2014 Software Global Client Conference

Transcription

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2 SS S&T - 03 B The impact of the operator on plant safety Gregor Fernholz DYNSIM Product Manager

3 Mobile App: Please take a moment Check into Session by: Select Detailed Schedule Select the specific session Click on Check in Take Session Survey by: Select Detailed Schedule Select the specific session Scroll Down to Survey and Provide Feedback

4 Agenda 1. Motivation 2. The Operator s Perspective Human Error 3. Case Studies 4. Outlook 5. Summary

5 1. MOTIVATION

6 Abnormal Situation Root Causes Industry studies of the 170 largest propertydamage losses over the last 30 years in the hydrocarbon processing industry have shown that 28% are due to operational error or process upsets....about 40% of abnormal operations were caused by human errors.

7 Does this mean that operators are a threat to plant safety? Operators have a significant impact on plant safety. Operators will make mistakes sometimes but how can we prevent them? Operators can save the plant from an accident......so what s making those successful?

8 2. OPERATOR S PERSPECTIVE: HUMAN ERROR

9 Classification of human errors The operator s perspective Mistakes I didn t know what to do! I thought I did the right thing. Violation or noncompliance Convenience it s easier/faster this way. For good reasons instruction might be wrong.

10 Classification of human errors The operator s perspective, cont d Mismatches Beyond my ability. Beyond everybody s ability. Slips/lapses of attention Confusion Lack of information Routine Miscommunication

11 Requirements Operator education Fundamentals of the process & operation. Understanding why accidents happen. Prevent accidents in the future. Validating and improving rules and procedures Identify and train best-practice. Violated rules: Change or adopt. Analyze new procedures on plant safety impact. Improving communication skills Improve critical situation readiness Sustain improvements!

12 Consequences 1. Training is key to enhance the operator s impact on plant safety. 2. Use training means matching all requirements: Operator Training Simulator (OTS) 3. Embed the use of OTS in design, operation and corporate training practice

13 Why Operator Training Simulators? Understand the process fundamentals. Understand why accidents happen. Prevent accidents. Identify Best Practices & roll-out. Adopt of rules and procedures. Analyze lack of information vs. information overkill. Test changes using the simulator on safety impact. Improve communication skills. Critical situation readiness. Avoid routine by re-training. Don t forget the lessons-learned.

14 progression for process safety competency Pyramid Copyright: John M Campbell and Company The Competency Pyramid & OTS Examples of applying OTS in the different training levels TRB P. Safety Mgmt. Incident Investigation Emergency Response Mitigation Anaylsis Hazards Operations and Management Processes Equipment Properties of Hydrocarbons Company Policy

15 3. CASE STUDIES

16 Brunner Mond Chemical Plant, UK Situation in 2001 Safe and Unsafe Acts (Susa) Training Initiative Training of Trainers Training of Observers (25% of the workforce) Training of all employees and of contractors Result 0 LTI in 1 million hours (1 st in 10 years) Top safety records in the UK chemical industries My lessons-learnt Accidents aren t fate. Training needs to be safety-centric. Active participation increases adoption. Higher than average accident rate. Statistics: 1 LTI per employee during working life

17 Chevron Richmond Refinery 2012 Handling of emergency situations The accident Pipe failure due to corrosion. Release of vapour which eventually ignited. Root cause: Corrosion and lack of maintenance. Some investigation results (Cal/OSHA and CSB) Chevron failed to implement its own emergency procedures to shut down the No. 4 Crude Unit......strong indicator that workers aren t properly trained for emergency situation. My lessons-learned Procedures might not be followed. Team readiness for emergency situations? Identify gaps in the operator s competency!

18 BP Texas City Refinery, 2005 The accident (a simplified version) Operator overfilled and overheated the column. Intervention steps: late, inadequate & wrong. Supervisory staff didn t verify the correct procedures were used or followed. Right procedures would have prevented the accident Some investigation results in the root causes BP has not... ensured that... refinery personnel have sufficient process safety knowledge and competence....process safety education and training needs to be more rigorous, comprehensive and integrated. Develop an implement a system to ensure safety knowledge and expertise.

19 Engro fertilizer plant, Pakistan 2007 Sequence of events August 2007 Shift found issue with the synthesis gas compressor. Operators tripped the compressor after analysis. Compressor repaired & restarted. Compressor still showed abnormal behaviour. Full shut-down, inspection and rotor replacement. Re-start after 10 days. Analysis by the plant engineers and management Well-trained shift identified the problems correctly. Operators took the right decision. Prevention of an accident or long shutdown. My lessons-learned Trained & empowered operators take right decisions. If you train them, you ll trust them.

20 4. OUTLOOK

21 Demographics Less opportunity for on-the-job training due to increased plant automation.

22 Changing job environments The experienced operators will retire. High training demand for new operators!

23 New regulations and technologies OTS is mandatory for nuclear power plants. Introduction of new (voluntary) standards, e.g. ANSI Z490.1 for best HSE practices. Industry leaders including OTS as a standard in their training concepts. A key driver is process safety. New technologies enable new concepts for operator-centric safety training. 3D virtual reality environments integrated with OTS for field and control room operator training.

24 5. SUMMARY

25 Summary 1. Human error is still a significant source for accidents. 2. Operators have a significant impact on plant safety. 3. Training for operators needs to be safety centric covering all safety relevant aspects. 4. Operator Training Simulators are currently the best technology for delivering operator-centric safety training. 5. Training needs to be embedded in a long-term, sustainable training concept and strategy. 6. Case studies clearly show that the mission is not accomplished, yet. 7. Demographics, changing job requirements and regulations will increase training demand and requirements.

26 Your Partner Excellence in project delivery Global delivery team More than 250 engineers More than 100 projects per year Expertise in all process industries Global customer base Side-wide programs Corporate-wide programs Cuttingedge software technology DYNSIM for dynamic simulation EYESIM for immersive 3D training System intergration for DCSs System integration for PLCs Wonderware for HMI Cloud-based systems Scalable Solutions DCS/HMI familiarization Generic OTS High Fidelity OTS Corporate OTS Consultancy services for training Software as a Service Training as a Service

27 Related Support, Services, Training & Expo Demos Support > SimSci software support Services > OTS Projects > OTS Consulting > Developing training programs > Customer First for OTS Training > DYNSIM Training Course > Instructor Training > OTS Maintenance Training Confidential Property of Schneider Electric Expo Demos > Dynamic Simulation and SimSci APC 2014 (booth #20) > Power Plant Operator Training Simulator (booth #21) > Immersive Operator Training System (booth #22) 27

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