Shift management through Systematic and Structured Operation of process plants

Introduction

One of the key operational activities in engineering, operations, and supervision in process plants is to assist and accompany the operations group and the multidisciplinary teams of industrial plants in the implementation of the Systematic and Structured Operation in Process Plants (SOP).

This approach seeks to develop and improve the plant operator’s knowledge of the situations that arise in the plants (both in the control room and in the field), during shift changes and shift development. The objective is to ensure that operators perform at the highest level during emergency or critical situations, based on extensive practical and experiential experience in this area.

To achieve Operational Excellence, the Systematic and Structured Operation in Process Plants (SOP) becomes a key tool. By implementing this approach, it is possible to transform the operational culture of organizations, putting the operator at the center of the process to achieve this goal.

Systematic and Structured Operation (SOP) in process plants

Systematic and Structured Operation in Process Plants (SOP) is a comprehensive and organized approach designed to achieve operational excellence in industrial plants running complex processes, such as chemical, petrochemical, refining, food, and pharmaceutical. This method not only maximizes industrial efficiency and safety but also ensures product quality, optimizes costs, and minimizes operational risks.

One of the pillars of SOP is effective communication, especially during shift changes. The ability to communicate clearly is a hallmark of humanity, but also one of the greatest challenges in the industrial environment. Accurate and smooth communication during shift handovers is essential to maintain operational continuity and move towards Operational Excellence.

Communication and the human factor

The Irish playwright George Bernard Shaw wrote: “The greatest problem in communication is the illusion that it has taken place”. This statement is especially relevant in today’s industrial context, where inefficient transmission of instructions and messages has led to chaos in process plants.

In many cases, organizations have neglected the human factor in their operations, prioritizing investment in technology over improving personnel performance. This trend has relegated to the background the critical role of operators in the field, who are responsible for executing the processes.

Plant operator performance is influenced by a combination of factors: standards, management systems, tools, communication, environment, and accumulated behavior over time, which make up the operational culture of each site. In this context, Systematic and Structured Operation in Process Plants (SOP) presents itself as a valuable approach to refocus attention on operators and optimize their performance.

Operational behavior

Implementing best practices with a pragmatic approach to plant operator performance can transform the organizational culture, preparing less experienced operators to assume key positions within the organization. Systematic and Structured Operation in Process Plants (SOP) is a vital tool for this.

Operational conduct is based on establishing the appropriate standards and management systems that plant operators must follow to ensure performance that meets safety requirements, minimizes operational risks, optimizes process economics, and keeps personnel highly trained and motivated. This translates into a substantial improvement of the organizational climate. The implementation of documented standards, such as shift handover, procedure management, and alarm management, for example, will improve the conduct of operations and plant operator discipline.

It is not enough to simply organize documents; it is crucial to involve workers in the creation of these standards. It is critical to focus on best practices and leverage the experience of operators in process plants.

Shift transfer

To achieve operational excellence in process plants through the implementation of the Systematic and Structured Operation (SOP) process, it is essential to consider the following aspects during shift handover:

• Communication challenges: Complexity in communication and reporting varies depending on the person involved. Difficulties can be significant, especially in high-pressure contexts or emergencies, where time for effective communication is limited.
• Operator overload: Effective communication starts with plant operators, who are often overwhelmed. In critical situations, finding time for a complete transmission of information is a constant challenge.
• Discontinuities in communication: Rotating shifts can create discontinuities in communication, which can result in the failure to transmit vital information from one shift to another, affecting operational continuity.
• Pressure on supervisors: Supervisors face similar pressures as operators, with the additional responsibility of managing data and making decisions under time constraints. Their role is critical to ensure proper information management.
• Information management: Through the SOP tool, shift handover management allows plant operators, supervisors, technical personnel, HSE, maintenance, and management to reap the benefits of technology, ensuring accurate information transmission and operational success.
• Continuous training: Ongoing training of plant operators is fundamental to maintaining safe and efficient operations. Regular training programs are essential so that personnel are prepared to face challenges and adapt to new operational demands, with a particular focus on shift handover.
• Stress management: In process plants, shift rotation and high-pressure situations influence the ability of plant operators to manage stress, which in turn affects the effectiveness of communication during critical times.
• Strong organizational culture: The culture of the organization impacts how issues are communicated and information is shared. Fostering an open and collaborative culture is key to improving information sharing and meeting operational challenges successfully.

To learn more about the functions of process plant operators and the importance of training in this area, we invite you to review the following articles: Gas Processing Plant Control Room Operator: The Complete Professional Guide and Process Plant Operator Training.

Where we are going

In many companies, a new role is emerging, known as Responsible for Excellence, Operational Discipline, or a similar title, that aims to improve the performance of plant operators. This professional works closely with internal experts and highly experienced consultants to identify and close performance gaps and to engage operators in the development of effective site standards.

Industry experience has shown that conducting assessments both in the field and in the control room, as well as accompanying and guiding the plant operator, are key practices for aligning teams with operational leadership. These activities not only identify real problems but also provide integrated solutions that can be documented and implemented efficiently in all operational areas.

Most, if not all, existing practices can be adjusted fairly easily and then documented as a standard. Once plant operators are trained, these standards can be easily managed by someone with authority to enforce the guidelines and ensure that proper conduct and discipline are used during all operational tasks: Create a Habit.

An example of a documented best practice is that all companies should be developing a standard for shift management, as shift-to-shift remains a major contributor to major accidents that have been made public. The failure of shift-to-shift communication has broken down situational awareness and loudly warns that preventable injuries and fatalities will occur in our industry if action is not taken, with plant operators bearing the brunt.

An external group should conduct an operational standards gap assessment to identify weaknesses in your defenses and identify which standards should be developed and be able to demonstrate experience in developing these best practices in field and control room operations in process plants.

Conclusions

The Systematic and Structured Operation (SOP) applied to shift shifts in process plants within the operational excellence is the fundamental key to guarantee safety, a reliable, economical, clean, efficient, and environmentally friendly operation.

Through proper planning, standardized procedures, effective communication, maintenance programs, continuous training, equipment care, and the constant search for process improvements to achieve effective plant management, reducing risks, and improving overall performance, putting plant operators at the center of this process.

At Inspenet, aware of the growing need for training in this area, we offer the course “Principles of Systematic and Structured Operation in Process Plants”. Find out more about this valuable training offer here.

References

1. George Bernard Shaw (July 26, 1856 – November 2, 1950), known by his insistence as Bernard Shaw, was an Irish playwright, critic, polemicist, and political activist. https://en.wikipedia.org/wiki/George_Bernard_Shaw.
2. PROCEDIMIENTO PARA REUNIONES DE INICIO DE JORNADA (RIJ) DOCUMENTO NORMATIVO N-2000-HC17.Comisión Federal de Electricidad. México.
3. Mobile Operator Rounds. Accelerate Maintenance Operations and Improve Regulatory Compliance. AVEVA. Copyright © 2019 AVEVA Group plc and its subsidiaries. All rights reserved. All product names mentioned are the trademarks of their respective holders.
4. Effective Shift Handover. Thomas Plocher, Jason Laberge and Jason Telner. Honeywell International, Automation and Control Solutions, Advanced Technology, Shanqing Laboratory, 1985 Douglas Drive, Golden Valley, MN 55422 USA. Yin, Nanyang. Technological University, School of Mechanical and Aerospace Engineering, 50 Nanyang Avenue, North Spine (N3), Level 2, 639798 Singapore. Brian Thompson.3 ENGEN Refinery a division of Engen Petroleum Ltd, Process Control Department, PO Box 956, Durban, 4000 South Africa.