Incidents investigation and dynamic analysis of large alarm databases in chemical plants: A fluidized-catalytic-cracking unit case study

Industrial and Engineering Chemistry Research

Volumn 49, Issue 17, 2010, Pages 8062-8079

  Pariyani, Ankur ^a   Seider, Warren D ^a   Oktem, Ulku G ^b   Soroush, Masoud ^c  

^a UNIVERSITY OF PENNSYLVANIA   (United States)

^b UNIVERSITY OF PENNSYLVANIA   (United States)

^c Drexel University   (United States)

Author keywords

[No Author keywords available]

Indexed keywords

DISTRIBUTED CONTROL; EMERGENCY SHUTDOWN SYSTEMS; EVENT TRACKING; INITIATING EVENTS; OPERATING RANGES; PERFORMANCE INDICES; PRODUCT QUALITY; PROTECTION SYSTEMS; SYSTEM STRUCTURES; TIME ANALYSIS;

ACCIDENT PREVENTION; CHEMICAL PLANTS; CRACKING (CHEMICAL); DISTRIBUTED PARAMETER CONTROL SYSTEMS; DYNAMIC ANALYSIS; FLUIDIZATION; PETROLEUM REFINERIES; PLANT SHUTDOWNS;

FLUID CATALYTIC CRACKING;

EID: 77956076376     PISSN: 08885885     EISSN: 15205045     Source Type: Journal    
DOI: 10.1021/ie9019648     Document Type: Article

References (54)

1. Meel, A.; Seider, W. D. Plant-Specific Dynamic Failure Assessment using Bayesian Theory Chem. Eng. Sci. 2006, 61, 7036
2. Yi, W.; Bier, V. M. An application of copulas to accident precursor analysis Manage. Sci. 1998, 44 (12) S257
3. Phimister, J. R.; Oktem, U. G.; Kleindorfer, P. R.; Kunreuther, H. Near-miss incident management in the chemical process industry Risk Anal. 2003, 23, 445
4. Rosenthal, I.; Kleindorfer, P. R.; Elliott, M. P. Predicting and confirming the effectiveness of systems for managing low-probability: Chemical process risks Proc. Safety Prog. 2006, 25 (2) 135
5. Cooke, D. L.; Rohleder, T. R. Learning from incidents: from normal accidents to high reliability System Dynam. Rev. 2006, 22 (3) 213
6. Jones, S.; Kirchsteiger, C.; Bjerke, W. The importance of near miss reporting to further improve safety performance J. Loss Prevention Process Ind. 1999, 12 (1) 59
7. Bullemer, P.; Nimmo, I. Tackle abnormal situation management with better training Chem. Eng. Progress 1998, 94 (1) 43
8. Bullemer, P. T.;; Nimmo, I. Understanding and supporting abnormal situation management in industrial process control environments: a new approach to training. Proceedings of the 1994 IEEE International Conference on Systems, Man, and Cybernetics. Part 1 (of 3); San Antonio, TX, October 2-5, 1994; Vol. 1; p 391.
9. Brown, D. C.; O'Donnell, M. Too much of a good thing- Alarm management experience in BP oil. Part 1: Generic problems with DCS alarm systems IEE Colloquium (Digest) 1997, 136, 5/1
10. Nimmo, I. Abnormal situation management in the petrochemical industry Instr. Chem. Pet. Ind., Proc. 1996, 26, 77
11. Nimmo, I. Industry initiative addresses 'abnormal events' Hydrocarbon Process. 1998, 77 (10) 71
12. Nimmo, I. Adequately Address Abnormal Situation Operations Chem. Eng. Progress 1995, 91 (9) 36
13. Andow, P. Abnormal situation management: A major US programme to improve management of abnormal situations IEE Colloquium (Digest) 1997, 136, 3/1
14. EEMUA. Alarm systems-a guide to design, management and procurement; EEMUA (Engineering Equipment and Materials Users' Association) publication: London, 2007.
15. Smith, H.; Howard, C.; Foord, T. Alarms management-Priority, floods, tears or gain- Introduction to the "problem Measure. Control. 2003, 36 (4) 109
16. Goble, G.; Stauffer, T. R. Don't be Alarmed: Avoid unplanned downtime from alarm overload, use top techniques to improve alarm management. InTech Magazine 2007, January; http://www.isa.org/InTechTemplate.cfm-Section=article- index1&template=/ContentManagement/ContentDisplay.cfm&ContentID=58395.
17. ARC White Paper, Emerson Strategies for Abnormal Situation Avoidance & Alarm Management. http://www2.emersonprocess.com/siteadmincenter/ PM%20DeltaV%20Documents/Whitepapers/WP-ARC-Alarm-Mgt.pdf.
18. Katzel, J. Managing alarms Control Eng. 2007, 54 (2) 50
19. Errington, J.; DeMaere, T.; Reising, D. V. After the alarm rationalization-Managing the DCS alarm system AIChE Spring National Meeting, Conf. Proc. 2004, 1234
20. Brown, N. Effective alarm management Hydrocarbon Process. 2004, 83 (1) 65
21. Brown, N. Alarm management-The EEMUA guidelines in practice Measure. Control 2003, 36 (4) 114
22. Nimmo, I. Alarm overload Chem. Process. 2005, 68 (1) 28
23. Wilkinson, J.; Lucas, D. Better alarm handling-a practical application of human factors Measure. Control 2002, 35 (2) 52
24. Wilson, M. Alarm management and its importance in ensuring safety IEE Colloquium (Digest) 1998, 279, 6/1
25. Bransby, M. L.; Jenkinson, J. Alarm management in the chemical and power industries-a survey for the HSE IEE Colloquium Stemming Alarm Flood (Digest) 1997, 136, 1/1
26. Marvan, M. Alarming blunders: What not to do in alarm management. ISA EXPO 2005 Technical Conference, Chicago, IL, October 25-27, 2005; Vol. 459, p 884.
27. Srinivasan, R.; Liu, J.; Lim, K. W.; Tan, K. C.; Ho, W. K. Intelligent alarm management in a petroleum refinery Hydrocarbon Process. 2004, 83 (11) 47
28. Gaertner, D. Bringing nuisance alarms under control Control Eng. 2007, 54 (3) IP10
29. Kettschau, H.-J.;; Brück, S.;; Schefczik, P. LUCAS-An expert system for intelligent fault management and alarm correlation. IEEE Symposium Record on Network Operations and Management Symposium, Florence, Italy, April 15-19, 2002; p 903.
30. Bransby, M.; Jenkinson, J. The management of alarm systems (Contract Research Report); HSE (Health and Safety Executive) Books: Sudbury, U.K., 1998.
31. Easter, J. R.; Haentjens, J. Advanced alarm management system. Advanced Control and Instrumentation Systems in Nuclear Power Plants. Design, Verification and Validation. IAEA/IWG/ATWR & NPPCI Technical Committee Meeting (VTT-SYMP-147), Espoo, Finland, June 20-23, 1994; p 199.
32. Mattiasson, C. T. Alarm system from the operator's perspective. Proceedings of the 1999 International Conference on Human Interfaces in Control Rooms, Cockpits and Command Centres, Bath, U.K., June 21-23, 1999; Vol. 463, p 217.
33. Swain, A. D.; Guttmann, H. E. Handbook of human reliability analysis with emphasis on nuclear power plant applications; US Nuclear Regulatory Commission: Washington, DC, 1983; NUREG/CR-1278.
34. Bustamante, E. A.; Bliss, J. P.; Anderson, B. L. Effects of varying the threshold of alarm systems and workload on human performance Ergonomics 2007, 50 (7) 1127
35. Cullen, L.; Anderson, M. Human factors integration for a new top tier COMAH site-Optimizing safety and meeting legislative requirements Process Safe. Environ. Protec. 2005, 83 (B2) 101
36. HSE. Reducing error and influencing behaviour (Health and Safety Guidance 48); HSE (Health and Safety Executive) Books: Sudbury, U.K., 1999.
37. Noyes, J.; Bransby, M., Ed. Proceedings of People in Control-Human factors in control room design; Bath, U.K., June 21-23, 1999; IEE Control Engineering Series: London, U.K., 2002; Vol. 60.
38. Brabazon, P.; Conlin, H. Assessing the safety of staffing arrangements for process operations in the chemical and allied industries (Contract Research Report); HSE (Health and Safety Executive) Books: Sudbury, U.K., 2001.
39. Nimmo, I. It's time to consider human factors in alarm management Chem. Eng. Prog. 2002, 98 (11) 30
40. Bullemer, P.; Nimmo, I. Tackle abnormal situation management with better training Chem. Eng. Prog. 1998, 94 (1) 43
41. Mayer, A. K.; Sanchez, J.; Fisk, A. D.; Rogers, W. A. Don't let me down: The role of operator expectations in human-automation interaction Proc. Human Factors Ergonomics Soc. 2006, 2345
42. Pariyani, A.; Seider, W. D.; Oktem, U. G.; Soroush, M. Dynamic Risk Analysis for Synergistic Enhancement of Process Safety and Product Quality using Large Databases: Part I-Theory and Modeling. to be submitted to AIChE J. 2010.
43. Pariyani, A.; Seider, W. D.; Oktem, U. G.; Soroush, M.; George, E. I.; Jensen, S. Dynamic Risk Analysis for Synergistic Enhancement of Process Safety and Product Quality using Large Databases: Part II-Bayesian Analysis and Results. to be submitted to AIChE J., 2010.
44. Brooks, R.; Thorpe, R.; Wilson, J. A new method for defining and managing process alarms and for correcting process operation when an alarm occurs J. Hazard. Mater. 2004, 115 (1) 169
45. Sepeda, A. L. Lessons learned from process incident databases and the process safety incident database (PSID) approach sponsored by the Center for Chemical Process Safety J. of Hazard. Mater. 2006, 130, 9
46. Grabowski, M.; Ayyalasomayajula, P.; Merrick, J.; Harrald, J. R.; Roberts, K. Leading indicators of safety in virtual organizations Safe. Sci. 2007, 45, 1013
47. Pariyani, A.; Oktem, U. G.; Seider, W. D. Perceived Root-Cause Survey of Operators at a Major Petroleum Refinery, in preparation.
48. Application of Safety Instrumented Systems (SIS) for the Process Industry, Instrumentation, Systems, and Automation Society, ANSI/ISA S84.01-1996; Instrumentation, Systems, and Automation Society: Research Triangle Park, NC, 1996.
49. Green, D. L.; Dowell, A. M. How to design, verify and validate emergency shutdown systems ISA Trans. 1995, 34 (3) 261
50. CCPS. Guidelines for Hazard Evaluation Procedures, 3rd ed.; Center for Chemical Process Safety/AIChE: New York, 2008.
51. Oktem, U. Near-Miss: A Tool for Integrated Safety, Health, Environmental and Security Management. 37th Annual AIChE Loss prevention Symposium, New Orleans, Louisiana, March 31-April 2, 2003.
52. Yuki, Y. Alarm system optimization for increasing operations productivity ISA Trans. 2002, 41 (3) 383
53. Ryan, T. P. Modern Engineering Statistics; John Wiley & Sons: New Jersey, 2007.
54. http://en.wikipedia.org/wiki/Fluid-catalytic-cracking (Accessed December 1, 2009).