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REFINERY UNIT CONTROL ROOM OPERATOR EMPOWERMENTMaintaining and developing an effective operator staff can be challenging. It can be compounded in many cases by turnover and changes due to retirement and restructuring. Our new iWare software is designed to support and help train control room operators. iWare can give you an edge over your competition and peace of mind from safer operations. It empowers your operators at a new level! By associating relevant business information with plant operations and production areas iWare provides the “missing link” between control system data and operational non-data information. Critical operator information – including text documents, CAD drawings, images and video clips, operating and emergency procedures, operator hand-written notes, safety and environmental regulations, inspection and safety reports, maintenance records, vendor manuals can be accessed, viewed and shared by all operators. This real-time view keeps the operators informed so they are able to resolve issues early and efficiently, improve control of temporary conditions, find and follow procedures and share supplemental operator knowledge to perform required functions. The structure is completely flexible and can be organized and defined to match your plant's activities. Operators can locate and view a real time complete picture of the needed part of the operational information on their control panel display without interfering with the operation of the control system. iWare functionality can be used to strengthen and improve many pinch and pain points and empower the operators. These tools enable you to deal in real time with issues like: •Effective interface with maintenance – The scheduling function allows the operator to schedule maintenance work directly from the control console, and provides the capability to monitor progress of the work. The compliance function can be used to require safe procedures to be followed. The next step can’t be executed until the previous step is completed and electronic logging verifies completion. •Finding and following procedures- Emergency, little used and best practice procedures can be quickly found through drop down menu’s and brought up on the operator screen. Compliance functions can be used to ensure safe step by step sequence of operator controls. When the operator accesses the procedure it can come from a secure and approved file that is available in real time. It can be set up so any changes are immediately available for use when they are part of this file. This removes binder updating issues. •Procedural guidance- All of the procedures that apply to the job function can be set up for immediate access from the drop down menu at the console. The operator simply clicks on the procedure and follows it step by step. •High standards of conduct enforced by management- This is an organizational issue which often breaks down when the information available is in the “provable” grey area where the supervisor doesn’t have the record of the actions to use as the reference for discussion with the operator. iWare provides both an electronic logbook and an electronic logging capability. This can provide a mix of data recorded and time stamped from sensors and control changes made as well as manual entry. This allows supervision to track operator control actions and the resulting changes in the process. This provides the information for the supervisor to know where to focus training, what to discuss during counseling, and the factual basis for disciplinary actions. It also provides capture of good procedures to translate to new operators. •Supplemental operator knowledge to perform required functions- The menu can be structured to provide reference material directly on the operator console for the operator to follow, or in compliance format. •Improved control of temporary conditions- The menu can be structured to provide reference material directly on the operator console for the operator to follow, or in compliance format. The operator can relate observed conditions to the reference material as an aide to identification of the right solution for a situation. This can deliver procedures directly to the operator, and removes reliance on operator memory of infrequently used procedures. iWare offers a comprehensive solution to help you improve your operational efficiency. Just consider the value per BARREL OF ADDITIONAL GASOLINE OR DIESEL PRODUCTION, or per THOUSAND MMBTU OR KWH ENERGY SAVED!! Or the value of improved peace of mind from operator empowerment! SOME EXAMPLES Do you use binders as references for key procedures and source information? Binder issues that iWare addresses include:
A Few Added iWare Features: Maintenance Work Order Initiation There are many cases where the operator either needs maintenance or is unsure whether a component is operating properly. Each individual component on a plant schematic, or photo can be related to the correct maintenance person or function. The operator can click on the schematic or photo, and in a drop down menu with a click or two can send a request for maintenance support/work order which will be routed to the designated maintenance person or function, time stamped and prioritized. Capture of Operator “Black Art” Many process operators have favorite set points for the process. These may be fully optimum, within the operating guide lines, leading to outstanding performance, and the operator may not be able to explain, or has not recorded why they did what they did. Electronic logging can be used to record selected time stamped plant floor data and operator settings, and logging sets display the effects of the operator fine tuning. Identification of Training Needs The same logging can show where more timely operator adjustments could have been done, indicating where training should be focused. It can also be used to track operator skills development. |
Operator / Decision 
