How to manage process parameters

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Process parameters are the benchmarks for the operating condition of chemical production units. If the human body is compared to a production facility, then body temperature, pulse, blood pressure, blood tests, uric acid levels, and so on are the process parameters of the body. If process parameter management is inadequate, the production units will deviate from the design specifications; this can affect product quality and output in mild cases, and even lead to safety accidents in severe cases. So, how do we manage process parameters? 1. Establish a management system for process parameters to ensure their controlled operation. Establish a management system for process parameters, defining the ranges, standards, and responsibilities for controlling these parameters, so as to ensure there are clear guidelines and rules to follow. Prepare process cards as required; these cards are single-page documents containing the key and important parameters of the operating procedures. It is recommended that enterprises manage process parameters at the company, plant, team, and other levels, based on risk and importance. In addition, indicators such as analysis parameters and toxic flammable gas alarms are also included in the management of process parameters. 2. Standardize process parameter alarms, interlock settings, and production management to ensure intrinsic safety in parameter control. Establish alarm and interlock management systems to standardize the management of process parameter alarms and the activation and deactivation of device interlocks. When an alarm is triggered by a parameter, the operator must immediately check it and confirm the situation, take appropriate actions for adjustment and verification, and record the information related to the alarm, the actions taken, and the confirmation in the alarm log. Reporting incidents thoroughly does indeed serve as a safeguard by reminding people to take action in advance, while at the same time it is necessary to avoid an overload of reports that consumes too much of people’s attention. When the DCS system is unable to adjust the parameters, personnel must take timely action to prevent accidents. Technical management personnel should regularly conduct root-cause analyses of indicator alarms, typically by examining factors such as people, machinery, materials, methods, and the environment, and then implement targeted measures including technical upgrades, staff training, modifications to operating procedures, and adjustments to raw materials. Alarm management should also be managed in a hierarchical and categorized manner. Before switching the interlock system on or off, a risk analysis should be conducted, and implementation is permitted only after approval. 3. Effectively identify the risks associated with deviations in process parameters, formulate control measures to prevent such deviations. The risks associated with production facilities are primarily reflected in deviations from process parameters. The upper and lower limits for process parameter control should be established based on the process package and design, as well as through HAZOP analysis and lessons learned from accidents, with regular reviews and revisions carried out. The prerequisite for establishing the upper and lower limits of process parameters is the identification of the risks associated with deviations from these parameters. For the risk analysis of indicator deviations, it is necessary to involve personnel from different specialties, especially those with hands-on experience in the field. It is crucial to carry out abnormal condition identification and risk assessment. Identify the risks that may arise from changes in process parameters, and establish principles and measures for dealing with abnormal operating conditions. This ensures that appropriate actions can be taken promptly and calmly when there are deviations from the normal parameters. 4. Conduct training related to process indicators to enhance personnel’s ability to handle indicator deviations. Training should be organized for staff regarding the identification and assessment of risks associated with deviations in process parameters, the control measures established, as well as the specific process parameter values and their upper and lower limits, to ensure that they are well familiar with these aspects. Training should be tailored to the needs of different individuals, in order to avoid ineffective training or gaps in coverage. Assessment methods for training should be appropriate, so as to prevent high scores from indicating low actual competence. 5. Implement strict management of process parameter changes to prevent new risks arising from such changes. Changing process parameters is a way to optimize production facilities, but the corresponding procedures must be followed. The person proposing the change specifies the details and reasons for it, and it is initially reviewed by some responsible persons. After the initial review, professionals from various fields should be organized to identify and assess risks; after weighing the pros and cons, a recommendation on whether to make changes should be made, with the final approval and implementation being handled by the process supervisors. Before implementation, modify the organizational operating procedures and process cards, as well as provide training for relevant personnel. After implementation, organize change verification and closure, and fill out the change log. 6. Ensure that monitoring and measuring equipment is in good condition, and guarantee the representativeness of the readings from various indicators. Improve the management system for monitoring and measurement equipment and facilities and ensure its implementation, so as to maintain the integrity of such equipment and facilities (including testing and measurement instruments). Regular calibration and verification should be carried out, and equipment and instruments that fail to meet the standards must be repaired or discarded. At the same time, conduct proper inspections of the instrumentation system, including checking whether the pressure transmission pipes are blocked, whether low temperatures cause an increase in viscosity that leads to measurement errors, and whether the signals are attenuated or affected by electromagnetic interference. 7. Stay vigilant, learn from past accidents, and continuously improve the management of process parameters. When suspected incidents or process accidents occur within a company, or when safety accidents take place at similar facilities domestically or abroad, relevant personnel should be organized to analyze such incidents in order to identify any gaps in the management of process parameters, thereby continuously improving the level of management of these parameters. In short, it is necessary to keep the process parameters within acceptable ranges to ensure the safe operation of the plant. Regularly conduct analyses of the reasons for any deviations in indicators, identifying potential inherent safety issues and management loopholes in the equipment from aspects such as personnel, machinery, materials, methods, and environment, thereby continuously improving the safe operation level of the equipment.