Ask Ron Besuijen

Ron's Response:

Freeze up is an unfortunate response to becoming overwhelmed. Reading through a procedure is a different experience than a major event or plant shutdown when the alarm page is flooded, and emergency alarms are blaring. There can also be radio calls, phone calls, communication with other panel operators or outside operators.

Running through the emergency procedures is the next knowledge progression after startup training. These are events like power failures, instrument air failures, or large compressor trips. Anything that has a large impact on the process and the results are quite predictable.

There can be a hesitancy to shut down the process or make large process changes to manage a major upset. For events like these it is helpful to review what the key indicators are that a certain set of actions (emergency procedure) are required. For example, large condensing steam turbines will have to be tripped if the cooling water pumps fail. Review which process variables need be checked to make that decision and what graphic they are on.

Understanding the reasons for each step and chunking up key steps can be helpful. There are likely similar steps in several of the procedures. Thought should be given to what should be memorized and which steps in a procedure can be used as a reference. Generally, the first five to ten minutes in a major process upset require immediate response and should be memorized. This will depend on your process.

The proper execution of emergency procedures is critical and should not be left to chance.

A simulator is a very powerful tool and can be used for a variety of purposes. Improving Emergency Procedures is just one of them. A simulator training program consists of preparatory work and hands-on experience, where board operators practice key routines such as startup, emergency procedures, and handling malfunctions or failures. These will be covered in future ProseraPods.