Real Time Data Analytics for Process Safety Governance-Case Study
Authors: Mahmood M Rashdan , Panwar Madan Kumar 
Published: November 2019

To assess and improve process plants safety and integrity in real time and intervene in timely manner. Assets are safe and we can prove it by employing Real Time Data Analytics to reduce operational process safety risk and improve plant safety and integrity assurance. Real time IPF/Bypass management and validation guarantee the overall effective safety system for safe Operational Excellence.

Petronas Upstream employed Data Analytical tool to facilitate analysis of Instrumented Protective Functions performance, Bypass Management, documentation of proof testing, and management of required test schedules for Process Safety. Automated reporting of analytical tool provides testing requirements for current and future protective functions throughout the facility. All Bypasses of Instrumented Safety System (IPF) are monitored in Real Time and Descriptive Analytics has been developed to provide insights to safe operation of the facility. The software analytical tool implemented enable validation testing when the system is activated. In the event of a failure or fault of the safety system, plant personnel are notified and all information updated in centralized Web Based Dashboard for high level of data transparency across all stake holders. Descriptive analytical system helps to identify potential equipment malfunction/failures in advance. Automatic Alert & Notification of anomalies are sent to identified stakeholders. There is no room for error, yet there are many ways to bypass IPF from Safety Instrumented System(SIS) so Real Time Bypass Management is a key success factor for Process Safety Assurance & Asset Integrity.

Real Time Web Based Dashboard designed to customize to user specific actionable analytics to Visualize Current Risk and Current availability of Instrumented Protective functions to identify risk. Performance Reporting strengthen the Analysis and reporting of IPF performance against design criteria. Real Time Analytics resulted from IPF Design Data for Design time, process safety time, testing interval, risk, consequence, severity, SIL level and more. Real Time Analytics are available on-demand through a single web based and mobile-enabled user interface (withing domain). Real Time Analytics for multiple user level provides indispensable capabilities to guarantee effective management of IPF Performance, Bypass Management, Demand on safety System rate tracking, Excusions Management, Safety and Operational Risk Visualization. The Data Analytics is aligned to management aspiration of Going Digital for sustainable future and to cultivate effective collaboration.

Additional Information

Standards, such as API RP 754, IEC 61508 and 61511, ISA 18.2; govern the monitoring and maintenance of Asset's Instrumented Protective Functions including tracking and documenting availability, demand rate and failures and proof testing. Employing Real Time Analytical tool will help PETRONAS to achieve proven in use high quality equipment Reliability data for value creation. Analytical information enables assurance of process safety governance to achieve objective of -