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What are the best practices for monitoring and adjusting process safety operating limits in real time?

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Process safety operating limits (PSOLs) are the maximum and minimum values of process parameters that ensure safe and stable operation of a chemical plant or facility. PSOLs are part of the Process Safety Management (PSM) system, which aims to prevent and mitigate major incidents involving hazardous substances. In this article, we will discuss some best practices for monitoring and adjusting PSOLs in real time, based on industry standards and guidelines.

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1 Why monitor and adjust PSOLs?

Monitoring and adjusting PSOLs is essential for maintaining process safety and reliability, as well as optimizing performance and efficiency. By keeping the process variables within the PSOLs, you can avoid deviations that could lead to loss of control, equipment damage, product quality issues, environmental impacts, or even catastrophic accidents. Monitoring and adjusting PSOLs also helps you identify and correct any abnormal situations, such as leaks, blockages, fouling, corrosion, or instrument failures, before they escalate into serious problems.

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Renee Cowell, CSP, CIH

HSE risk assessment leader| Environmental compliance | HSE audit and training junky| Change management pioneer| Injury prevention specialist| Continuous improvement
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When I was at Hess, these were reviewed weekly at a minimum and more often including adjustments if needed. This was indeed a best industry practice.

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2 How to monitor PSOLs?

To monitor PSOLs, you need to have a reliable and accurate process instrumentation system that can measure and record the relevant process variables, such as temperature, pressure, flow, level, pH, concentration, and composition. Additionally, you should have a process control system that can compare the measured values with the PSOLs and alert you of any deviations or alarms. To ensure a good process instrumentation and control system, you should include sensors and transmitters that can provide precise and consistent readings of the process variables. Also, controllers and actuators that can regulate the process variables by adjusting the valves, pumps, heaters, or other devices should be included. Furthermore, indicators and displays to show the current status and trends of the process variables and PSOLs are essential. Alarms and interlocks to warn of any violations or potential violations of the PSOLs as well as initiate corrective actions or shutdowns if necessary are also important. Lastly, data loggers and historians to store and analyze the process data and PSOLs over time are necessary for a successful system.

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Hugo Hernandez

Process Safety Manager
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In my experience, monthly metrics where you can see, where PSOL was activated, what was variable demanded (Level, Pressure, Temperature,etc.) and which was equipment involved. Are key to analyze so take actions to prevent recurrence

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3 How to adjust PSOLs?

To adjust PSOLs, you need to have a clear and documented procedure that defines the roles and responsibilities of personnel, the criteria and methods for changing PSOLs, and the records and reports to be kept. Reasons for adjusting PSOLs may include changes in process design, product specifications, raw materials, regulatory standards, or findings from process hazard analysis. When adjusting the PSOLs, review the current PSOLs and evaluate the impact of proposed changes on process safety, reliability, performance, and efficiency. Consult with relevant stakeholders, such as operators, engineers, managers, regulators, and customers; obtain necessary approvals; implement changes in instrumentation and control system; communicate changes to personnel; provide training if needed; monitor results of changes; verify objectives are met; document changes; and update process safety information and procedures.

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4 What are some best practices for monitoring and adjusting PSOLs?

A PSOL management system should be established and maintained to ensure the process safety of units, equipment, and components. PSOLs should be defined and documented based on process safety information, risk assessment, and operational experience. It is important to review and update the PSOLs regularly or whenever there is a significant change in the process or its environment. Accurate instruments and devices should be used to measure and control process variables and PSOLs. Operators and personnel should be trained to monitor and adjust the PSOLs effectively and safely. An alarm management system should also be implemented to prioritize and manage alarms related to the PSOLs. Periodic audits and inspections should be conducted to verify the compliance of the PSOL monitoring and adjustment system. Any incidents, near misses, or deviations involving the PSOLs should be studied for corrective and preventive actions.

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Devendra Rathore, PEng

Process Safety Enthusiast | Refinery Engineer | Passionate Pianist
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Process Safety Operating Limit (PSOL) or Integrated Operating Window (IOW) can be monitored using an online tool integrated with Plant DCS. Any excursion of defined process limit will generate alarm and trigger immediate notifications to plant management. KPIs such as Nos. of excursion, duration of excursion, or response time by Operator can be established for effective monitoring.

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5 What are some challenges and opportunities for monitoring and adjusting PSOLs?

Monitoring and adjusting PSOLs is not without its challenges and opportunities. Challenges can include dealing with complex, dynamic, and nonlinear processes, handling uncertainties in process variables, integrating and coordinating different systems, ensuring the reliability of process data, and balancing safety, quality, efficiency, and profitability. Opportunities include leveraging advanced technologies such as AI or machine learning to enhance monitoring and adjustment of PSOLs, adopting smart sensors or digital twins to improve accuracy and flexibility of PSOL measurement and control, developing adaptive or optimal control strategies to adjust PSOLs in real time, applying predictive or preventive maintenance techniques to detect and prevent degradation or failure of PSOL instruments or devices, and sharing best practices for monitoring and adjusting PSOLs across industries.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What are the best practices for monitoring and adjusting process safety operating limits in real time?

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1 Why monitor and adjust PSOLs?

2 How to monitor PSOLs?

3 How to adjust PSOLs?

4 What are some best practices for monitoring and adjusting PSOLs?

5 What are some challenges and opportunities for monitoring and adjusting PSOLs?

6 Here’s what else to consider

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