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Process Systems

Alarm Management ServicesProductie Proces AutomatiseringsdagAula TU Delft

14:30 – 15:00 uur

Author: Theo van ‘t Hof

30-11-2005

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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

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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.

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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

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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

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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”.

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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

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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

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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

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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

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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:

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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

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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

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Analyse your current situation.

OverloadedOverloaded

ReactiveReactive

StableStable

RobustRobust

PredictivePredictive

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Alarm Flood Periods

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Performance Metrics Manager

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Time to Acknowlegde

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Controller Setpoints

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What is the Master Alarm Database?

§ Data from CC

§ Document

§ Audit Trail

§ Cause & Effect

§ Operator Action

§ Rationalise

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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

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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

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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.

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Foxboro IA Architecture

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Any questions?