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The annual meeting of the American Fuel and Petrochemical Manufacturers (AFPM) focused on various issues facing petroleum refiners, including process safety. Presentations highlighted strategies to reduce human errors, which are a major cause of negative incidents in refineries according to available data. One approach discussed was automating manual procedures using modular procedure automation software, which can help improve safety, efficiency and quality. Meanwhile, water management and alkylation technology were other topics of focus at the meeting.
The annual meeting of the American Fuel and Petrochemical Manufacturers (AFPM) focused on various issues facing petroleum refiners, including process safety. Presentations highlighted strategies to reduce human errors, which are a major cause of negative incidents in refineries according to available data. One approach discussed was automating manual procedures using modular procedure automation software, which can help improve safety, efficiency and quality. Meanwhile, water management and alkylation technology were other topics of focus at the meeting.
The annual meeting of the American Fuel and Petrochemical Manufacturers (AFPM) focused on various issues facing petroleum refiners, including process safety. Presentations highlighted strategies to reduce human errors, which are a major cause of negative incidents in refineries according to available data. One approach discussed was automating manual procedures using modular procedure automation software, which can help improve safety, efficiency and quality. Meanwhile, water management and alkylation technology were other topics of focus at the meeting.
An evolving set of issues facing petroleum refiners in the U.S.
figured prominently at the
annual meeting of the American Fuel and Petrochemical Manufacturers (AFPM; Washington, D.C.; www.afpm.org), held in March in San Francisco, Calif. Among wide-ranging sessions on topics such as crude-oil supply, regulatory and legislative issues, fluid catalytic-crackingunit (FCCU) operations and others, the meeting featured presentations highlighting some of the many areas in which petroleum refiners are looking to adapt and improve. One area of focus was process safety, where a number of new tools are emerging to help reduce human errors in refinery operations. Meanwhile, water issues are becoming more prominent for refineries, along with industry in general, and the AFPM meeting featured a session on that topic. In addition, several presentations reported progress in the area of alkylation technology. Curbing human errors In the process safety session, several presentations focused on strategies to reduce the possibility of human errors in petroleum refinery operations. Yokogawa Electric Corp.s (Carrolton, Tex.; www.yokogawa.com/us) Thomas Fiske said data show that 42% of negative incidents in the process industries had human error as the major cause, and deficiencies with procedures and employee training were critical in the majority of those incidents. Fiske discussed a focus on procedures, the effective use of which can have a major positive impact on safe and reliable facility operations. One error-reducing approach involves the automation of manual procedures, a technique pioneered by Yokogawa. Fiske said that modular procedure automation is becoming an increasingly popular method, not only to mitigate human errors that are associated with accidents, but also to help improve product quality, production efficiency, and capture best practices, especially in higherrisk operations, such as startups, shutdowns and transitions. Procedural automation refers to the set of activities in which operator knowledge and best practices are captured and assembled into specific procedures that are then consistently followed to complete plant tasks. Automating certain procedures can help reduce
operator workload and avoid human
errors, Fiske said. But since automating every procedure does not make practical or economic sense, Fiske discussed how best to determine which procedures should be automated. He suggested focusing on procedures associated with the operations most likely to lead to production disruptions, and then determining what type of procedure automation could mitigate the consequences of those events. Opportunities where procedural automation makes sense include low-frequency, highconsequence operations, such as startups and shutdowns, highly complex procedures, transitions and others, Fiske said. Fiske also reported progress by a technical committee under the auspices of the International Society of Automation (ISA; Research Triangle Park, N.C.; www.isa. org) in formulating a consensus standard on procedure automation in continuous processes. The forthcoming ISA Standard 106 is in the planning stages currently, and the technical committee is now working on its second technical report. The committee has already published its first technical report: ISA-TR106.01 on Procedure Automation for Continuous Process Operations Models and Terminology
A Review of Process Fault Detection and Diagnosis Part I Quantitative Model-Based Methods (2003, Venkat Venkatasubramanian, Raghunathan Rengaswamy, Kewen Yin, Surya N. Kavuri)