Upload
trankhanh
View
216
Download
0
Embed Size (px)
Citation preview
Alarms are an essential part of modern systems and the primary means of alerting operators of abnormal situations in their facilities. Even the best designed systems can become ineffective in the absence of alarms, resulting in potential human and financial setbacks.
Research has shown that many process plants have improperly configured alarms that do not follow international guidelines and add to operators’ confusion. For an effective alarm system and smooth unobstructed plant operations, alarms need to be relevant, unique, timely, prioritized and understandable. Nearly all facilities with ineffective alarm systems show distinct symptoms of poor alarm system design.
Symptoms of Poor Alarm System Design:
A Need for Good Alarm Management
Alarm Management Overview
A significant number of alarms are raised by minor issues
Alarms remain active for very long periods of time
There are no guidelines for alarm implementation
Operators are unsure of how to respond to some alarms
Processes run normally despite some alarms constantly going off
Some alarms do not require an operator’s response or attention
Numerous alarms go off during routine operation but have no purpose
Poorly configured alarms risk the safety of: Plant, Personnel, Equipment
Good alarms increase safety of all three by: Reducing unnecessary alarms Prioritizing important alarms
Safety
Alarms not configured properly result in: Reduced production revenue Losses from damaged assets
Properly configured alarms increase profitability by: Increasing uptime Decreasing incidental losses
Profitability
Over 40% of incidents are caused by human factors
Poorly configured alarms add to these risks
Good alarms reduce errors from the human factor by facilitating operators
Human Factor
Philosophy
Identification
Rationalization
Design
Implementation
Operation
Maintenance
Audit
Monitoring&
Assessment
Managementof
Change
A comprehensive document of work processes, sites and control systems along with best practices for alarm management.
A complete description of processes to update,
change or remove alarms in order to meet changing
requirements or optimize systems.
Data is monitored and benchmarked against
performance standards defined in the alarm
philosophy.
Data is collected for a baseline assessment of current alarm systems against standards, “Bad Actor” alarms are identified.
Areas of trouble in the alarm systems are identified and compared to the alarm philosophy document to evaluate a course of action.
Alarms are re-engineered according to the alarm principles defined in the philosophy document.
The re-engineered alarms are implemented and documented; relevant operators are trained how to respond to alarms.
The site is run with the new alarm systems. Operator- supporting tools are installed; further trainings are given.
Alarms are periodically calibrated and tested for accuracy, repairs and replacement activities are performed.
INTECH provides a unique customer-tailored Alarm Philosophy Document.
INTECH analyzes data for 6-8 weeks and helps customers understand the cause of bad actors
INTECH helps the site team understand, classify and prioritize alarms.
INTECH makes the Master Alarms Database (MADB) for the site.
INTECH installs the MADB and performance management tools; also trains operators.
INTECH trains operators how to handle alarms and provides alarm management tools.
INTECH follows standard maintenance procedures and performs fidelity tests.
Part of the continuous
improvement effort, with
periodic alarm and system
audits
ISA 18.2 Compliant Alarms Management Life Cycle
Time
Normal Operating Region
Maximum Profitability Region
Break Even Point
Profitable Region
Plan
t Pro
fitab
ility
Substantial Net LossDue to Unscheduled
Plant Shutdown
Optimum ProfitabilityAPC & Optimization
Net Loss Due toMinor
Process Upset
0
1500
3000
4500
6000
7500
9000
10500
12000
13500
15000
# of Daily Alarms
All AlarmsEnabled Alarms
Alarms Optimization ImplementedBefore Rationalization After Rationalization
Daily Alarm Count: > 16,000 Daily Alarm Count: < 5,000Hourly Average for Week: 742 Hourly Average for Week: 390High Priority Alarms Contribution: 65% High Priority Alarms Contribution: 43%
INTECH’s Alarm Management Solutions ensure that incidents occurring from bad alarm configuration are minimized. INTECH achieves this by classifying, prioritizing and optimizing alarms to generate useful information for operators. This ensures that operators are immediately alerted to issues that can potentially cause serious damage to the plant and environment, and offset a large portion of the plant’s past profitability.
Most modern alarm systems are implemented at the software level and require no physical hardware installation, this has led to a significant increase in the number of available alarms at any site - a growth fueled by international standards that require periodic monitoring for process assessment. The major drawback to all this however is an overwhelming amount of alarm notifications being constantly generated during operation in the absence of alarm management.
INTECH’s Alarm Management reduces overall alarms going off to manageable numbers through continuous improvement. INTECH identifies “bad actor” alarms - alarms that cause nearly half of all alarms - and optimizes them. Additionally nuisance alarms - which don’t serve any real purpose - are identified and reconfigured to reduce overall alarms. This results in up to 90% reduction in average daily alarms.
Reduction in Overall Alarms:
INTECH’s Alarm Management Suite
Performance and Financial Benefits
INTECH delivers software and services for operations and process optimization with a variety ofdeterministic optimization techniques that may be manually or automatically selected based on theobjective function and constraints. Alarms Analytics Dashboards module delivers KPIs, metrics andreports based on ISA 18.2 standards and EEMUA 191 guidelines.
This module provides comprehensive data management for identifying & documenting causes,consequences, and corrective actions as well as alarm set points, alarm enabled states, priorities,purpose, operator action, consequence of not attending alarm, min. time to respond to the alarm, deadband, requirement of alarms suppression and requirement of de-bounce timer
INTECH, with it's rich experience in operations and process, identifies process and equipment states.Based on ON, OFF, INITATING, START UP, SHUT DOWN etc. states, alarms can be dynamically enabled ordisabled.
Alarms Analytics Dashboards Module
Alarms Rationalization Module
Static, State-Based and Dynamic Alarms Suppression Module
INTECH’s Advanced Solutions Deployment - Software Architecture
REPORTS
Hand Held Terminal
PDC-Windows CE
Manual Logging
Manual Logging /Hand Held Terminal
Client
1. Data Acquisition
8. PDC/Historian Interface
2. Advanced Process Historian
Production Data
REPORTS
SAP PM
RAW DATA
RESULTS Process Historian
Historic Process Data
Manual Data
Historic Process Data
5. Reporting7. Processing Simulation
LEGEND:
Equipment Run Hours, Starts and KPIs Efficiencies
Process DATA
OPCDAI/F
MS-Excel Reports
Ontology Framework
Excel-Data Link
Thin Client WEB-APPS (Browser)
Process Engr. Data Analysis/
Extract
KPIs
Process Simulation
Server
3. AlarmManagement
4. Control LoopPerformanceManagement
Alarms & Events AE I/F
Loop Tuning
DAI/F
Alarms Analysis, Rationalization Module
Control Loop Performance Management Module
Visual Interfaces (GUI) - To be
deployed by INTECH
Sometimes Already Deployed or To Be Offered by INTECH
Already Deployed Systems within IT / CCR Landscape
6. Condition based Maint.
Advanced Process Historian to SAP PM Interface
ACE (Advanced Calculation Engine) Tank Mass/Vol KPI. Run Hours total
Starts, Efficiency Calculations
Alarm & Loop Analysis Client DCS
OPC Server
Notice: All registered logotypes, trademarks, brands, product and services marks used in this document are acknowledged as properties of their respective companies/owners and such companies/owners have not consented to their use by INTECH (Term INTECH is used for INTECH Process Automation Inc. and its affiliates). INTECH is not affiliated with these logotypes, trademarks, brands, product and services marks and any use by INTECH should not be construed as an endorsement of INTECH or its services. The services described herein are provided solely by INTECH. © 2017. All rights reserved by INTECH Process Automation Inc. facebook.com/Intechprocessautomation
linkedin.com/company/intech-process-automation
Vendor Expertise Standards & Certifications
End User EPC
What Our Customers Say...“I commend you on your efforts in customizing the business analysis software for trial deployment for a Web Based Alarm Management Dashboard. It meets our objectives and has produced the desired results.”
Control & Automation Leader
“[We] commend INTECH’s knowledge of alarm management, dedication, commitment and effort. Most importantly, works have been completed safely and INTECH has been able to work successfully in our diverse environment”
Central Maintenance Coordinator
“INTECH’s team worked with extraordinary zeal & efforts at the Adhi Electronic Flow Metering Project which included on-line trends and alarms of sales gas parameters’ limits. The competency level and performance of their deputed team is satisfactory and commendable. “
Deputy Chief Engineer
PPL
OEM
AmericasWORLD HQINTECH Process Automation Inc.4903 W. Sam Houston Parkway N. Suite A-100Houston, TX 77041, USATel: +1 713 849 1000 Fax: +1 713 856 0785
INTECH Process Automation Perú S.A.C.Av. República De Panamá N°3030 Oficina 7a San Isidro, Lima, Perú Tel: +511 606 6849Cel: +51 982117562
EuropeINTECH Process Automation Sarl168 Avenue Charles De Gaulle, 92 522 Neuilly-sur-seine Cedex, [email protected]
Central AsiaINTECH Process Automation LLP.5A Erniyazova Str. Atyrau, KazakhstanTel: +7 7122 32 01 16Fax: +7 7122 32 00 52
AsiaINTECH Process Automation Pte. Ltd600 North Bridge Road, #23-01 Parkview Square, Singapore 188778Tel: +65 68289118Fax: +65 68289112
PT INTECH Process AutomationRukan Permata Senayan, Blok C Nomor 5, 4th Floor,Jalan Tentara Pelajar, Kebayoran Lama,Jakarta Selatan, 12210 IndonesiaTel & Fax: +62 21 579 49 444
INTECH Process Automation (Shanghai) Co. Ltd.Room 1605c, 16f Feidiao International Building, No.1065 Zhaojiabang Road, Xuhui District,Shanghai 200030 – P.R.C.Tel: +86 21 2426 1951Fax: +86 21 2426 1877
INTECH Process Automation Pvt. Ltd.2nd Floor, Commercial Building #2PCSIR Phase – IILahore 54782, PakistanTel: +92 42 111 468 324Fax: +92 42 3531 4149
Middle EastINTERNATIONAL HQINTECH Process Automation FZCOP.O. Box 61479, RA08ZC01, JAFZA, DUBAI, United Arab EmiratesTel: +971 4 8810056Fax: +971 4 8810057
INTECH Process Automation Inc. Br.G-201 Al-salah Tower, P.O. Box 4270, Al-khobar - 31952,Kingdom Of Saudi ArabiaTel: +966 13 8966052, +966 13 8966053
INTECH Process Automation FZCO Br. 470, Italian City, Erbil, Iraq Tel: +964 780 131 2198, +964 750 309 3766
North Africa OperationsTel: +971 55 607 3230, +971 553768482
Email: [email protected]
AfricaINTECH Process Automation Nigeria Ltd.64b, Abacha Link Road, G.R.A. III,Port Harcourt, Rivers State, Nigeria
Liaisons Office, Victoria Islands, Lagos, Nigeria
Tel: +234 807 5396201Tel: +234 705 1404326Tel: +234 805 [email protected]
INTECH Process Automation Inc.(Sucursal De Angola)Casa Nº B07, Condominio Boulevard, Via Al16, Talatona, Luanda - Republica De AngolaTel: +244 222 720 471Fax: +1 281 377 3455 [email protected]
www.intechww.com