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Across the process industries many plants are still using paper-based procedures, or the digital equivalent, to guide employees through critical transitions, such as process startups, shutdowns, and product grade changes. Often, the procedures have not been kept up to date, or even if they have, operators can miss or forget steps that could result in an incident. It’s widely assumed that automation will eliminate the need for some of these operator-oriented procedures in favor of fully automated processes. In reality, statistics show that there are still opportunities for human error to cause incidents, production failures, and even major accidents.
A session at ARC’s recent Industry Forum in Orlando, Florida discussed the need to consider an option to blend automated procedures with manual operator procedures. Technology, standards, and know-how are now available to bridge the gap between fully automated and fully manual procedures. By partially automating highly complex procedures, plants can ensure that procedures that might be too complex for either the control system or the operator to perform independently will be performed safely, efficiently, and in the correct sequence.
The session featured examples of how to utilize standards such as ISA106 and ISA88 as well as project approaches that offer the potential to reduce operator error while keeping the plant operators fully engaged in running the operations.
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Keywords: ISA 106, Manual Procedures, Automated Procedures, Human Error, ARC Advisory Group.