Mary Kay O'Connor Process Safety Center

Texas A&M Engineering Experiment Station

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Abnormal Situation Management

List of Center Publications

About

An abnormal situation is a disturbance or series of disturbances in a process that causes plant operations to deviate from their normal operating state. The disturbances may be minimal or catastrophic, and cause production losses or, in serious cases, endanger human life. A disturbance of an industrial process system that an automated control system cannot cope with requires human intervention.

The purpose of this research is to establish and maintain safety of processes through automation and analysis methodologies. Because modern chemical plants are large and complex, early and accurate fault detection and diagnosis is imperative. Effective application of these methods can reduce product rejection rates, limit downtime, and help to attain stringent safety requirements. The central goal of abnormal situation management is to document all possible normal modes of a plant operation and detect deviations from normal behavior. Fault detection and diagnosis have gained a central importance in the chemical process industries over the past decade. This presents a need for fault diagnosis systems which use limited information of the process dynamics and accurately detect, isolate, and identify faults.

What is Abnormal Situation Management and Why is it Important?

An abnormal situation is a disturbance or series of disturbances in a process that causes plant operations to deviate from their normal operating state. The disturbances may be minimal or catastrophic, and cause production losses or, in serious cases, endanger human life. A disturbance of an industrial process system that an automated control system cannot cope with requires human intervention.

Fault Detection and Diagnosis

Fault diagnosis is destined to hold central importance in maintaining a chemical industry after installation of Advanced Process Control system (APCS). MKOPSC has conducted research with a purpose to establish and maintain safety of processes through automation and analysis methodologies. Because modern chemical plants are large and complex, early and accurate fault detection and diagnosis is imperative. Fault detection and diagnosis have gained a central importance in the chemical process industries over the past decade. This presents a need for fault diagnosis systems which use limited information of the process dynamics and accurately detect, isolate, and identify faults.

Optimal Alarm Identification and Management

Another aspect of dealing with abnormal situation is alarm management. It is essential to maximize the time available for operators to respond to faults while keeping the number of alarms triggered at a minimum. Research at MKOPSC focuses in developing a quantitative approach for optimal alarm identification.

All of the above accelerates by the abundance of data becoming available as a result of digitalization of the industry and the variety of analytic techniques (see Also Big data and Machine Learning).

List of Center Publications:

Optimal Alarm Identification and Management:

1. Safety-centered process control design based on dynamic safe set:
Venkidasalapathy, Joshiba Ariamuthu, and Costas Kravaris. “Safety-centered process control design based on dynamic safe set.” Journal of Loss Prevention in the Process Industries (2020): 104126. https://www.sciencedirect.com/science/article/abs/pii/S0950423019303614

2. A quantitative approach for optimal alarm identification:
Venkidasalapathy, Joshiba Ariamuthu, M. Sam Mannan, and Costas Kravaris. “A quantitative approach for optimal alarm identification.” Journal of loss prevention in the process industries 55 (2018): 213-222. https://www.sciencedirect.com/science/article/abs/pii/S0950423017306204

3. A data-driven alarm and event management framework
Goel, Pankaj, et al. “A data-driven alarm and event management framework.” Journal of Loss Prevention in the Process Industries 62 (2019): 103959.
https://www.sciencedirect.com/science/article/abs/pii/S0950423019303638

4. Mannan, M.S. and H.H. West, “Process Alarm Management,” Instrument Engineers’ Handbook, Process Control and Optimization, 4th edition, Editor-in-Chief: B.G. Liptak, pp. 59-63, CRC Press, Boca Raton, Florida, 2006.
PDF (no link available)

Fault Diagnosis and Detection:

5.Zhou, Y., J. Hahn, and M.S. Mannan, “Process Monitoring Based on Classification Tree and Discriminant Analysis,” Reliability Engineering and System Safety, vol. 91, no. 5, pp. 495-626, May 2006. https://www.sciencedirect.com/science/article/abs/pii/S0951832005001079

6. Rajaraman, S., J. Hahn, and M.S. Mannan, “Sensor Fault Diagnosis for Nonlinear Processes With Parametric Uncertainties,” Journal of Hazardous Materials, vol. 130, no. 1-2, March 2006, pp. 1-8.
https://pubmed.ncbi.nlm.nih.gov/16298476/

7. Rajaraman, S., J. Hahn, and M.S. Mannan, “A Methodology for Fault Detection, Isolation, and Identification for Nonlinear Processes with Parametric Uncertainties,” Industrial and Engineering Chemistry Research, vol. 43, no. 21, 2004, pp. 6774-6786.
https://pubs.acs.org/doi/10.1021/ie0400806

8. Zhou, Yifeng, Juergen Hahn, and M. Sam Mannan. “Fault detection and classification in chemical processes based on neural networks with feature extraction.” ISA transactions 42.4 (2003): 651-664.
https://www.sciencedirect.com/science/article/abs/pii/S0019057807600135

9. Zhou, Y., W.J. Rogers and M.S. Mannan, “A Sensor Fault Detection Scheme Using a Semi-Independent Process Model,” Proceedings of the 4th Annual Mary Kay O’Connor Process Safety Center Symposium – Beyond Regulatory Compliance: Making Safety Second Nature, College Station, Texas, October 30-31, 2001, pp. 693-701.
PDF (no link available)

10. Rajaraman, S. and M.S. Mannan, “Issues in Fault Diagnosis and Isolation,” Proceedings of the 4th Annual Mary Kay O’Connor Process Safety Center Symposium – Beyond Regulatory Compliance: Making Safety Second Nature, College Station, Texas, October 30-31, 2001, pp. 703-716.
PDF (no link available)

11. Zhou, Y., N. Kazantzis, H.H. West, W.J. Rogers and M.S. Mannan, “Abnormal Situation Management: A Process Dynamics Approach,” Proceedings of the 3rd Annual Mary Kay O’Connor Process Safety Center Symposium – Beyond Regulatory Compliance: Making Safety Second Nature, College Station, Texas, October 24-25, 2000, pp. 228-230.
PDF (no link available)

List of Center Publications:

Optimal Alarm Identification and Management:

1. Safety-centered process control design based on dynamic safe set:
Venkidasalapathy, Joshiba Ariamuthu, and Costas Kravaris. “Safety-centered process control design based on dynamic safe set.” Journal of Loss Prevention in the Process Industries (2020): 104126. https://www.sciencedirect.com/science/article/abs/pii/S0950423019303614

2. A quantitative approach for optimal alarm identification:
Venkidasalapathy, Joshiba Ariamuthu, M. Sam Mannan, and Costas Kravaris. “A quantitative approach for optimal alarm identification.” Journal of loss prevention in the process industries 55 (2018): 213-222. https://www.sciencedirect.com/science/article/abs/pii/S0950423017306204

3. A data-driven alarm and event management framework
Goel, Pankaj, et al. “A data-driven alarm and event management framework.” Journal of Loss Prevention in the Process Industries 62 (2019): 103959.
https://www.sciencedirect.com/science/article/abs/pii/S0950423019303638

4. Mannan, M.S. and H.H. West, “Process Alarm Management,” Instrument Engineers’ Handbook, Process Control and Optimization, 4th edition, Editor-in-Chief: B.G. Liptak, pp. 59-63, CRC Press, Boca Raton, Florida, 2006.
PDF (no link available)

Fault Diagnosis and Detection:

5.Zhou, Y., J. Hahn, and M.S. Mannan, “Process Monitoring Based on Classification Tree and Discriminant Analysis,” Reliability Engineering and System Safety, vol. 91, no. 5, pp. 495-626, May 2006. https://www.sciencedirect.com/science/article/abs/pii/S0951832005001079

6. Rajaraman, S., J. Hahn, and M.S. Mannan, “Sensor Fault Diagnosis for Nonlinear Processes With Parametric Uncertainties,” Journal of Hazardous Materials, vol. 130, no. 1-2, March 2006, pp. 1-8.
https://pubmed.ncbi.nlm.nih.gov/16298476/

7. Rajaraman, S., J. Hahn, and M.S. Mannan, “A Methodology for Fault Detection, Isolation, and Identification for Nonlinear Processes with Parametric Uncertainties,” Industrial and Engineering Chemistry Research, vol. 43, no. 21, 2004, pp. 6774-6786.
https://pubs.acs.org/doi/10.1021/ie0400806

8. Zhou, Yifeng, Juergen Hahn, and M. Sam Mannan. “Fault detection and classification in chemical processes based on neural networks with feature extraction.” ISA transactions 42.4 (2003): 651-664.
https://www.sciencedirect.com/science/article/abs/pii/S0019057807600135

9. Zhou, Y., W.J. Rogers and M.S. Mannan, “A Sensor Fault Detection Scheme Using a Semi-Independent Process Model,” Proceedings of the 4th Annual Mary Kay O’Connor Process Safety Center Symposium – Beyond Regulatory Compliance: Making Safety Second Nature, College Station, Texas, October 30-31, 2001, pp. 693-701.
PDF (no link available)

10. Rajaraman, S. and M.S. Mannan, “Issues in Fault Diagnosis and Isolation,” Proceedings of the 4th Annual Mary Kay O’Connor Process Safety Center Symposium – Beyond Regulatory Compliance: Making Safety Second Nature, College Station, Texas, October 30-31, 2001, pp. 703-716.
PDF (no link available)

11. Zhou, Y., N. Kazantzis, H.H. West, W.J. Rogers and M.S. Mannan, “Abnormal Situation Management: A Process Dynamics Approach,” Proceedings of the 3rd Annual Mary Kay O’Connor Process Safety Center Symposium – Beyond Regulatory Compliance: Making Safety Second Nature, College Station, Texas, October 24-25, 2000, pp. 228-230.
PDF (no link available)

Fault diagnosis is destined to hold central importance in maintaining a chemical industry after installation of Advanced Process Control system (APCS). It has been estimated that US- based petrochemical industry could save up to $10 billion annually if abnormal process behavior could be detected, diagnosed and appropriately dealt with [Nimmo et al, 1995]. Further, it is highlighted [Vedam, 1999] that the same industry loses over $20 billion annually due to inappropriate reaction to abnormal behavior.

The purpose of this research is to establish and maintain safety of processes through automation and analysis methodologies. Because modern chemical plants are large and complex, early and accurate fault detection and diagnosis is imperative. Effective application of these methods can reduce product rejection rates, limit downtime, and help to attain stringent safety requirements. The central goal of abnormal situation management is to document all possible normal modes of a plant operation and detect deviations from normal behavior. Fault detection and diagnosis have gained a central importance in the chemical process industries over the past decade. This presents a need for fault diagnosis systems which use limited information of the process dynamics and accurately detect, isolate, and identify faults.

WHAT IS ABNORMAL SITUATION MANAGEMENT AND WHY IS IT IMPORTANT

An abnormal situation is a disturbance or series of disturbances in a process that causes plant operations to deviate from their normal operating state. The disturbances may be minimal or catastrophic, and cause production losses or, in serious cases, endanger human life. A disturbance of an industrial process system that an automated control system cannot cope with requires human intervention.

Fault Detection and Diagnosis:

Fault diagnosis is destined to hold central importance in maintaining a chemical industry after installation of Advanced Process Control system (APCS). MKOPSC has conducted research with a purpose to establish and maintain safety of processes through automation and analysis methodologies. Because modern chemical plants are large and complex, early and accurate fault detection and diagnosis is imperative. Fault detection and diagnosis have gained a central importance in the chemical process industries over the past decade. This presents a need for fault diagnosis systems which use limited information of the process dynamics and accurately detect, isolate, and identify faults.

Optimal Alarm Identification and Management

Another aspect of dealing with abnormal situation is alarm management. It is essential to maximize the time available for operators to respond to faults while keeping the number of alarms triggered at a minimum. Research at MKOPSC focuses in developing a quantitative approach for optimal alarm identification.

All of the above accelerates by the abundance of data becoming available as a result of digitalization of the industry and the variety of analytic techniques (see Also Big data and Machine Learning).

Mary Kay O’Connor Process Safety Center
Room 200, Jack E. Brown Building
Texas A&M University, 3122 TAMU
College Station, TX 77843-3122
E-mail: [email protected]
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