Professional Documents
Culture Documents
GOALS
3/11
ESP OVERVIEW
• Objective:
To increase and sustain reliability by operating our plants safely and efficiently
• Limits are defined and controlled
• Corrective Actions are taken and recorded
• Early failure detection by Proactive monitoring
• Empowerment to stabilize, slow down or shut down to prevent unsafe operating conditions.
• Maintain Situational Awareness
Managing Abnormal Situation :ability to manage and control the risk when
limits are exceeded Management of
Abnormal
Situations
GASCO ESP
while meeting all operational and business targets Proactive Monitoring
Override of
Alarm Operating
Knowing your Limits Management
Safeguarding
Windows
Systems
Shift Cycle
Managing
Start of Shift End of Shift
Abnormal
Orientation Review
Situations
Plant performance
is monitored from
different angles
Operational/technical support
PRO ACTIVE MONITORING OVERVIEW
Operating
Integrity
Outside
Operators
operator
Control room/
Operators
Panel operator
Production
Various specialists in
Operational support
Technical Support
Operations Suppour
WHY PRO ACTIVE MONITORING?
Reactive Proactive
• Wait for alarms/escalations to respond to • Periodically “walk” the unit both physically and via
• Look only at groups or graphics periodically trends and graphics
• Focus on known problems • Impending failures are detected
• Take preventative action before the situation
escalates
• Standardized Panel and Field Operators Pro Active Monitoring rounds take advantage
of operators’ and Operations Support’s best practices, knowledge and experience
Technical Proactive Monitoring in GASCO
Performed by Operational/technical support
• Standardized reporting sheets and RACI to analyze performance and address issues
6/11
ESP – Situational
PRO ACTIVE MONITORING Awareness
DEFINITIONS
• Taking action by causing change and not only reacting to change when
it happens: “Companies are going to have to be more proactive
about environmental management, a proactive approach/role”.
5/11
ESP – Situational
PRO ACTIVE MONITORING Awareness
DEFINITIONS
5/11
ESP – Situational
PRO ACTIVE MONITORING Awareness
DEFINITIONS
Proactive Monitoring
• Taking action by causing change and not only reacting to change when it
happens “Developing the mitigation plan in advance”
5/11
ESP – Situational
PRO ACTIVE MONITORING Awareness
DEFINITIONS
5/11
ESP – Situational
PRO ACTIVE MONITORING Awareness
PROCESS
• Define Parameters/Checks
• Schedule rounds
Schedule
Operations Coordinator/
Compile checklist
Operations Engineer
(Field Pro Active
Monitoring)
• Execute rounds Define Pro Active
Monitoring
Execute parameters & Set
Compile checklist
frequencies
& Display trends
Panel Pro Active
Monitoring)
Shiftcontroller
Validate
Assistant
Correct and
Execute rounds Report
Deviations
8/11
PROACTIVE MONITORING: WHAT TO
ESP – Situational Awareness
MONITOR?
1.As first priority, any parameter that potentially impacts SAFETY, be it the
safety of personnel, process safety or environmental performance
2. Any parameter potentially impacting reliability and the ability to meet the short
and long term production plans, the planned length between shutdowns or the
operating budget
• Only focus on the most he most important parameters, which indicate the general
health of the process
7/11
ESP – Situational
PRO ACTIVE MONITORING Awareness
SOURCES
Outside Pro Active
Monitoring
Some Limits, Levels or Targets
Operator Round schedules
RCM tasks
Many Operator Surveillance Task
Some Maintenance. / Engineering. PM from other processes and
Many Limits, Levels or Targets collects data.
RBI
Some Operator Surveillance Task
5/11
ESP –MONITORING:
PRO ACTIVE HOW TO SET UP
Situational Awareness
11/11
ESP – Situational
PRO ACTIVE MONITORING Awareness
KEY POINTS
• Only the trend of the data will yield information on the direction, speed and
acceleration of any change in the Parameter observed.
• Limits will trigger an early deviation and need to defined (normal operating
ranges NOT alarm limits)
• The observed data must reflect the monitored parameter its true behavior in
order for the information to be valid.
8/11
ESP
INSIDE – Situational
PRO Awareness
ACTIVE MONITORING
Is it new?
• By a “virtual” round trough the
plant, just like the old days
walking the panels:
• One look and the state of the
process was known.
8/11
ESP
INSIDE – Situational
PRO Awareness
ACTIVE MONITORING
8/11
ESP
INSIDE – Situational
PRO AwarenessHOW
ACTIVE MONITORING
TO DEFINE THE PARAMETERS
1. Assign Pro Active Monitoring (PAM) Team (Experienced Panel Operators, Process
Engineering)
4. Review the long list and compress into a shortlist (max 40 trends per “panel”)
6. A subset of the variable could be included in the shift report (as key process variables)
8/11
ESP
INSIDE – Situational
PRO AwarenessSCOPE
ACTIVE MONITORING
Plant Pipe-
PAM content Objective line
Feed and Product Flow Rates Critical input streams and output streams need to be monitored regularly (at least every 2 x x
hours) as these are subject to change based on upstream and downstream upsets or
change in mode of operation.
Quality Parameters in FEED and The online analyzers for feed and product streams need to be monitored from time to time x x
Product Streams (at least every 2 hours) as any change in these could indicate deviation from normal
operation. Regular verification (daily) of analyzer readings with lab analysis validates the
analyzer performance.
Critical Tags as per Unit Operating Critical tags need to be identified for periodic monitoring (every 2 hours on an average) x
Window with their defined limits to aid the panel operator in prevent exceedance of the limit.
These tags can be selected from the operating envelope, Integrity Operating Window and
Safe Operating Limit tags.
Critical Equipment and Auxiliary Operating parameters of critical equipment and their auxiliaries need to be monitored x x
Performance timely during the shift. It is recommended to note these parameters twice during the shift
totaling to 4 times per day.
Interphase Levels on Separators A key parameter to be monitored especially for feed gas separators as the inter-phase x
levels if not monitored properly can lead to flaring/gas blow by. Monitoring of these
interface levels is done regularly (every 2 hours on an average) (Plant)
8/11
ESP
INSIDE – Situational
PRO AwarenessSCOPE
ACTIVE MONITORING
Plant Pipe-
PAM content Objective line
Product Storage and Export Product inventory levels need to be noted as certain storage tanks/spheres are designed x
for continuous export and can hold inventory only for few days. Export flow rates need to
be monitored as well as per customer requirement. Typically storage and export
parameters are recorded on a daily basis.
Status of Flare Valves and Flow to All key connection to flares need to be identified and displayed on a separate x
Flares panel/monitor for the panel operator’s surveillance. Monitoring of valves lined up to the
flare is typically done every 2-4 hours. Camera and CCTV footage needs to be monitored
frequently for changes in the flares.
Overridden Tags and Inhibited Tags closely monitor all overridden tags and inhibited tags to ensure timely intervention in case x x
of failure of other safeguards. The override register is validated before handover and is
discussed during the handover
Controllers on Manual The controllers that have been changed to manual mode of operation during certain x x
upsets or due to process requirement, need to be recorded and monitored until
normalization. A register needs to be maintained for the same. This register is validated
before handover and is discussed during the handover
Emission Monitoring from Stacks CEMS and PEMS data needs to be monitored at regular intervals (ideally twice per shift) to x
ensure process performance and compliance to emissions in accordance to ADNOC COP.
Deviations from normal operations can be detected at an early stage and correctively
actions can be taken accordingly.
8/11
ESP
INSIDE – Situational
PRO AwarenessSET UP
ACTIVE MONITORING
Limit (Low)
Process Value
8/11
ESP – Situational
INSIDE PROACTIVE Awareness
MONITORING SUMMARY
• A picture speaks thousand words: Trends and associated graphics designed into a
standard scientific and engineered view of the process utilizing Operator experience.
• Operator should “walk” the unit using the Control Room Operator rounds (PI/DCS
trending displays) to assess the current state of the process frequently
• Prevention of unsafe conditions and offspec, as defined by the Limits, clearly requires
knowledge of where the variables and process is headed and how quickly.
• By providing standardized and structured Control Operator rounds, each Operator will
see the process from the same perspective and have the advantage of the cumulative
knowledge that went into constructing the round.
9/11
Outside Pro Active Monitoring
ESP
OUTSIDE – Situational
PROACTIVE Awareness
MONITORING
9/11
ESP
OUTSIDE – Situational
PROACTIVE Awareness
MONITORING
Be at the equipment: Field operators use their own senses when doing
their round to detect and mitigate early “non-instrumented” Abnormal
Situations
9/11
ESP
OUTSIDE – Situational
PROACTIVE Awareness
MONITORING
9/11
SCOPE ESP – Situational
OUTSIDE PROACTIVEAwareness
MONITORING
Plant Pipe-
PAM content Objective line
Operator Round The operator is expected to record the various operating parameters of the equipment/Sample x x
(parameters/sampling products and highlight deviations from normal operating conditions:
Steam Traps Survey check the steam traps for normal functionality, passing, leaks and if they are lined up or isolated with x
justifications for isolations. ,resulting deficiencies to be be reported with the tag number and
location. raise necessary work orders to rectify deficiencies..
Chemical Inventory Checks list the chemicals present in his unit along with their current stock in the field. Any deficiencies are to x x
be noted. checks availability of MSDS (either at the storage shelters or the operator shelters needs to
be confirmed) as well as the date of expiry of the chemicals. Ensure housekeeping and that chemicals
are stored in the correct manner/place. Any deficiencies need to be reported and rectified
Monthly PSV Checks Confirm the current status of the PSVs with that of the P & IDs and report any deficiencies, for x x
example, the PSVs removed to workshop for PM or non-availability of chain locks/padlocks for the
isolation valves. (Plant and Pipeline)
Containment Conformity to identify sources to flare during exceptional flaring in addition to the monthly schedule. The
Checklist checklist contains the item description (valves and lines), content, sizing, P&ID number and release
source. The operator is required to confirm if the service is as per its required status including the
position of the blinds and if there is any passing to the flares. The deviations are to be reported.
(Plant)
Critical Valves Position The checklist shall identify all critical valves in the operations area with their tag numbers and the x x
Checklist location. The Operator is required to update the status of these valves in comparison to their
required position as Pad lock Open (PLO) with remarks if any. (Plant and Pipeline)
One of the most critical checklists and is to be used by the operators
9/11
SCOPE ESP – Situational
OUTSIDE PROACTIVEAwareness
MONITORING
Plant Pipe-
Plant Walktrough Objective line
General Leaks Survey identify hydrocarbon, steam, oil, Sulphur and solvent leaks in his area and report them with the x x
equipment tag number and line number where applicable. The shift controller is to raise a work
order to rectify the same. On execution of the job, the records are to be updated
Emission Survey report the colour of smoke/emission from the furnaces, stacks and flares. Additional checks are X
to be conducted for the furnaces: Flame colour, flame impingement, flame vibration, refractory
condition, hot spots are to be reported for follow up.
Waterboot Level Verification The level gauge and level indicator reading are to be taken by the field operator and the same is X
to be verified by the panel operator. This is necessary to prevent flaring of lighter hydrocarbon
ends from high water accumulation in the water boots. Any deviations are to be captured and
necessary corrective actions to be taken by the Shift controller.
Pipe Support Vibration, examine the pipe support and expansion joint conditions for visible cracks, fractures and in case X X
Friction/Erosion Survey of spring supports, the housing and spring for corrosion. Operators shall also determine changes
in the space between the grating and pipes and also for signs of erosion/friction between lines.
(Plant and Pipeline)
Walkways/Pavement & Grating report any obstruction or damage to the walkways, pavement and gratings. For pipeline x x
Status additionally the status of culverts, culvert crossings and accessibility to the pipeline shall be
reported as well
Missing Plugs & Caps Survey confirm that all plugs and caps are in place as per the P&ID. X X
9/11
SCOPE ESP – Situational
OUTSIDE PROACTIVEAwareness
MONITORING
Plant Pipe-
Plant Walktrough Objective line
Flanges, Bolts and Rust inspect the pipe flanges and bolts for signs of rust. Missing bolts and screws shall also be x x
Identification reported. It is advisable to educate the operators on how to report rust of flanges and bolts
through a pictorial representation of various stages of rust.
Instrument Gauges Verification ensure proper functioning of gauges, pointer condition (broken or not visible), liquid filled x x
gauges for high vibration services, leakage from liquid filled gauges, gauge line up and gauge
range (within range or out of range). Deficiencies are to be reported and shift controllers are
required to raise work orders accordingly. (Plant and Pipeline)
Swales Verification check all swales within their units for accumulation of water, dust, sand, oil etc. and report the x x
status in the survey forms. In addition, they are also required to report the presence of any solid
material such as insulation, cladding or waste that have been dumped into the swales. The shift
controllers are to take actions accordingly for empting out the swales
Compressor, Pump and Export check the skids for any oil leaks from the source, oil accumulation at the skids, skid drainage as x x
Metering Skid well as housekeeping around the skid. Additionally, they are required to check the condition of
breathers and oil mist eliminators for blockage or if they are plugged. The form shall list the
equipment number/location as well as the status, with a section for comments or remarks
Plant lighting Survey Operators are required to check and report the lighting and corresponding supports are fixed x x
properly, fused lights that need to be replaced, if there is enough illumination/brightness in the
area, the auto on/off timings are synchronized with winter and summer times, emergency
lighting is fixed and functional.
9/11
PRO ACTIVE MONITORING BY FIELD
ESP – Situational Awareness
OPERATORS
10/11
PRO ACTIVE MONITORING BY FIELD
ESP –TYPICAL
OPERATORS Situational Awareness
CONTENT PARAMETER
LIST
General Remarks:
10/11
ESP –MONITORING
PRO ACTIVE BY A FIELD
Situational Awareness
OPERATOR; EXAMPLE
11/11
ESP –MONITORING
PRO ACTIVE BY A FIELD
Situational Awareness
OPERATOR; VISUAL CHECKS
11/11
Proactive Monitoring for
supervisors
PROACTIVE – Situational Awareness
ESP MONITORING SHIFT
CONTROLLER / SUPERINTENDENT
Shift performance
- Active Alarms
- Other Abnormal Situations: Shift manning (staffing and competence level), mass
(un)balance, abnormal process and equipment behaviors / conditions and any other
developing threats, etc.
- Adherence to procedures and validation of effectiveness
- Fulfilling and meeting the production plan
- Interface issues
9/11
Proactive Monitoring
Performance & Summary
ESP –MONITORING
PROACTIVE PERFORMANCE
Situational Awareness
Equipment
Integrity Electrical
Mechanical
Engineering Process
Console Operators Engineering
Laboratory Instrumentation
11/11
Exam Questions
ESP –MONITORING
PROACTIVE SUMMARY
Situational Awareness
10. (Select all that apply) The Field operator Proactive Monitoring Answer: A, B,
round may include C, D and E
A. Check tasks D. Correcting deviations
B. Do tasks E. Reporting deviations
C. Measurement tasks
D. Correcting field exceedences