Questions from plant manag­ers (continued)

Process Optimization
Typography

Michel Ruel answered a number of questions frequently asked by plant managers. Other questions were addressed in the previous article.

 Question 10
Who should be involved in an alarm rationalization project?
Simple answer: Operations, maintenance, engineering and management
Detailed answer: Ideally, operations should lead the project. M­anagement support is key. An alarm rationalization committee should be created and meet once a week for several months to review the alarm history with software tools and the support of an external facilitator.

Question 11
What is the investment for alarm rationalization?

Simple answer: From $50,000 to $250,000
Detailed answer: First, performance is measured using software tools. Next, an "alarm philosophy" is prepared. Finally, alarms are rationalized by a committee with members from various departments.
Rough investment:

- Software, servers: ~$30,000
- External support: $20,000 to $60,000
- 500 to 2,500 hours from plant personnel

Question 12
Who should be involved in a control performance monitoring project?

Simple answer: Maintenance, operations, engineering and management
Detailed answer: Ideally, maintenance or operations should lead the project. Management support is key. Performance is evaluated with software, then roles and responsibilities are defined and targets selected.

Question 13
How should a control performance monitoring program be rolled out?

Simple answer: Planning, roles and responsibilities, targets and schedules
Detailed answer: Plan for four phases:

  • Achieve percentage of use target
  • Achieve stability target
  • Achieve performance target
  • Sustain the results

Each of the first three phases should last several weeks. Implementing continuous monitoring will require changes in plant practices.

Question 14
What is the investment for control performance monitoring?

Simple answer: From $85,000 to $250,000
Detailed answer: Rough investment:

- Software, servers: ~$80,000
- External support: $20,000 to $80,000
- 500 to 2,500 hours for plant personnel


Michel Ruel
BBA - Top Control
BBA is an independent Canadian consulting engineering firm operating internationally. Its team is composed of highly-qualified experts in several engineering disciplines including electrical, civil, mechanical, industrial data processing, mining, metallurgical processes, automation, and construction management.

 

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