7/27/2019 ESP Handbook Rev1 with cover.doc
1/18
Page 1 of 18
Page 1 of 18
Ensure Safe Production integrates limits
7/27/2019 ESP Handbook Rev1 with cover.doc
2/18
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 !
Page 2 of 18
ESP Vision
7/27/2019 ESP Handbook Rev1 with cover.doc
3/18
ESP has 4 sub-processes:
1. Initial Setup
2. Validate Targets
3. Monitor & Control Conditions
4. Learn & Improve
Page 3 of 18
ESP Sub-Processes
7/27/2019 ESP Handbook Rev1 with cover.doc
4/18Page 4 of 18
ESP Process Overview
7/27/2019 ESP Handbook Rev1 with cover.doc
5/18
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.
Page 5 of 18
Initial Setup?
7/27/2019 ESP Handbook Rev1 with cover.doc
6/18Page 6 of 18
7/27/2019 ESP Handbook Rev1 with cover.doc
7/18Page 7 of 18
Validate Targets tARGETSTargets
Ensure Safe Production integrates limits
Initial Setup?
7/27/2019 ESP Handbook Rev1 with cover.doc
8/18Page 8 of 18
Critical Limit, Standard & Target LimitsMonitor & Control Conditions (MCC)Critical Limit, Standard & Target Limits
7/27/2019 ESP Handbook Rev1 with cover.doc
9/18Page 9 of 18
Critical Limit, Standard & Target Limits
7/27/2019 ESP Handbook Rev1 with cover.doc
10/18
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.
Page 10 of 18
Monitor & Control Conditions (MCC)
7/27/2019 ESP Handbook Rev1 with cover.doc
11/18
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).
Page 11 of 18
Variable Table
7/27/2019 ESP Handbook Rev1 with cover.doc
12/18Page 12 of 18
ACM Web
7/27/2019 ESP Handbook Rev1 with cover.doc
13/18Page 13 of 18
Metric Review Process Flow
7/27/2019 ESP Handbook Rev1 with cover.doc
14/18
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
Page 14 of 18
Time in Exceedance (Hours)
7/27/2019 ESP Handbook Rev1 with cover.doc
15/18
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
Page 15 of 18
Alarm
7/27/2019 ESP Handbook Rev1 with cover.doc
16/18
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.
Page 16 of 18
Managing Abnormal Situation
Abnormal Situation Management
7/27/2019 ESP Handbook Rev1 with cover.doc
17/18
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.
Page 17 of 18
Stabilize, Slow Down, Shut Down
7/27/2019 ESP Handbook Rev1 with cover.doc
18/18
We know our limits
and we operate within those limits
all the time !