MANAGE INSTRUMENTS FOR RELIABILITY AND SAFETY : Effective monitoring and maintenance mitigates hazards while it raises productivity, by William Mostia, P.. ne rk ncn esa Serene arta ra peepee ee eememane mee sueeteaeta a eee pce deena erent ae eet cane ag ceenreomee Taft cctaence res ae 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 B40 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 i [Sees {Sets tawoment | Hse 1 fest |— resin 1 rete ‘ cl | — sity eral re | Aeastunenes Insumesteg —f— Sit ns te 2 salty neon Salty tuned tn [Eran ston, Lees nd sein ‘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 aASSET MANAGEMENT Procedures can be created within AMS sofiwate to help ensure consistency and documentation 36 required ly TEC 61511, and potentially to help create test- ing meties for mana TAMS that have SIS management capability typically have the ability to schedule when proof tests and inspec erent tions must be performed; to work with the maintenance management systern tw arrange for notifications and work orders for esting: amd fo later tabulate testing result and metrics, [the JAMS allows multimedia formats, enhanced procedures ean be incorporated. for maintenance, testing and inspections Information is Power. ‘Maple Systems edge gateway HMIs. uitilize MOTT protocol to unlock valuable data from existing machine processes. ‘Monetize that data today using the power ‘of information technology. Achieve better | ‘access to data and increase your ‘company’s bottom line by joining the lloT with Maple Systems, Why do without? An IAMS is something that you can hardly do without to meet the my iad requirements of a modeen chemical plant, which aren't going to get any simpler. Most manufacturers cf modern DCSs and some PLCs pro- fide some form of asset management, and some also support SIS, The SCAL world may be new to some, as is IPL asset management. If your DCS/PLC system offers these management ss tems (and theyee not generally free they should be evaluated to see if they will be a good fit for your overall con trol and safety systems and your instr ment management goals T they aren't, look at thirdsparty ss tems. Make suze the [AMS is vendors neti, as. facility may have instruments from man diferent wnamafactarers and managing only a subset is unlikely to ate of retin and meet your goals. TMS interconnectivity is also important to allow connectivity to ‘ther plant systems and to enterprise sys- tems (hgh suitable Firewalls Be wary of snake oil salesmen, and understand that the benefits of AMS are strongly affected by implement sive yo des tment, the alization rate Fits capabilities, and the effectiveness Competent inte. nal and enteral support peaple mst be available to ensare the sytem is suse tainable over the long term, Bespoke systems are to be avoided, but the sys tein should have the Fesibility to grow and adapl to future needs. A manage ‘ment champion and an impl tion champion area necessity fora suc cessful, sustainable system You also can't make it too hard on the instrament technician. 1 was told 28.2 young ey at iF L bought (designed something that made the maintenance technician’s life harder or if they ealleetively did not | my project would likely fil for reasons other than technical. ‘Their support is a necessity for this type of project. 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