Dynamic Risk Analyzer (DRA)0af3960b693179f23c05... · Dynamic Risk AnalyzerTM (DRA) Early Risk...
Transcript of Dynamic Risk Analyzer (DRA)0af3960b693179f23c05... · Dynamic Risk AnalyzerTM (DRA) Early Risk...
Dynamic Risk AnalyzerTM (DRA)
Early Risk Detection for the Process and Energy Industries
Ulku Oktem, PhD Co-founder, CEO and President [email protected]
www.nearmissmgmt.com | Philadelphia, PA
Ankur Pariyani, PhD Co-founder, Chief Innovation Officer [email protected]
Deb Grubbe Chief Marketing Officer [email protected]
Accidents
Hidden Near-Misses
(Not Casually Observable)
Incidents (Observable Near-Misses)
Core Concept
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Initiation Phase
Hidden Risks (in Process Data)
Incident Major Event
Time
Imp
act
Alarm / IOW
Resolve Process Risks at Initiation Stage with DRA
Early identification of process issues when process is still within normal limits
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Dynamic Risk AnalyzerTM (DRA)
Early Risk Detection Software
Detects process problems at initiation stage autonomously
Alerts operating team
timely
Analyzes hundreds of tags using patented
technology
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Problem Initiation
DRA Detection
Operations Team
Safe & Reliable Operation
Process Data
Precursors
Corrective Actions
• Spends 10-15 mins to review all tags (full peripheral vision) DRA points out problem areas – autonomously
Typical Operating Unit: • Has thousands of tags (temperatures, pressures, etc.)
Typical Engineer: • Spends 1-2 hrs and reviews 20-30 tags/day (~3% tags)
using Spreadsheets / Historian / Trending tools
Engineer WITH DRA:
DRA Difference
Industrial Control System
Firewall
DCS
SCADA
PLC/ Instrument
systems
Process Control Network
Business Network
SECURED CUSTOMER NETWORK
Managers
Engineers
Operators
Firewall
OPC
DRA Architecture
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ONSITE DRA SERVER
Historian
EQUIPMENT ISSUES Compressor Vibration Problem Product Bucket Problem Control Valve Plug Erosion Pressure Control Valve Plugging Level Control Valve Plugging Pump Cavitation Pump Clogging
Customer Case Studies Early Detection of Operations Issues
PROCESS ISSUES Steam Leak in Sulfur Bath Hydrocarbon Carryover Furnace Plugging Line Plugging Lube Oil Filter Clogging Temp. Controller Problem Overhead Seal Oil Issue
INSTRUMENTATION ISSUES Sensor Flatlining Faulty Transmitter I/O Card Module Failure
OPERATOR ISSUES Operator Error Unstable Operating Procedure
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Customer Case Study: Compressor Vibration Problem
• DRA identified anomalies in vibration variables for a rotary equipment
• Unit was running at higher load than normal
• No alarms were activated (high alarm at 1 mm)
• Rectified by center realignment of compressor
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120-day Trend of LPC Axial Vibration (in mm)
Early indications by DRA
Maintenance shutdowns
Customer Case Study: Control Valve Plug Erosion
• DRA identified anomalies in valve
opening, indicating slow but steady decrease
• Possible root causes were identified early on and spare parts were ordered
• Investigation showed that the valve plug erosion caused the decrease in opening (see below)
Level Control Valve Opening (60-day trend)
Early indications by DRA
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Findings Anomalies detected by Production Supervisor on mid-level indicator for an amine sweetener column and communicated promptly to Operation Engineer.
Actions Operation Engineer confirmed the abnormality and raised notification.
Benefits Early detection of the anomalies prevented a possible hydrocarbon carryover which will have resulted in potential further downstream unit interruption.
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Customer Case Study: Hydrocarbon Carryover Avoidance
Findings Anomalies detected by Operation Engineer through
DRA – indicating sudden drops in LC503.PV
Actions Maintenance Order was raised to apply engineering
solutions for the equipment.
Benefits Early detection of drops prevented further
possible pump cavitation (P-21254 ), which will
have resulted in costly equipment damage and
process interruption.
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Customer Case Study: Pump Cavitation
Early indications by DRA
Benefits of DRA – Beyond Just Risk Detection
Uptime, Efficiency, HSE, Quality
Prevent emergency maintenance
Move from reactive to PROACTIVE culture
Increase peripheral vision and team’s productivity
Benchmark plants and operations
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DRA INSTALLATION
DRA Hardware Requirements (Per License)
Processor: 4 CPU cores (physical cores) at 2.8 Ghz RAM: 16 GB Storage: 1 TB of HDD Operating System: Windows Server 2012 or Linux OS (RedHat/SUSE/Ubuntu) Server type: Virtual machine (VM) or physical server NOTE: • Specs are for each DRA unit and are sufficient to support ~5 years’ worth of data. • A higher end server can be used to install multiple DRA instances on a single server.
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DRA Implementation Steps
For each DRA Unit to be installed
Configure a Server for DRA (IT)
Identify tags to be monitored (Operations)
Organize tags into groups (Operations)
Identify shutdown rule(s) (Operations)
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FACILITY CHECKLIST
Install DRA software in collaboration with Facility IT
Populate tags to be monitored
Program shutdown criteria
Schedule historical calculations
Conduct user training
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DRA Implementation Steps NMM CHECKLIST
~ 1-2 days
~ 2 weeks
~ 2 hrs x 3 sessions
DRA in PETRONAS Annual Sustainability Report 2015
Award Finalist – Nov 2017
Award Finalist – June 2017
Process Interventions & SAP Maintenance –Summary
HYDROCRACKER
AFTER DRA
Autonomous analysis of 700+ tags
Results available for morning meetings
Problem Resolution
Selection of 15-25 tags by Engineers
Identification of potential problems
Quick identification of potential problems
Fast communication with Maintenance/Operations
BEFORE DRA
~ 2 hrs
700+ TAGS
1M+ DATA POINTS
RECORDED DAILY
How does one identify the risk
information buried in this data timely
and efficiently?
BIG DATA (Per Process Unit)
~ 15 mins
Communication with Maintenance/Operations via Emails, Phone Calls, etc.
Problem Resolution
~ 1-2 hrs
Analysis via trending tools (Historian, Excel, etc.)
~ 2 hrs
MORNING MEETING WITH OPS GROUP
Actions based on review of 25 tags
Analysis of 700+ tags
Quick identification of top 5-10 risks
Actions based on review of 700+ tags
Follow-up on effectiveness of
actions
Review impact of change
Review of ~15-25 tags
DAILY REVIEW BY ENGINEER
Review based on operating limits and alarms: • Urgent process response • Maintenance requests
FOLLOW-UPS DURING DAY
WITHOUT DRA
WITH DRA
MORNING MEETING WITH OPS GROUP
Review based on DRA indicators: • Early process interventions • Timely Maintenance requests
FOLLOW-UPS DURING DAY
24x7 PROCESS MONITORING BY OPERATORS
DAILY REVIEW BY ENGINEER
Self-Directed Engine
Drill-Down to Problem Areas
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Peripheral Vision (Enterprise-Wide Risk Information)
Rapid ROI
DRA Differentiators
Intuitive Interface
Institutional Memory
Early Detection of Problems