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ASCON IEEChE16 Minowa - Draft
ASCON IEEChE16 Minowa - Draft
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All content following this page was uploaded by Hirotsugu Minowa on 21 January 2017.
Hirotsugu Minowa 1*, Kazuhiro Takeda 2, Yukiyasu Shimada3, and Tetsuo Fuchino4
1
Dept. of Business Administration, Okayama Shoka Univ., 2-10-1 Tsushima
Kyomachi, Kita-ku, Okayama, 700-0087, Japan
2
Center for Risk Management Research, Shizuoka University, 3-5-1 Johoku,
Naka-ku, Hamamatsu-shi, Shizuoka 432-8561, Japan
3
Chemical Safety Research Group, National Institute of Occupational Safety
and Health, Japan, 1-4-6 Umezono, Kiyose-shi, Tokyo 204-0024, Japan
4
Dept. of Chem. Sci. and Eng., Tokyo Institute of Technology, 2-12-1 O-
okayama, Meguro-ku, Tokyo 152-8552, Japan
*E-mail: minowa@po.osu.ac.jp
Abstract
A change in criteria, procedure, and method of maintenance or design of chemical and nuclear
plants can have high associated risks, resulting in large-scale accidents. Therefore, a
management of change (MOC), which dictates managing change correctly when it comes to
criteria, procedure and method of maintenance or design, is important for life cycle
engineering. MOC is a type of business process management using business process model
(BPM). . The problem with executing an MOC is that it lacks explicit defined procedures and
sufficient time for execution. Such problems will result in accidents in the future.
To solve these problems, we propose a solution by using a software system to support the
execution of MOC procedure. Software support will be helpful as it can be used
anytime/anywhere. Our developing system supports operators to follow MOC procedure
correctly according to an rule defined as plant-life cycle engineering (Plant-LCE) based on
IDEF0 by controlling their execution, and sharing and updating the information of changes to
each administrator. This is expected to decrease operator’s loads and increase efficiency. This
study describes a support methodology by a software system based on BPM and Plant-LCE.
The results of the study show that it is advantageous and useful to implement a software
system, using an algorithm that supports MOC procedures. And shows a prototype software
incorporates our proposed idea.
1. Introduction
A change in criteria, procedure, and method of maintenance, or design of large-scale plants
such as chemical and nuclear plants can have high associated risks, resulting in large-scale
accidents. Therefore, a management of change (MOC), which dictates managing change
correctly when it comes to criteria, procedure, method of maintenance, or design, is important.
There was an accident that was caused by a flawed MOC procedure, which resulted in a vapor
cloud explosion at a chemical plant, owned by Nypro, in Flixborough1-2 (England), on 1 June
1974; the accident killed 28 inhabitants and injured 53. The direct cause of the accident was
the shear failure, which was caused by the use of a bent valve to connect two reactors.
However, the root cause behind the accident was that such a problem was not clearly defined
in the MOC procedure. Incorrect execution of MOC can result in some accidents. The causes
of the failure are, for example, the insufficient sharing information of change or the neglected
or insufficient rule of preventing appropriate MOC procedures. MOC is important for
sustainable engineering when it comes to industrial plant administration.
The Safety Division in the Society of Chemical Engineers, Japan, discusses the management
model of MOC procedure based on Integrated DEFinition Methods 0 (IDEF0) by considering
the importance of MOC in the study of process safety management (PSM)3. The results of this
research led to an advanced research that realized a software program to support MOC
execution. This study describes a support methodology using a software system for a business
process model (BPM). The results of the study show that it is advantageous and useful to
implement a software system, using the proposed algorithm that supports MOC procedures.
And shows a prototype software incorporates our proposed idea.
2. Conventional Works
Enterprise Level E1 E2 E3 E4 E5
Announce corporate Make basic plan Perform Plant- Evaluate result of Provide resources
philosophy and for Plant-LCE LCE PSM Plant-LCE PSM for Plant-LCE
management policy PSM PSM
Site Level
A1 A2 A3 A4 A5 A6 A7
Manage Make Perform Perform Perform Provide human Provide
Plant-LCE execution process and construction manufacturing / organization resources for
plan for plant design resource for performing
Plant-LCE Plant-LCE Plant-LCE
A31 A32 A33 A34 A35 A36 A37 A41 A42 A43 A44 A45 A46
Perform Perform Perform Perform Perform
PSM PSM PSM PSM PSM
Manage Plan activities activities activities at Check P.R. Manage Plan activities at activities at Check P.R.
at R/D at design construction production maintenance
stage stage stage stage stage
Typical Typical Typical Typical Typical
tasks tasks tasks tasks tasks
(PDCA- (PDCA- (PDCA-PR) (PDCA-PR) (PDCA-PR)
PR) PR)
3. Research
3.1. Methodology
This section describes the research direction. Our research aims to support the execution of
MOC procedure in PSM. Therefore, a computer-aided solution using software technology
was implemented to solve problems mentioned in 2.1. The problems and ideas to solve by
software are mentioned in 3.2.
request is RIK or not. This process corresponds to “Is it RIK?” in Fig. 3. Flow of
Fig. 3. RIK indicates whether or not the change is replacement of procedure
the same kind. If the current activity does not coincide with RIK, then the reason is
recorded as “not RIK” and this phase shifts to Step 4. Otherwise this phase shifts to Step 3.
4. Evaluation
This section reports the results of the evaluation of our proposed method mentioned in 3.3.
The target is a case4 where a worker changed the amount of flow corresponds to a minimum
in a gasoline desulfurization unit that removed the sulfur component in residual gasoline; this
gasoline was produced from a fluid catalytic cracking (FCC) device. Although the detailed
results of the analysis are omitted because of space constraints, our proposed method
concluded that it has no problems in guiding the MOC procedure to a worker because our
procedure was coincided with the procedure which an expert executed.
5. Implementation
We developed a prototype software for operators to easily and correctly follow the
procedure in 3.3 for the purpose of solving the problems mentioned in 3.2.
Fig. 6. A window to record changes on this Fig. 7. A window to select a next activity
activity
6. Conclusion
This paper reported results of our method to support the execution of BPM by software
development. The results of the study shows that it is advantageous and useful to implement a
software system, using an algorithm that supports MOC procedures. And shows the prototype
software incorporates our proposed ideas. In the future, the authors will evaluate the support
performance of our software in some other case study.
Acknowledgements
This work was supported by JSPS KAKENHI Grant Number JP26350469.
References
1. Warner, S. F. The Flixborough Disaster. Chemical Engineering Progress, 71(9), 77–84 (1975).
2. Gould S. J. Chapter 8 Flixborough. Learning from Accident 3rd Edition (pp. 83–102). Gulf
Professional Publishing (2008).
3. Shimada, Y., Kitajima, T., Fuchino, T., & Takeda, K.. Disaster Management Based on Business
Process Model Through the Plant Lifecycle. Approaches to Managing Disaster - Assessing
Hazards Emergencies and Disaster Impacts, 19–40 (2008).
4. Takeda, K., Saito, H., Shimada, Y., Kitajima, T., Fuchino, T., & Naka, Y.. Analysis of Business
Flow of MOC based on Business Process Model of Plant Lifecycle Engineering. Chemical
Engineering Transaction, 31, 325–330 (2013).