Simplifying Your MOC Process Through Automated Workflows
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1 PAS Technology Conference 20 Years of Connecting the Dots People, Assets, Information Automation Asset Management Track Simplifying Your MOC Process Through Automated Workflows Presented by: Brian Nixon Senior Consultant, PAS May 19-21, 2014 Hilton Americas Houston, Texas, USA 1
2 Brian Nixon Brian Nixon is a Senior Consultant at PAS. He has experience in the processing industries, including agricultural processing, specialty chemicals and plastics compounding. He joined PAS in 2008 where his roles have included Alarm Management consultant, Control Loop Performance consultant, and Software Development. He received a Bachelor of Science in Chemical Engineering with a minor in Computer Science from Rose-Hulman Institute of Technology. 2
3 About PAS Founded in 1993» Provider of Human Reliability Software for safe production» Serving Power, Oil & Gas, and Processing industries globally» Global Locations (Europe, Middle East, Asia, Australia) Technology» Integrity Automation Asset Management Software» PlantState Suite Operations Decision Support System Business Strategy» Innovative technologies inspired by domain expertise» Strategic customer relationships» Mission critical software solutions» 20% annual R&D Reinvestment Thought Leadership & Strategic Partnerships» Alarm Management and HP HMI Handbooks» AICHE, NPRA, EPRI, ISA, EMMUA 191, OSHA 3
4 Background, why MOC? Integral part of plant safety and reliability Regulatory mandates Assess risks Review of change histories Documentation of Knowledge Knowledge Sharing 4
5 Background, The MOC Process Wait Wait Wait Wait Wait Wait 5
6 Challenges of Automation System MOC Multiple sources/systems for Automation system change records» Larger project MOC» Work Order» Notes/comments within the configuration» Handwritten/Electronic change journals Wedged into existing MOC processes» Forms/processes built for Physical Assets» Reliance on attachments» Reviews/Approvals not always appropriate» Poor scope documentation Risk assessment a moving target As Built documentation? 6
7 Automation MOC Survey Results Frequency of Change 28% 38% Daily Weekly Monthly 35% Is MOC Required? 0% Never 47% Always 53% Sometime 58% 35% Age of System 13% 30% Incidents Due to Change 65% 0-5 Yrs 5-10 Yrs > 10 Yrs Yes No Conclusion: Something must be faulty with current MOC practices if so many incidents can be attributed to making changes 7
8 The Need for Automation MOC Automation systems are the platform for continuous improvement Daily/weekly changes to automation systems is a norm Lack of proper MOC is as contributor to industrial accidents Risks and vulnerabilities» Unauthorized changes» Undocumented changes» Configuration errors» Patches and software updates» Malicious attacks & new viruses Many automation changes are not-in-kind MOC is essential to control system security! Sometimes What you Don t know Can hurt you! 8
9 Introducing Workflow Integrity Customizable workflow engine Built within the Integrity application framework» Same application that detects the changes also manages the changes» Automation system change management within a system designed to provide automation system documentation Reconciliation of changes» Provides complete change history with documentation of the change Integration with PSS» Work process for master alarm database changes Integration Active Directory Integration Extends/Enhances existing processes 9
10 Sample workflows built with Workflow Integrity SDL/SOL reporting Alarm Change requests Automation System change requests Shift Changeover documentation Point to Point verification 10
11 Integrated Systems Provide Value Automation System Documentation Automation System Change Detection Alarm System Change Management Master Alarm Database Automation System Change Management 11
12 Workflow Integrity A Complete Automation System MOC Solution 12
13 PAS Technology Conference 20 Years of Connecting the Dots People, Assets, Information Breakout Session Simplifying Your MOC Process Through Automated Workflows May 19-21, 2014 Hilton Americas Houston, Texas, USA 13
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