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Get More from OneAvantis • Foxboro • SimSci-Esscor • Triconex
Process Systems
Alarm Management ServicesProductie Proces AutomatiseringsdagAula TU Delft
14:30 – 15:00 uur
Author: Theo van ‘t Hof
30-11-2005
2Productie Proces Automatiseringsdag.
Process Systems
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What is the Process Improvement mind Map?
K.A.Grieve 19th Feb 2002
Process AnalysisDisplay &
HCIOperatorAlarm
InterpretationP& ID
Fault treeetc
AlarmManagement
Alarm annunciation
Alarm Handler
ShelvingGrouping
etcAlarm
detection
ManagementOf change
FaultAssessment &
analysis
Process
ControlsMotorsPumpsvalves
Measurements
Controlstudy
Controlsettings
ProcessCorrection
AssetManagement
Policy & strategyRaw materials
EquipmentManpower
environment
Alarmsettings
Alarmanalysis
Alarmstorage
Target
s
ARPM
DatabaseDocumentation
Drawings
Tunin
g
ModificationsAdditions, MPC
3Productie Proces Automatiseringsdag.
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Alarm Management Services
§ These Services are based on the Publication # 191 of EEMUA
“ALARM SYSTEMS”
“A GUIDE TO DESIGN, MANAGEMENT AND PROCUREMENT”
EEMUA stands for :
Engineering Equipment and Materials Users Association
The Members are National - and Multi-National Companiesof the Petroleum -, Gas -, Chemical - and Energy Industry.
4Productie Proces Automatiseringsdag.
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EEMUA Members
§ ABB Engineering Services
§ Associated Octel
§ BP
§ ConocoPhilips
§ Dow Corning
§ ExxonMobil
§ Foster Wheeler Energy
§ Huntsman Petrochemicals
§ RWE National Power
§ Shell
§ Total
5Productie Proces Automatiseringsdag.
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EEMUA Associate Members§ AstraZeneca
§ BASF
§ Chevron Texaco
§ D & C Engineerning
§ Flexsys
§ HPi Verification
§ Hydro
§ Johnson Matthey
§ MB Inspection
§ E.ON UK
§ Royal Vopak
§ Syngenta
§ Veritec Sonomatic
6Productie Proces Automatiseringsdag.
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EEMUA … a “de-facto” standard
•License to Operate•The KPI tied to EEMUA Guidelines:
•demonstrate good practice;•reduce exposure to litigation;•facilitate appropriate Alarm design/maintenance;•offer a complete audit trail of all decisions;
•Operate reliably“The joint study by EEMUA & ASM have found that plant upsets result in annual losses of up to 8% per year”.
7Productie Proces Automatiseringsdag.
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Alarm Optimization Features
§ Such as– Graphs EEMUA-191 or user defined metrics– Automatically publishes reports to any e-mail distribution– Performs 28 different statistical analyzes of historical data – Imports Alarm System Messages, Settings and Operator Changes– Tight integration to ABB, Fisher, Foxboro, Honeywell,
Westinghouse, Wonderware and Yokogawa– Collect data from many historians simultaneously– Collect any parameter through OPC connection– Enterprise application installed on control or business LAN– Built using Microsoft .NET technology– Easy installation of client software on any PC on the network– Automatic maintenance of upgrades to clients from server – Best in class alarm analysis tool for last 10 years
8Productie Proces Automatiseringsdag.
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Results from 20 DCS users
5-Predictive
4-Robust 3-Stable
2-Reactive
1-Overloaded
60 600 6000
600
606
# Peak Alarms/Hour/Operator
# A
vera
ge A
larm
s/H
our/
Ope
rato
r
Comfort Peak <90Zone Avg <12
No correlation betweenRationalisation & floods
Very Likely acceptableManageable
Possibly over demandingLikely over demanding
Very Likely unacceptable
1230
§ From 20 Clients, various Industries & Block counts only 3 operating within the guidelines
9Productie Proces Automatiseringsdag.
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Alarm System Overview
Normal Optimum
Upset
Shut-down
ControlSystem
OperatorIntervention
ESD
Normal : Monitoring & Optimalisation Minor operator adjustmentsUpset : Situation management Operator action neededShutdown: Ensure safety shut down Safety actions needed
10Productie Proces Automatiseringsdag.
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Typical Alarm Setting
Maximum rate of changeof alarmed variable during fault
Alarm setting
Limit of largest normaloperational fluctuation
Limit at whichprotection operatesTime for the operator
to respond to an alarmand correct fault
B
A
The setting of a high alarm
11Productie Proces Automatiseringsdag.
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Alarm System Overview
An effective alarm system
Normal Optimum
Upset
Shut-down
ControlSystem
OperatorIntervention
ESD
X
X
X
XX
X
X = Alarm
X
X
XX
X
X
XX X X X X X X
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§ Direct the operator’s attention towards plant conditions requiring timely assessment or action.
§ Alert, inform and guide the operators, allowing them to diagnose problems and keep the process within its “safe envelope”.§ Prevent unnecessary shutdowns.
§ Only present the operator with useful and relevant alarms§ Use prioritisation to highlight critical alarms
§ Have defined response to each alarm
§ Be ergonomically designed to meet user needs and capabilities§ Allow enough time for the operator to respond.
An effective Alarm System should:
13Productie Proces Automatiseringsdag.
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Alarm System Overview
Ineffective alarm system
NormalOptimum
Upset
Shut-down
ControlSystem
OperatorIntervention
X
X X
X
X
X
X = Alarm
X
XX
X
X X
XX
X
X
X
X
XX
ESD
14Productie Proces Automatiseringsdag.
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Phased approach
§ A typical Invensys Phased approach
– Phase I: Alarm System Analysis§ Used to identify problem area’s and
basis for alarm philosophy
– Phase II: Alarm Rationalisation§ Alarm Philosophy: reinforce or create§ Document & Rationalisation: Clear
“Nuisance Alarms”.§ HMI Design.§ Re-engineer appropriate alarms, point
by point.§ Initiate regular monitoring of alarm
system performance§ Dynamic Alarm management
– Phase III Maintain & Sustain§ Progress beyond the ‘just acceptable’§ Maintain and enforce “If you have something big to eat, have it in small pieces”.
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Alarm Management Services§ Phase I: Measure Performance against Key Performance Indicators.
Nominated Guideline
16Productie Proces Automatiseringsdag.
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Analyse your current situation.
OverloadedOverloaded
ReactiveReactive
StableStable
RobustRobust
PredictivePredictive
17Productie Proces Automatiseringsdag.
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Alarm Flood Periods
18Productie Proces Automatiseringsdag.
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Performance Metrics Manager
19Productie Proces Automatiseringsdag.
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Time to Acknowlegde
20Productie Proces Automatiseringsdag.
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Controller Setpoints
21Productie Proces Automatiseringsdag.
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What is the Master Alarm Database?
§ Data from CC
§ Document
§ Audit Trail
§ Cause & Effect
§ Operator Action
§ Rationalise
22Productie Proces Automatiseringsdag.
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Alarm Management Services§ Phase II: Implement Recommendations & Alarm Philosophy.
§ EEMUA Guidelines– Techniques for improving Alarm Systems§ High Benefit
– Review alarm behaviour following all upset incidents– Tune alarm settings on nuisance alarms– Eliminate alarms with no defined operator response– Ensure critical and high priority is assigned appropriately
§ Medium Benefit– Suppress alarms from out of service plant– Introduce logic to combine and simplify redundant alarms– Apply filtering to alarms– Apply dynamic alarm management
§ Other– Apply auto-shelving– Suppress on plant operating mode
23Productie Proces Automatiseringsdag.
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Priority Settings
The primary purpose of Priorisation is Ergonomic,
i.e. to make it easier for the Operator to identify important Alarms
when a number of alarms occur together.
The recommended figures for target maximum rates of occurrence are:
Priority band Max. occurrence rate Configured at design Priority
Safety related Very infrequently about 20 together 0
Critical Very infrequently about 20 together 1
High less then 5 per shift 5% of total 2
Medium less then 2 per hour 15% of total 3
Low less then 10 per hour 80% of total 4
24Productie Proces Automatiseringsdag.
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Alarm Management Services
§ Phase III: Measure & Sustain performance Improvements
– Report & Measure performance against guidelines.
– Check ongoing time to acknowledge.
– Relate abnormal conditions with associated activity.
– Document, Report & enforce Alarm Philosophy.
25Productie Proces Automatiseringsdag.
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Foxboro IA Architecture
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Any questions?