Protective Systems Lifecycle Management and IPL Data Repository A database solution

Transcription

1 Lifecycle Management and IPL Data Repository A database solution OSHA Compliance Manager U.S. Patents Pending Nigel James President - Gulf Coast Division njames@manganinc.com /1/2012

2 Agenda What is the OSHA requirements for Safety Lifecycle Management What are the data management challenges How does SPI fit in Important data fields to manage within SPI and other software Quick Demo 3/1/2012

3 Mangan Background An Engineering and Automation Specialty Company 20 years old 2009 Sales of $35M 250+ employees Converted to ESOP in 2000 CSIA registered member Seven offices: Long Beach, CA Westlake Village, CA Lake Jackson, TX Houston, TX Alpharetta, GA Boulder, Colorado Cary, North Carolina Five Industries Refining Chemical Pipeline Oil and Gas

4 OSHA Process Safety Management of Highly Hazardous Chemicals Process Safety Information (d)(3)(iii) For existing equipment designed and constructed in accordance with codes, standards, or practices that are no longer in general use, the employer shall determine and document that the equipment is designed, maintained, inspected, tested and operating in a safe manner Operating Procedures (f) Training and Training Documentation (g) Pre-Startup Safety Reviews (PSSR) (i) Mechanical Integrity (j) Inspection and Testing Requirements Maintenance Training Test Frequency Management of Change (MOC) (l) Compliance Audits (o) Recognized and Generally Accepted Good Engineering Practices (RAGAGEP) (d)(3)(ii)

5 S 84 Regs Origins and Evolution Regulation and Standards move from a Prescriptive to a Performance basis OSHA Process Safety Management of Highly Hazardous Chemicals IEC (International Electrotechnical Commission) Recognized as world standard on Safety Instrumented Systems 1996 ISA (Instrument Society of America) issued standard S84 Application of Safety Instrumented Systems for the Process Industries Then adopted by ANSI now replaced by ANSI / ISA S Achieve performance thru analysis of hazards and protection using tools such as LOPA Contains a grandfather clause not part of IEC61511 for existing equipment Specifies aspects of a Safety Lifecycle for covered systems OSHA linkage (November 29, 2005 ) Recognized ISA S84 as representing good practices for protective instrumentation 29CFR includes ID & managing instrumented systems for safe operation

6 IPL Independent Protective Layers Risk Evaluation Severity & Likelihood Layers of Protection Mitigation Rating Layer 1 Example: High Temperature Alarm SRA = Safety Related Alarms SIL 0 Example: Layer 2 Example: High Pressure Trip SIF = Safety Instrumented Function SIL 1 Unmitigated SIL 4 Hazard Layer 3 Example: Relief Valve PRV = Pressure Relief Valve IL 2 Accepted Risk Acronyms Used IPL = Independent Protective Layer LOPA = Layers of Protection Analysis SIL = Safety Integrity Level SIS = Safety Instrumented Systems SRA = Safety Related Alarms

7 S 84 What are the requirements?

8 What is The Challenge? Lack of continuity across three departmental groups: No single Software package to bridge the gap SRS and SRA data Daily Operation IPL List SIS/ Engineering Operations Inspection / Testing / PM PSM (PHA/LOPA) Maintenance

9 Data is not Direct Coupled Engr g Ops. Maint. SIS Design Reference Maintenance and Verification PSM Proprietary PHA Tool PHA / LOPA Data Reconciled LOPAs Asset List Excel/Access Plant LOPAs Detailed IPF Data Document Shares HAZOP [N] LOPA [N] SRS [N] FAT [N] SAT [N] MP [N] MP Records [D] MOC [D] Enterprise PM System Asset List Maintenance Procedures [N] Service Notifications Scheduling No Reconciliation Methods Calibration System Critical Instrument Catalog Calibration Procedures [N/S] Calibration History No Automated Syncing of Asset Lists No Authoritative Master Records

10 What is the Immediate Need? Management Simple and Single Portal one stop soup to nuts Cross system audits what, where, when Management reporting and executive dashboards realtime KPI s MOC activity tracking PSM Engr g Ops. Maint. Plant wide visibility of PHA data, LOPAs of Record Ensure LOPA consistency IPL lists: SIF/SIS/SRA/BPCS and Non Instrumented IPLs (RVs, Mechanical Stops, Flares, etc.) Evergreen PHA/HAZOP/LOPA data change tracking IPL assessment tracking with reporting (usually paper based) SIS IPL design data management Single location for additional SRS design data Unique SIF/SRA/BPCS enumeration (master lists) MOC tracking and reporting Accurate SIS Data Quick access to safety related device data Ability to report Failure event data and see the results ITPM Proof test procedure scheduling Overdue test Compliance reporting Live Auditing Safety lifecycle audits management and progress tracking Interface to 3 rd Party systems

11 The Vision A Single Portal Quick Searches Live Feeds Flexible not the traditional IT model Comprehensive and adaptable The Google for Lifecycle data Operations Live Feeds SIS/ Engineering PSM Maintenance LOPA of Records view IPL Registry PHA Pro data Summary Tables IPL Checklists Status charts SIL levels, etc. SRS tables Test dates 3 rd party interfaces Scheduled Test dates Live auditing

12 The Solution

13 The Modules * Patent Pending

14 So what should we capture in SPI? Key devices for PSM safety related services. severe or toxic services. environmental protective or reporting services CONSISTENT Identification of instruments and loops SIF safety integrated functions BPCS basic process control system SRA safety related alarms (stooped using the word critical ) RV relief valves Specification data for pressure containing parts pressure and temperature operating conditions pressure containing parts pressure and temperature ratings (i.e. valve bodies, transmitter bodies, but also includes level chambers, instrument piping and tubing specs, analyzer sample systems, etc. )

15 Use the Criticality Tables

16 Thoughts for SPI and ProSysDR Interface From SPI to ProSysDR Interface: 1. To identify the SPI Instruments (Tags), we can use the SPI Criticality and Category tables or use the UDT tables. 2. Possibility of including control system tag to use the CS tag UDF fields. 3. Excel to be used to upload to ProSysDR using the adaptor module. From ProSysDR to SPI Interface: 1. Any information can be transferred; however, the customer will have to identify the data and where to store in SPI. 2. A module can be built in ProSysDR for SPI interface where the user will have to define the fields for the interface. 3. Excel to be used to upload to SPI using the import module.

17 Questions? Flip to demo 3/1/2012

18 ProSys LOPA View Summary Table Quick search for any asset or keyword. All IPL types Single Portal View Lookup by IPL type Quick drill down feature

19 ProSys LOPA Assess Employ Mangan s EnsureComply tasklists to your LOPAs Design custom tasklists as well Track whether your assets meet compliance requirements

20 EnsureComply Tasklists Based on our extensive experience Customizable SRA SIF / Interlock BPCS Check Valve Relief Valve Mechanical Stop Refractory Damper Stop Flare Etc Aligns with S the design of the protection layers shall be assessed. Independence Diversity Physical separation Common cause failures Auditability

21 ProSys SIS/IPL SRS Tool Manage SIS SIF & SRS data in central location Provide view portals into other enterprise systems View Compliance Status of SIS

22 ProSys SIS/IPL SIF Registry Manage SIF data in central location Provide view portals into other enterprise systems Live link to LOPA data stored in ProSys LOPA View

23 ITPM Brings data from all systems into one interface (SAP, Loveland, Siemens, etc.) Highly customizable data import and display capability Audits reports can show differences in critical data across systems

24 ProSys Operate/Maintain Failure Analysis Brings data from all systems into one interface (SAP, Loveland, Siemens, etc.) Highly customizable data import and display capability Audits reports can show differences in critical data across systems

25 Device Event Reports Analyze the integrity of your systems Failure/Demand/Proof Test Reports, charts, graphs all customizable.

26 ProSys RV Data Sheets View RV Data in the meeting, at the unit

27 Summary Practical, Simple, Cost effect Knowledge of OSHA requirements Proven Software platform Flexible / Responsive Independent OSHA Verifier