ESP Handbook Rev1 with cover.doc

7/27/2019 ESP Handbook Rev1 with cover.doc

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Ensure Safe Production integrates limits


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No one gets hurt in a

process safety incident.

100% environmentalcompliance - meeting the

intent as well as the letter of

the law.

No lost opportunity or

maintenance costs relatedto process safety incidents.

How do we achieve ESP vision?

We

know our limits

and we operate within those limits

all the time !

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ESP Vision


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ESP has 4 sub-processes:

1. Initial Setup

2. Validate Targets

3. Monitor & Control Conditions

4. Learn & Improve

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ESP Sub-Processes


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ESP Process Overview


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This is a sub-process, involves defining

limits A cross-functional team (including

operators)

reviews multiple sources of

information (P&IDs, etc.).

uses operational experience. creates criticals and standards

limits where appropriate.

produces a single repository.

This singlerepository is the variable table

which contains Clearly defined,

conflict-free limits and targets.

Explicitconsequences of deviation.

Operator

actions to return to desired state.

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Initial Setup?


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Validate Targets tARGETSTargets

Ensure Safe Production integrates limits

Initial Setup?


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Critical Limit, Standard & Target LimitsMonitor & Control Conditions (MCC)Critical Limit, Standard & Target Limits


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Critical Limit, Standard & Target Limits


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MCC is how we operate. Its the all-

the-time-work of ESP.

M&CC is characterized by the

following: A monitoring plan is in place to guide

and assist operators. Proactive monitoring is required to

prevent alarms.

Getting help, when needed, is part of

the process.

Operators optimize within limits. Operators stabilize, slow down, or

even shut down the process units, if

needed to stay safe.

Consistent shift reports and effective

shift relief are prepared.

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Monitor & Control Conditions (MCC)


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Variable?

Is a property or condition which is beingmeasured.

This refers specifically to those variables

which areintended to bemonitoredand

controlled.

Examples: temperature, pressure, flow,level, composition, cloudy vs. clear oil

sample, noisy vs. quiet bearings, pH,

ambient temperature, acid concentration,

rate of change, etc.

Variable Table? Is a database that contains all variables

for a process unit.

Most of the information in this

database will be underManagement OfChange (MOC).

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Variable Table


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ACM Web


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Metric Review Process Flow


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TIE is that duration of time that the

Variable can exceed the Standard Limit

and then be brought back into the saferange without consequence. TIE for a

Standard Limit should be used to guide

the Operator as to when he/she should

stabilize, slowdown or shutdown the

equipment followed by escalation and

obtaining help. TIE default for StandardLimit in Port Dickson is 24 hours.

Time in Exceedance (TIE) does not

apply to Critical Limits.

Alarm Rates

Is the total number of Critical Limits &

Standard Limit exceedances per hour per

console, excluding disabled Critical

Limits and Standard Limits

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Time in Exceedance (Hours)


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Is the number of Repeating Critical

Limits and Standard Limits per day per

console position.

Standing Alarms Is the number of Standing Critical

Limits and Standard Limits per day per

console position

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Alarm


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Is to identify potential and active

abnormal situations, prevent their

escalation in severity and to facilitate a

return to safe, environmentally

responsible, and stable operation while

managing the risk to personnel, the

environment, equipment, andthe

community.

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Managing Abnormal Situation

Abnormal Situation Management


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Stabilize, Slow Down or Shut

Down to Avoid Process Safety

and Environmental Incidents.

Variables exceeding critical limits or

standard limits must be brought back into

control to avoid unwanted events.

If the normal response doesntestablish a safe condition, stabilize, slow

down, or shut down the unit to get to a

safe condition and get help.

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Stabilize, Slow Down, Shut Down


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We know our limits

and we operate within those limits

all the time !

ESP Handbook Rev1 with cover.doc

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