“Give the OPERATOR the BEST tools and knowledge” · “Give the OPERATOR the BEST tools and...
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1 Introduction Huntsman “Give the OPERATOR the BEST tools and knowledge”
Transcript of “Give the OPERATOR the BEST tools and knowledge” · “Give the OPERATOR the BEST tools and...
“Give the OPERATOR the BEST tools and knowledge”
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Introduction Huntsman
“Give the OPERATOR the BEST tools and knowledge”
“Give the OPERATOR the BEST tools and knowledge”
POM
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OPERATOR
TRAINING
HMI
ALARM MANAGEMENT
CONTROL
STRATEGY
“Give the OPERATOR the BEST tools and knowledge”
Topics
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• Introduction
• Challenges Huntsman and project
• Vision / URS control strategy
• Project organisation
• Factors for success
• First results
“Give the OPERATOR the BEST tools and knowledge”
Introduction
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Introduction
Challenges
Vision / URS
Organisation
Factors for success
First results
Jasper Rutten Sr. Process Engineer
Project rol: Sr. Process Engineer & Commissioning manager
Tom Verbruggen Project manager TA
Project rol: Lead Engineer Process Control
“Give the OPERATOR the BEST tools and knowledge”
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Markets include:
Adhesives, Coatings
and Elastomers
Appliances
Automotive
Insulation
Composite Wood Products
Footwear
Furniture & Bedding
TPU
“Give the OPERATOR the BEST tools and knowledge”
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“Give the OPERATOR the BEST tools and knowledge”
4500 I/O: 3500 real I/O 1000 serial I/O in 7 serial links
375 graphics
DeltaV HMI
DeltaV DCS Chrystalisers 3&4, AWZI
PROVOX DCS
PROVOX HMI
HIMA SIS
MIMIC
FIELD EQUIPMENT
VOPAK YORK compres
sor
Fire & Gas
Truck loading
HCL compres
sor
RTO QC Analy-
sers
Fire water pumps
AWZI
Start engineering – Jan. 2014
MIMIC DeltaV HMI
DeltaV DCS
HIMA SIS
VOPAK YORK compres
sor
HCL compres
sor
Turn Around – April 2015
DeltaV HMI
DeltaV SIS
Turn Around – 2017
10 DCS controllers
45 SIS Logic Solver
4 I/O-shelters
300 multicores + system cabling
“Give the OPERATOR the BEST tools and knowledge”
Challenges Huntsman
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Introduction
Challenges
Vision / URS
Organisation
Factors for success
First results
Qualified operators
• Aging experienced operators
• Increased mobility operators
• Certification (CCR-) Operators
Process Control System
• Current system is limiting the production goals
• Aged control strategy
• EndOfLive current DCS- and SIS-system
“Give the OPERATOR the BEST tools and knowledge”
Project Challenges
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Introduction
Challenges
Vision / URS
Organisation
Factors for success
First results
• Parallel projects Major plant revamp
Development Operator Training System (dynamic model)
• Fast track project Start engineering Jan. 2014
Turn Around Apr. 2015
• TurnAround DCS-migration
Plant modifications
Regular maintenance works
Specific plant units will stay operational
“Give the OPERATOR the BEST tools and knowledge”
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Introduction
Challenges
Vision / URS
Organisation
Factors for success
First results
Operator knowledge
System and control strategy
Safety
Future
“Give the OPERATOR the BEST tools and knowledge”
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User Requirement Specifications
Control strategy Support operations • 2 CCR-operators in Q2-2015; 1,5 in Q2-2016 for normal operation
• Basic control functional copy of current DCS and SIS.
• Redesign of the automated sequences.
HMI Human Centric Design • HMI Designed according ISA 101.4
• Use of latest supplier standard library comply to ASM / HCD-guidelines
“Give the OPERATOR the BEST tools and knowledge”
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User Requirement Specifications
Alarm/trip-management Alarmreduction, -suppression, LOPA’s
• Meet EEMUA-standard
• Re-evaluate SIL - Safety provisions.
• Re-evaluate production related tripfunctionality
Operator Training System incl. dynamic plantmodel OTS
• Train operators for TA2015
• Support DCS-FAT
Phase 2:
• Advanced training and certification with high fidelity plantmodel
• Testing future modifications
“Give the OPERATOR the BEST tools and knowledge”
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Client / End user
EPC
Delivery and configuration DCS / SIS-system
Design HCD HMI
Design control strategy
Dynamic model and Training
Alarm evaluation
“Give the OPERATOR the BEST tools and knowledge”
Factors for success (1/2)
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Introduction
Challenges
Vision / URS
Project Organisation
Factors for success
First results
• Clear vision and user requirements
• Priority awareness At ALL participants and organisation levels
• Make choices - decisively Quick decision process
Stick to the plan
Management of expectation (documented and communicated)
“Give the OPERATOR the BEST tools and knowledge”
Factors for success (2/2)
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Introduction
Challenges
Vision / URS
Project Organisation
Factors for success
First results
• Resource management Assure competence and knowledge
Organisation – clear accountabilities
Team motivation – eye for the invidual
Best personel for the job
• Integrated team Focus on solutions
Always looking for most effective way of working
Using expertise of all members
Pro-actively call in expertise when needed
“Give the OPERATOR the BEST tools and knowledge”
First results
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Introduction
Challenges
Vision / URS
Project Organisation
Factors for success
First results
• URS phase 1 implemented
• Intuitive HMI design
• Control Strategy fit for purpose
• Complex dynamic plant trainingsystem accurately built in short time
• Operator training in progress
• Fast track schedule on track
“Give the OPERATOR the BEST tools and knowledge”
POM
fit for
TASKS
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OPERATOR
CENTRIC
TRAINING
and
CERTIFICATION
HMI
fit for
TASKS
ALARM MANAGEMENT
Supply the right
information
at the right time
CONTROL
STRATEGY
Operator
always
IN CONTROL
