ABSTRACT
Process control safety is a critical aspect of ensuring safe production in Liquefied Natural Gas (LNG) plants, given the hazardous nature of their operations. This study focuses on developing advanced safety models that rationalize alarms and optimize control configurations to enhance safety, efficiency, and reliability in LNG production facilities. LNG plants are characterized by complex systems with a high density of alarms, which can overwhelm operators and increase the likelihood of human error during critical situations. Alarm rationalization techniques are employed to reduce alarm flooding, prioritize critical alarms, and ensure operators receive actionable and timely information. Additionally, control system configurations are analyzed and optimized to improve fault detection, system response, and overall plant safety. The proposed safety models integrate modern alarm management strategies with advanced process control systems, leveraging real-time monitoring and predictive analytics to detect and mitigate potential hazards. A systematic approach, including hierarchical control structures and risk-based alarm prioritization, is employed to ensure compliance with industry standards, such as ISA-18.2 and IEC 62682. By addressing alarm fatigue and suboptimal control configurations, the models aim to enhance situational awareness and decision-making capabilities of operators. The study presents a case analysis of an LNG plant, demonstrating the application of the safety models in rationalizing over 30% of non-essential alarms while improving the mean time to respond to critical alerts by 40%. Key performance indicators, including process stability, alarm rates, and safety incident reduction, are evaluated to quantify the effectiveness of the models. Findings indicate significant improvements in operational safety and efficiency, underscoring the potential of rationalized alarm systems and optimized control configurations in high-risk industrial environments.
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