole a
yer of
protection ina process hazards analysis depends on managing the asset intagy of
‘2fety equioment from alaims and canirosta interlocks and emergency shutdown
systems. Source: ANSVISA841 01-2012,
a
what the US. Occupational Safety and
Health Administration (wwwosha gov)
calls “recognized and generally sc-
cepted good engineering practice (RA~
GAGEP)” Note that OSHA issued a
*Memorandam for Regional Admin-
istrators and State Plan Designees" on
June 5, 2015, which provides added gen=
eral guidance on enforcement of the
Process Safely) Management (PSM)
Standard’ RAGAGEP requirements
(www.osha.govfpls/oshaweb/owadisp
show_doeument?p_table=INTER-
PRETATIONSSp_id=29414
Areview ofany LOPA will show that
abasic process control system (BPCS)
failure is a common initiating cause.
le we'll probably not improve the
BPCS failure frequeney used in the
LOPA, if we ean improve the rliabil-
ity of our control system, then we ean
innprove the safety of the facility:
There may also be an ovedap be-
‘meen some ofthe components used in
the BPCS and the SIS. particularly on
the input side. For exemple, i's not un-
common for feilitis to use the same
‘model transmitler as the safety trans=
miter, or the same model without the
Sl approval papers. So reliability im.
provements can benefit both sides.
‘There’ also a push in industry to
collect failure rate and failure mode
data to better evaluate current tech=
nology in reliability calculations and
to improve instrument reliability. In
2012, an industry consortium formed
the Instrument Reliability. Network
(IRN. hitipsiimanmuedu), whieh s
hosted by the Mary Kay OC
Process Safety Center at Texas A&M
University. IRN has the goal of devel
‘oping common toals and methods for
collecting quality instrument reliable
ity data that wovld benefit industry
An IAMS combined with 2 properly
configured maintenance management
syster could collect this kind of infor
imation, which could not only benefit
sour company by improving your ine
stument reliability but by sharing sane
itized data with the IRN, could help
develop industry benchmasks for SIS
and control system performance.Then there's security
Security is also an issue for management of safety critical
SCAT assets in an JAMS. Ifthe SCAI management i «sepa
rate system, the separation ean provide an element of security
ifthe access population is limited. When the SCAL manage:
‘ment portion is an add-on to 2 general-purpose instrument
asset management system or general-purpose AMS, the pop-
tlation with access may include everyone up to the instru
‘ment maintenance department dae to its usefulness. Default
or shared passwords shouldn't be used to access safety criti-
calSCAL instrumentation, The acceso safety critieal/SCAL
instrumentation should be tightly controlled to only person
nel authorized to perform SISMIPL snaintenance and modifi-
cation activities to help prevent inadvertent or unauthorized
changes in safety critical instrumentation. Procedises should
be established to ensure proper use of handheld conmunica-
tors when working wth critical instrumentation,
Cybersecurity must also be a consideration to help limit
sy intemal or extemal attempts lo access and change data
that could affect the safety ofa facility. Adequate firewall nd
zonal segregation should be provided. Something as simple
as plugging in a thumb deve with the Stuxnet eyber worm,
or worse an intentional act of sabotage, can compromise your
ASSET MANAGEMENT
whole system and the safety of your facility. Wireless also of
fers new possibilities of connectivity to LAMS, but opens the
{oor to potential eyber vulnerabilities. Cybersecurity protee-
tion sno longer in option for most petrochemical operations.
‘The [AMS can also help collect leading and lagging pro-
cess safely metrics (ala API 754) for management. Itean also
facilitate colletion of contol system performance data on a
.op basis. Some common contro loop statistics are that
% of our control loops are on manual, while another 10-
20% aren't performing well f this is true, an ISAM system
capable of spotting these problem loops could be invaluable.
Make an audit trait
One of the other key powers of the IAMS is providing an
“audit trail for changes ineluding MOC, eonfiguration and
calibration data, version management, ete. This ean be crit
ieally important for managing SCAL and surviving a com
pany or third-party audit ora visit from OSHA.
‘Maintaining an auditrail for meeting the SIS standards and
regulatory purposes can be diffcul. One of the powers of the
IAMS is that it ean typically provide an audit ral for changes
and testing, inspeetion and calibration, IAMS can be an es+
sential part of SIS petiodic inspection and prooftest processes.
Connect
Automagically. —
Honeywell
‘The New Experion’ PKS Orion, coming
soontoa control room nesryou. Also.vsit
uset Honeywell Users Group Americas.
‘wn. honeywellusersgroup.com
Formore information, please visit
wow honeywellprocess.com/experion
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