Remote isolation of fixed plant - AOG · REMSAFE will not allow personnel to apply a lock until the system has verified the isolation. RI = Whole Current Isolation . The information

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.

Remote isolation of fixed plant

Mark Spinks

Electrical Manager - FLSmidth


What is functional safety (FS)?

Part of the overall safety that depends on a system or equipment operating correctly in response to its inputs.

It’s a way of managing the reliability of safety-related electrical systems.

A key measure is ‘SIL’ (Safety Integrity Level)

Based on safety functions in their entirety - not just components

Internationally accepted standards for safety systems


Remote Isolation - a great application for FS


AS4024.3611 Appendix B

People will take short cuts and push the limits

RI systems make isolations quick and easy

At the same time, RI systems make isolations more reliable

Complexity to simplicity

Remote Isolation - why bother?


Unsafe Acts

Unintended Action

Slips

Attention failures

Lapses

Memory failures

Intended Action

Violations

Routine or exceptional deviations

Mistakes

Rule or knowledge-

based mistakes

Human Error


Image above: From Qld DNRM safety

alert# 163

Human Factors - SLIPS

Attention Failures – knowing what to do, but accidentally getting it wrong

Failing to identify a necessary isolation point, despite being competent.

Inadvertently turning an isolation point to on, rather than off.

Knowing where to isolate, but operating the wrong handle.


Memory Failures – knowing what to do, but forgetting in that instance

Forgetting to controlled-stop a process before isolating it

Opening, but forgetting to rack-out a CB isolation point

Forgetting to properly verify the isolation.

Human Factors - LAPSES


“But I thought…” kind of issues

Misunderstanding which isolation points should be isolated for a task.

Difficulty verifying an isolation on a process that was already stopped.

Isolating correctly, but working on the wrong (un-isolated) equipment

Human Factors - MISTAKES


Deliberate deviation from procedure.

May be routine (‘normalisation of deviance’), or exceptional.

Not isolating correctly or fully due to:

Time pressures (real or perceived).

Belief that the process will not start without all permissives ready.

The imbalance between perceived risk and the effort or time required to isolate.

Human Factors - VIOLATIONS


“Conventional isolations are better. Remote isolations are done through

control systems and therefore not as good”.

Common Misconceptions #1:


Unwanted Event

Ineffective isolation

Preventative Controls

Mitigating Controls

• Isolation device/point • Padlock

• Isolation procedure • Competent people • Signage

• Prestart alarm

• Procedures (eg no-go zones)

Bowtie: Conventional Isolation


Preventative Controls

Mitigating Controls

• Isolation device • Padlock

• Isolation procedure • Competent people • Signage

• Prestart alarm

• Procedures (eg no-go zones)

Unwanted Event

Ineffective isolation

• Constant status monitoring with action taken as required

Bowtie: Conventional Isolation


Common Misconceptions #2:

“Remote isolations are not WHOLE CURRENT isolations”.


Whole current isolations are performed, however these are initiated via a control system.

Arcflash advantages to remotely switching whole-current isolation points.

REMSAFE will not allow personnel to apply a lock

until the system has verified the isolation.

RI = Whole Current Isolation


Recommendations: Engage an expert supplier

Engage a FSEng to assist (eg TUV certified)

In any case, please don’t forget the ongoing maintenance/proof-testing (discussed next).

Also, consider in advance how to safely bypass the system, should it fail.

Image courtesy of Marcus Punch

Design


Testing


Eliminates arc flash exposure

Fail-to-safe system design

Fosters a positive safety culture

Eliminates human error:

Isolations completed without errors

One isolation point, near the equipment to be worked on. As simple as possible.

Effective verification

Simplifies the process

Safety


Imagine being able to perform a fully effective isolation, in a few minutes.

Intrinsic benefits for;

Regular (common), or complex isolations (which take time to complete).

Significant revenue increase, particularly for bottleneck processes.

More ‘spanner time’ for skilled personnel and the ability to take advantage of small maintenance opportunities.

Productivity & ROI


Mark Spinks

Electrical Manager

FLSmidth

Mob. 0417 312 249

E. [email protected]

Mark Gemmell

Key Account Manager

Remsafe

Mob. 0455 222 695

E. [email protected]

Contacts

Documents

Remote isolation of fixed plant - AOG · REMSAFE will not allow personnel to apply a lock until the system has verified the isolation. RI = Whole Current Isolation . The information