As a plant operations manager, you are responsible for ensuring the safety of your workers, equipment, and environment. Safety is not only a moral and legal obligation, but also a key factor for productivity, quality, and profitability. How can you leverage the latest tools and technologies to improve safety in your plant? Here are some tips and examples.
Digital sensors are devices that can measure and monitor various parameters, such as temperature, pressure, flow, level, vibration, and more. By installing digital sensors on your equipment and processes, you can collect real-time data and detect any abnormal or hazardous conditions. For example, you can use digital sensors to prevent overheating, overpressure, leaks, or corrosion. Digital sensors can also alert you to the need for maintenance or repairs, reducing the risk of breakdowns or accidents.
Use PPCL's GPC method to quickly give your plant a set of consistent alarm limits with far fewer false alarms and many alarms that today have limits set so wide they almost can't annunciate. The alarm limits should all be at the vertices of a multi-dimensional Operating Window. This is easy to do when you can see what you are doing! CVE is the self-service analytics product that shows you Operating Windows and Envelopes for 1000 or more variables in a single view. No maths needed - its done with geometry! Better alarms will give you better operations, improve rocess safety and happier process operators. Use it for Continuous and batch processes including multi-mode.
I agree digital sensors are usefull set of accident prevention and damage to equipment, for example installation of anti-collision systems will prevent losses associated with machine and equipment accidents.
These sensors provide real-time data on critical parameters like temperature, pressure, and flow, enabling prompt identification of potential hazards. This proactive approach not only prevents issues such as overheating or leaks but also minimizes the risk of breakdowns and accidents by signaling the need for timely maintenance and repairs.
Improve plant safety with the latest tools: 1.IoT Sensors: Monitor equipment in real-time for proactive maintenance. 2.Predictive Analytics: Forecast and prevent equipment failures. 3.Augmented Reality (AR): Enhance training and situational awareness. 4.Drones: Conduct remote inspections to reduce personnel risk. 5.Robotics: Automate high-risk tasks to minimize accidents. 6.Digital Twins: Simulate and analyze operations for safety optimization. 7.Wearable Technology: Monitor worker health in real-time for quick response. 8.Machine Learning Algorithms: Analyze historical safety data to identify trends. 9.Collaborative Platforms: Facilitate real-time communication during emergencies. 10.Virtual Reality (VR):Use immersive training for trained
There are so many physical and chemical aspect that not possible to be detected safely by human senses. High temperature, pressure, toxic gas, etc. Digital sensor playing critical role to identify those kind of hazard so that workers can prepare appropriate mitigation or safety precaution. Digital sensor also provide real time information which is important to take timely action and prevent reduce risk.
Smart automation is the use of software and hardware to control and optimize your plant operations. Smart automation can help you improve safety by reducing human error, enhancing efficiency, and enabling remote access. For example, you can use smart automation to program and coordinate your machines, robots, and conveyors, avoiding collisions or jams. You can also use smart automation to monitor and adjust your settings, parameters, and outputs, ensuring quality and compliance. Moreover, you can use smart automation to operate your plant from a safe distance, minimizing exposure to hazards or contaminants.
By leveraging both software and hardware, smart automation minimizes human error, boosts efficiency, and allows for remote access. This technology enables precise programming and coordination of machines, robots, and conveyors, mitigating the risk of collisions and jams. Additionally, the ability to monitor and adjust settings remotely ensures adherence to quality standards, while operating the plant from a safe distance reduces exposure to potential hazards or contaminants.
Across all industries, AI and automation systems have shown?significant growth. Pros, Increased productivity and efficiency Increased flexibility and versatility Improve safety by reducing human error, enhancing efficiency, and enabling remote access Cons, The high initial investment Inflexibility once the system is in place Risk of downtime Need for skilled operators
Using smart automation can really help to improve safety of overall plant operation. To identify the hazard in the process plant through smart automation and make suitable control measures will work and leas to smart workplace.
An example of "Smart Automation" that mitigates the probability of "Operator Error" are Automated procedures such as Exapilot. Utilizing Standard Operating Procedures, the tool performs the steps with the Panel Operator (and field) oversee the actions. It must be noted that the quality, efficiency and inherent safe nature of the procedure remains with the Operations Team that created and implemented the procedure that is imputed into the tool.
It's proven that smart automation is very helpfull in improving safety by reducing human error, enhancing efficiency, maintain consistency, prevent bias from different level of worker's understanding, operate in safer distance, and minimize exposure to the hazard.
Wearable devices are gadgets that can be worn or attached to your workers' bodies, such as smart glasses, helmets, gloves, vests, or badges. Wearable devices can help you improve safety by providing information, communication, and protection. For example, you can use wearable devices to display instructions, warnings, or feedback to your workers, improving their awareness and performance. You can also use wearable devices to communicate with your workers, sending messages, alerts, or signals, enhancing their coordination and collaboration. Furthermore, you can use wearable devices to protect your workers, tracking their location, health, or exposure, preventing injuries or illnesses.
In the context of Smart Industries embracing connectivity and technological advancement, the adoption of wearables is recommended. However, Indian industries encounter challenges with technological implementation and the need for upgrades, despite the potential high ROI. Moreover, wearables can be costly to procure for large-scale industrial use. Therefore, in my view, the use of wearables for safety in Indian plants should be reconsidered due to potential hazards related to battery, electromagnetic interference with production machinery, and cost.
Virtual reality is a technology that can create and simulate realistic and immersive environments. By using virtual reality, you can train your workers in a safe and effective way. For example, you can use virtual reality to teach your workers how to operate, maintain, or troubleshoot your equipment and processes, without risking damage or injury. You can also use virtual reality to expose your workers to different scenarios, conditions, or emergencies, preparing them for any situation. Additionally, you can use virtual reality to evaluate your workers' skills, knowledge, or behavior, providing feedback and improvement.
I'm a huge advocate for VR/AR training platforms, especially as it affords "Hands On" practice/experience in a safe environment. The structure and quality of the program must be monitored to ensure optimum output while providing assurance of a competent technician/team. Another lesser mentioned benefit is that these platforms can permit training/assessment scenarios done as a team rather than just individually.
Using advance technology like 1)machine learning,2)Deta entry, 3) Artificial intelligence, people's enough time to learn like me can TTT
Virtual reality is great for learning muscle memory which is great for the task but its mind memory that recognises the dangers. Keeping it real is the next level.
Data analytics is the process of collecting, analyzing, and interpreting data to gain insights and make decisions. By using data analytics, you can learn from your plant operations and improve safety. For example, you can use data analytics to identify and eliminate the root causes of accidents, incidents, or near misses, improving your safety culture and performance. You can also use data analytics to optimize your processes, resources, and schedules, reducing waste, stress, or fatigue. Moreover, you can use data analytics to predict and prevent potential risks, hazards, or failures, enhancing your safety preparedness and resilience.
The identification of the problem in a safety incident is crucial for understanding its causes. Accessible data is key to reducing safety incidents. For example, sparking in an electrical panel could be caused by overcurrent, leakage, or environmental factors. Open source data on a common platform can reduce incidents. Utilizing tools like Heinrich's triangle or the Bird's triangle, along with AI, can aid in preventing and eliminating safety incidents.
Der Begriff Security Information and Event Management (SIEM) spielt hier eine wesentliche Rolle. SIEM-Systeme implementieren, um Sicherheitsereignisse in Echtzeit zu überwachen, zu analysieren und darauf zu reagieren.
Data analysis is the best opportunity for continuous improvement. Some risk might not be seen explicitly. By doing data analysis, it's very possible to identify hidden risk and help to find the root cause when incident or abnormal condition happen. It's proven that data analysis very helpful for process safety and occupational safety.
In general, the optimal use of digital tools should provide your Operations Team with all the necessary information and even practical scenarios (in the case of VR platforms) to adequately prepare for identified "High Risk" activities and visiting incidents captured in "Lessons Learnt" repository.
Considering the complexity of plant and more sophisticated engine has been used in may plants recently, utilize and optimizing technology to manage safety aspect is required. Technology can be used to enhance safeguards, controlling hazard effectively, minimize human exposure to the hazard, identify hidden hazard and potential risk, analyze plant behavior, maintain consistency, minimize error, and identify room for improvement.
Human interface To achieve safety, organizations may use digital tools, advanced systems, and solutions to protect people and property. However, a crucial element is that in order to operationalize or make it happen at various levels, a human interface is required; if this interface is ineffective, all processes and systems may fail, resulting in incidents. For successful plant operations, our attention and effort should be spent on people to keep them fit and continuously drive them towards a positive culture through visible safety leadership. This way, we can prevent system failures because every system has gaps and weak places
There are number of huge benefits utilizing technology in the area of HES both offshore and onshore activities. In the area of facility or equipment inspection or even hazardous with significant degree of hard to reach in term of location, application of drone gives a big hope for safe inspection. In the area of hazard detection, sensing technology provides capability to quickly identify potential risks in workplace, i.e. gas leak, pressure anomaly and temperature fluctuation. Technology also enables oil and gas industry to optimize detection, monitoring and control of operating parameters by the use of human machine interface, thus improving hse performance
To me, enhance plant safety by embracing state-of-the-art tools. Utilize real-time monitoring with sensors and IoT for hazard detection, integrate wearables to track worker health, and employ data analytics to proactively address safety concerns. Implement augmented reality (AR) for advanced training, drones for aerial inspections, and smart maintenance tools for predictive upkeep. Continuously update safety protocols based on technological advancements to maintain a proactive and secure plant environment, ensuring the latest industry best practices are incorporated for optimal safety measures.