Abstract
Operator error accounts for 42% of unscheduled plant shutdowns (O’Brien, 2010). This is expected to get worse with retirement of the aging but experienced workforce, and with constant pressure to reduce operating costs by expanding operator scope of responsibility. In order to reduce human error, improve operational efficiency, and ensure consistent execution of critical tasks, operators will need to transform from “valve turners” to “process managers”.
Industrial Procedure Automation refers to embedding operating procedures in digital operations platforms (like the DCS or PLC) to guide operators through the execution of sequential tasks or procedures. Procedures for continuous process operations include situations of startup, shutdown, abnormal situations, hold steps, and transitions of process feed/output. These procedures might exist in manual form, are often outdate, and can range from equipment control to enterprise level control. The ISA-106 standard on procedure automation for continuous process operations defines models, styles, strategies, philosophies, and the lifecycle for automation of procedures in the continuous process industries.
This presention will explore the field of procedure automation in the mining and mineral processing industry. The presentation will focus on best practices and practical tips related to the deployment of procedure automation ranging from selection criteria for cases to deployment and sustainability strategies. Guiding principles from ISA-106 will be reviewed, and real use cases will be presented.