Effectively managing the safety lifecycle requires teamwork between multiple disciplines, departments and companies, but it shouldn’t require multiple solutions. See how you can consolidate the entire safety lifecycle into a streamlined solution ensuring risk is reduced, instrumented systems are available and compliance requirements are met. The “cradle to grave” lifecycle approach that is enabled by the APM Safety work process provides visibility across the organization to what teams are doing, and how well their doing it.
In this third webinar in a series about APM, Stork, SOCAR Turkey and GE Digital share their insights on process safety best practices, from various perspectives: the process, the solution and the culture.
What Are The Drone Anti-jamming Systems Technology?
Webinar | APM Best Practices - Effectively managing the safety lifecycle
1. Plaatje leaflet
hier invoegen
The webinar starts at 12.00h CET
You can ask questions through the Q&A button in the Zoom menu
During the webinar all participants are on ‘mute’.
Effectively managing the safety lifecycle
2. INTRODUCTION OF SPEAKERS
Hans Minnaard
Principal consultant
Stork Asset
Management
Technology
Saif Abdelnabi
Senior Consultant
APM - Functional
Safety and Reliability
GE Digital
Ömer Metecan
Reliability
Chief Engineer
Socar Turkey
Johan Schroevers
Senior Consultant
Stork Asset
Management
Technology
3. 12.00 – 12.15 an introduction to APM and
process safety
Hans Minnaard
12.15 – 12.45 best practice on:
effectively managing
the safety lifecycle
Johan Schroevers
Ömer Metecan
Saif Abdelnabi
12.45 – 13.00 panel discussion Johan Ferket
There will be poll questions after the first presentation and we will discuss the results
during the panel discussion together with your specific questions.
APM BEST PRACTICE
AGENDA
4. High overview
introduction
Full integrated APM
solution
Best Practice Cases Open table
An open table with
attendees related with
the application
Mechanical
Integrity and compliance
Reliability Added Values
Effectively managing
the safety lifecycle
Asset Strategy Library
SEMINARS
APM BEST PRACTICE
5. Clients
Accelerated Adoption + Time to Value + Sustainable ROI
Market Leader in
Asset Performance
Management Technology
& Services
World Class
Functional Asset
Management Solutions
THE PARTNERSHIP
6. o Planned / Preventive / Predictive /
Prescriptive Maintenance Strategies
o Lean and Performance Based Maintenance
programs
o Reliability Centered Maintenance (RCM)
o Risk Based Assessment (RBA)
o Reliability, Availability & Maintainability (RAM)
analysis
o Inspection and integrity services to manage
risk, reduce failures and increase asset life
o Reliability engineering services
o Evergreen your approach
o Asset management performance modeling
(objectives and KPIs)
YOUR APM ADOPTION
HOW STORK ACCELERATES
APM Software and Continuous
Improvement Work Processes
7. Stork together with GE Digital are the best
partners in Asset Performance
Management. Through an integrated
approach, we can support our clients to
improve their overall Asset Performance
Management.
Through this seminars, we would like to
show and discuss best practices application
examples related to Asset Performance
Management.
INTEGRITY MANAGEMENT MODEL
ASSET RELIABILITY AND
9. Herkese Açık
PROCESS SAFETY LIFECYCLE
THREE PHASES TO AN OPTIMUM
The (IEC 61511) process safety lifecycle can be divided in three
phases:
1. Analysis phase (Risk Assessment, LOPA, SRS)
2. Design phase (Design & Installation)
3. Operational phase (Operation & Maintenance + MOC or
Decommissioning)
Gather and use own data during operational phase
Improve the level of process safety applicable for your situation!
• Re-visit the HAZOP
• Re-assess the LOPA
• Verify the SIL-Loops
Closing the loop
10. Herkese Açık
PROCESS SAFETY LIFECYCLE
GREEN FIELD BROWN FIELD INSTALLATION
Green Field vs Brown Field
Different focus on the phases.
Observations brownfields:
• Instrumented functions in place but is no overview on the actual
performance of the layers of protection.
• Maintenance plan (proof testing) present, update required
• Re-HAZOP fed with operational experience
APM project creates opportunity:
• To improve process safety lifecycle
• Redefine HAZOP, LOPA, SIL, documentation
• Clear recommendations
• System in place to store operational data
11. Herkese Açık
PROCESS SAFETY LIFECYCLE
GE APM ACTIVITIES
(1) Hazard & Risk
Assessment
2) Determination of
Protective Layers and
Unmitigated Risks
(3) Safety
Requirements
Specification
Design & Develop
other means of risk
reduction
(5) Installation,
Commissioning &
Validation
(6) Operation &
Maintenance
(7) Modifications
(8) Decommission
(10) Management
of Functional
Safety &
Functional Safety
Assessments &
Audits
(11) Life Cycle
Structure &
Planning
(9) Verification
(4) SIS Design &
Engineering
12. Herkese Açık
EXECUTION
ASSESS OPERATING RISK
Identify all known equipment risks for their critical
production assets mechanisms by:
• Engage multiple departments in process safety
discussions, training and facilitation.
• Data gathering of equipment datasheets, process
P&ID, PFD, Equipment failure data, shift books,
maintenance and operation inputs.
• Link Process Safety Analysis, causes and safeguards
with SAP Common equipment database so the risk
analyses are always linked to equipment records.
• Align results with maintenance and reliability
departments for integrity assurance tasks
Define
Proof Test
and/or
Calibratio
n Strategy Execute
Strategy
Operate &
Monitor
Performan
ce
Assess
Operating
Risk
Determine
Safety
Integrity
Level
(SIL)
Validate
Instrument
Design
Establish common
understanding of Risk
between different
sites
13. Herkese Açık
EXECUTION
DETERMINE SAFETY INTEGRITY LEVEL
• Should we use a qualitative or quantitative risk
analysis? We identified high risk scenarios from the
HAZOP analysis and then applied the LOPA methodology
to further quantify the risk and provided risk reduction
needed to close the risk gap.
• Utilizing LOPA tool by GE, it was possible to move from
HAZOP to LOPA without the need to re-do the analysis.
• Any HAZOP or LOPA recommendations? Following
HAZOP and LOPA studies, multiple redesign and loop
verifications recommendations came. These are
sometimes related to and MOC which needs an
engineering and design change, or sometimes a cronical
problem wihch can be a trigger for and RCA, or a simple
data update.
Creating
Recommendation
Define
Proof Test
and/or
Calibration
Strategy Execute
Strategy
Operate &
Monitor
Performanc
e
Assess
Operating
Risk
Determine
Safety
Integrity
Level
(SIL)
Validate
Instrument
Design
Building LOPA study
directly from HAZOP data
14. Herkese Açık
EXECUTION
SIL VERIFICATION
• Does the safety loop meet its Safety Integrity
Target?
• SIL Calculation requires gathering lots of data from
site and design documents.
• Accurate data for C&E was not available for some of
the sites. As-building of C&E diagrams, P&ID was
managed by multiple teams.
• Revesting existing SIL studies carried out by other
contractors and verification against current operating
design for current loop design.
• Guidelines from IEC 61511/61508 are used and applied
to related loops during design phase.
Define
Proof Test
and/or
Calibration
Strategy Execute
Strategy
Operate &
Monitor
Performanc
e
Assess
Operating
Risk
Determine
Safety
Integrity
Level
(SIL)
Validate
Instrument
Design
Verify and document
Cause and Effect Matrix
Managing loops
calculation through GE
APM
15. Herkese Açık
EXECUTION
DEFINE PROOF TEST
• Following the completion of SIL verification and
Validation phases. Complete review of all Proof Test
Procedure and Tasks took place to ensure full
compliance with IEC61511 requirement.
• Review of the proof test procedure was developed
with the full engagement of field instrument
technicians and instrument engineers to ensure all
comments captures.
• Proof tests procedure and tasks have been loaded
in the GE software with full integration with CMMS
and other critical Asset Performance Management
tasks.
Documented proof test
records for easy verification
Proof Test Templates for
each Instrument function
Define
Proof Test
and/or
Calibration
Strategy Execute
Strategy
Operate &
Monitor
Performanc
e
Assess
Operating
Risk
Determine
Safety
Integrity
Level
(SIL)
Validate
Instrument
Design
16. Herkese Açık
MONITORING
SAFETY LIFECYCLE DASHBOARD
Common dashboard to
visualize all process safety
lifecycle
Define
Proof Test
and/or
Calibration
Strategy Execute
Strategy
Operate &
Monitor
Performanc
e
Assess
Operating
Risk
Determine
Safety
Integrity
Level
(SIL)
Validate
Instrument
Design
17. Placeholder confidentiality disclosure. Edit or delete from master slide if not
needed.
Work Process
Item
GE APM Software Tool
Hazard Analysis HAZOP and What if
analysis.
Risk
Assessment
Asset Criticality
Assessment (ACA), RBI,
RCM, FMEA, SIS
Management,
Work Process Item GE APM Software Tool
SIL Assessment LOPA, Risk Matrix,
Internal PHA, External
Assessment
Work Process
Item
GE APM Software Tool
SIL
Calculation
SIS Management
Custom Failure
Data
Reliability Analytics
Work Process
Item
GE APM Software Tool
Optimize task
cost, reduce
risk, optimize
PM interval
SIS Management,
Asset Strategy
Management (ASM)
Work Process Item GE APM Software Tool
Evaluate SIF
Performance
SIF Trip Rates, Spurious
Trips rates, Failed Proof
Tests.
Modifications,
Change
Management
Management of Change
(MoC)
Root Cause
Analysis
RCA
Work Process
Item
GE APM Software Tool
Implement
Actions
ASM, ASI to SAP,
Calibration
Management,
Operator Rounds,
Inspection Task,
Proof Test Task
Consolidate
Plan to
Achieve
SIL
Execute
Strategy
Operate &
Monitor
Performance
Assess
Operating
Risk
Determine
Safety
Integrity
Level
(SIL)
Validate
Instrument
Design
18. Herkese Açık
Compare Risk Reductionn
between different Actions
• Maintenance plans are
updated with process safety
and integrity tasks.
• Process safety study outputs
are implemented into
equipment strategies aligned
with RCM, FEMA and RBI
outcome.
• Ability to compare actions
and risk reduction achieved
between different
recommendations from RBI
or RCM and optimize actions
based on ROI and Risk
Reduction.
ALIGNING PROCESS SAFETY WITH APM BEST PRACTICES
ASSET STRATEGY MANAGEMENT
19. Herkese Açık
• Risks and Actions across
multiple studies are reviewed
and managed before
deciding to implement these
recommendations to actions.
• Apply strategy templates to
multiple similar equipment.
• Provide the ability to review
and modify/approve
inspection tasks and check
the impact on safety,
production and financial.
Review list of Risks and
Actions against Each Asset
ALIGNING PROCESS SAFETY WITH APM BEST PRACTICES
ASSET STRATEGY MANAGEMENT
20. Herkese Açık
• Roll out process safety studies for the other
parts of the company.
• Develop company’s failure rate data and
using reliability analytics, for cost optimizing
and maintain safety performance.
• Develop automated policies to record Safety
Instrumented Trips associated with
developed instrumented functions through
OPC connectivity.
• Develop automated policies to trigger Root
Cause Analysis process based on safety
instrumented system failures.
SIS trips recorded by
instrumented functions
based on OPC data.
NEXT STEP?
22. Questions
Via Q&A
Or get in touch with
our host:
Johan Ferket
Johan.Ferket@stork.com
+32 473 864 083
APM BEST PRACTICES
EFFECTIVELY MANAGING THE SAFETY LIFECYCLE
Hans Minnaard – Principal consultant Stork Asset Management Technology. Hans is principal consultant in the field of Asset Performance Management and is the competence leader in various GE Digital APM software selection and implementation projects.
His passion is to coach people to strengthen their ability to deal with the challenges in their daily life at work. As a trusted advisor he supports clients in O&G and Chemicals in projects with a strong change management component. Hans holds a Bachelor degree in Electrical Engineering and a Master degree in Organizational Change Management.
Luciano Narcisi - Senior Consultant - Stork Asset Management Technology
Luciano is a mechanical engineer with a master degree in risk and reliability. With more than 10 years of experience in Mechanical Integrity Management, he specialized in Risk Based Inspection methodology and implementation of Mechanical Integrity systems in the Oil & Gas industry. He had the opportunity to lead projects in different contexts: downstream and upstream, offshore and onshore, greenfield and brownfields operations in South America and Europe. Currently working as a Senior Consultant at Stork AMT, he is supporting clients to implement sustainable APM systems.
Vipin Nair - Senior Product Manager, APM Integrity solution, GE Digital
With more than 14 years of experience in Asset Performance Management, Vipin Nair is product leader for GE APM Integrity, delivering high-value product solutions and managing the overall product life cycle of fixed and linear assets. He joined Meridium in 2012 and has served the needs of customers through various roles in consulting, pre-sales and product management. Vipin’s previous experience includes reliability and maintenance positions with a major corporation in the process and manufacturing industry. Vipin holds a Bachelor of Technology in Mechanical Engineering, is an active member of the API 581 task force group, and holds several active API certifications like API 580, 571.
Hans Minnaard will introduce the concept of Asset Performance Management and the various domains leading to more efficiency and long term success for your organization. In this webinar he focusses on foundations for Mechanical Integrity in an Asset Management journey. He explains the various roles in this process and the benefits of an integrated approach for APM solutions. As a prelude to best practices he describes the concepts behind the application examples.
Luciano Narcisi will guide you through two examples of successful APM implementation focused on mechanical integrity. At SOCAR in Turkey, Stork and GE Digital channeled a journey that enabled SOCAR to extend the mandatory inspections period by adjusting government inspection requirements through RBI. At Freeport LNG, Stork was selected to build the foundations for a Mechanical Integrity System. Together with GE Digital, we helped the client maintain the asset's integrity and ensure operational safety while extending government requirements for inspection intervals.
Insight into changing German legislation on inspection requirements.....
We have field proven practices for defining adding value asset strategies and we implement the strategy in your EAM maintenance management module. We support the execution of maintenance and inspection with knowledge about the behavior of equipment. And we support you with the evergreening process to evaluate the effectiveness of the strategies. The GED APM software has all the functionalities in it to make these steps.
We use a basic workflow model called Asset Reliability & Integrity model which is used as a basis for training of APM building blocks. The model is based on the international standard NEN-EN16991-2018 Risk-base inspection framework.
There are two PDCA loops. Outer loop is designed to define and implement effective asset strategies which reduce the risk to the acceptable level. The innerloop is to define and evaluate efficient maintenance tasks to assure on time execution and first time right.
This is a bit more of a granular view of the GE Digital Continuous Improvement framework and how the entire suite of software holistically works together. This gives you an idea of all the different functions and work processes the Asset Performance Management solution can enable.
For today's discussion we will be focused on the maroon portions of this visualization specific to APM Strategy and APM Reliability
In subsequent seminars we will cover additional work processes and functions and how GE Digital’s solutions and stork best practices can be leveraged in your organization.
Today we will take you through several case studies that discuss how the GE Digital APM Strategy and Reliability modules and Stork best practices enable organizations to generate and execute optimized risk mitigating maintenance & inspection tasks, while streamlining auditability and compliance governance.
Today Keyvan and Yerem will discuss two appl
The process safety lifecycle can be divided into three phases with activities.
The IEC 61511 standard first depicts an Analysis phase.
In this slide shown by the green part with a “risk assessment”, “the allocation of safety functions to protection layers” and the “safety requirements specification”.
The Second phase, let’s call it the design phase, the yellow part in this slide, shows the activities where the safety loop is first “designed” and later on in the process is “installed and commissioned”.
In the operational phase maintenance tasks are executed and information of the performance must be gathered.
During operation data on proof test results, equipment failures and process excursions must be gathered.
When striving for an optimum level of process safety, applicable for your situation, some activities from the earlier phases need to be revisited.
For example lets take the frequency of events, a number you would use during the HAZOP.
If you experience a different number for frequency of events during operations.
Then the next time you revisit the HAZOP you will need to use your own statistics.
The HAZOP then represents the actual situation, based on your statistics.
Or in your case of failure numbers for certain instruments: If you find that your equipment failure numbers are different (better of worse) then the numbers you used before need to be adjusted. In your situation you should assimilate your actual operational statistics.
So although the process lifecycle is depicted as a flowchart with a beginning and an end it really should be a continuous process; More like a circle of activities. Activities like HAZOP, LOPA and SIL calculations should be updated when the necessity is there. With the renewed result your maintenance activities should adapt. Also de-bottle necking, revamping, projects or simple changes should initiate the process safety lifecycle.
For a modern green field situations the focus on process safety will be present. The activities for the relative short first two phases of the lifecycle are executed and documented very well. The documentation is stored mostly in a digital manner and is made available to those who need to have access. This makes it easy to perform your planned maintenance during the longer third phase according. Together with data from the operational phase, closing the loop on these installations takes less effort compared to Brown field installations.
For the Socar Turkey the project team was confronted with both situations. At the stat of our APM project the new oil refinery was installed and almost ready to go into operations. The petrochemical installations were more mature and experienced already decades of operational lifetime. The approach on process safety activities for the APM project for the Green field parts of the installation was different then for the Brownfield part.
For the new installation a HAZOP was already done, but there was no operational data present. The LOPA was revisited and existing SIL loops calculations were available. The maintenance activities needed to be defined and planned and communicated with the maintenance organization merged with all the other APM defined activities.
The mature installation part however has been commissioned before the safety standard (IEC 61511) was released. The HAZOP needed revisiting and the exact risk reduction for the layers of protection was not updated with operational data. The instrumented safety functions were in place and were being tested according to planning. But the planning was not reviewed recently. Maintenance activities on safety loops were assigned to certain departments but there was no overall planning of safety related activities. Documentation was present but not always in a digital format.
STORK advised to revisit the process safety activities according to the standard and process all activities with GE APM. The plan fro the petro chemical part was to start with a Re-HAZOP and follow the process safety activities for one unit. In such a way of work the organization would gain knowledge and experience on the installation and the process safety standard, while working on the improvements. In the continuous operational phase, data would be gathered and analyzed and the loop could be closed. Following this way of work STORK support would decrease until the activities could be handled without any support.
For all the activities a training was hosted before execution. As part of the overall APM project we knew we would have access to the GE APM so all data was documented in the system from the start. Some challenges we came across are:
The operational data was stored in several location in different formats.
Instrumented functions were in place but there was not a clear overview on the actual performance of any of the safety layers.
Of course there is a maintenance plan in which tasks are assigned to perform the necessary proof testing. But it is unclear if any adjustment is needed.
The project at Socar Turkey with GE meridium and STORK was a unique project because it was a mix of Greenfield and Brownfield installations. Also the practical adoption of process safety activities within the APM approach was unique. The process safety integration really became a group effort realized by mutual support between the departments.
With the execution of the APM project the focus was not only on the maintenance strategy and tasks, but it provided the opportunity to focus on getting process safety to a higher standard.
The level of process safety will improve over time with the growing availability of the operational data and the continuation of the process safety activities.
During the project, the implementation of the GE APM system provided support because the system more or less forces you to execute the process safety activities.
The HAZOP was executed and all results were documented in the system.
For those scenario’s applicable the LOPA reviewed if the present risk reduction was sufficient. Otherwise the required SIL was defined.
For the existing instrumented safety loops, the SIL calculation have been executed.
Define Proof Test and/or Calibration Strategy maintenance activities were defined and planned.
Recommendations, items which need additional attention to improve, have been made.
Were before the project the several departments executed their own assigned tasks and data was generated at multiple locations in different formats.
Now the information is stored within the APM tool automatically processed and easy accessible.
We experienced that by involving several engineers and technicians during the process the level of awareness has risen. Now common knowledge is that improving the level of process safety is a combined effort.
But better is to hear how the SOCAR Turkey has experienced the project, so I will hand over to Ömer
Where do you record your failure data of SIL loops? / How do you track the HAZOP and LOPA recommendations?
-CMMS (SAP, Maximo, etc)
-Excel worksheets
-Soft Copy (Shiftbooks, reports..)
-Software
-Not recorded
Do you have a Functional Safety Management plan?
-Yes, and up-to-date
-Yes, but needs to be revised
-No.
-Not sure what it is.
The two examples I just described are clear business cases for the client and demonstrate the value added by an Asset Performance Management System implementation, specifically related to Mechanical Integrity.
On the other hand, we need to be clear that RBI is not a tool designed to extend inspection intervals, but a methodology that aims to design value added inspection strategies on critical equipment, and appropriate scope for less critical ones.