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Yokogawa Electric Corporation
<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004> Company Confidential
November 25 2004
Step 2 Vigilant PlantStep 2 Vigilant PlantAlarm ManagementAlarm Management
Yasunori Kobayashi
Confidential
Company Confidential Page.2<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Contents
1. Why now alarm mgt. ? (15min)
2. AAASuite (10min)
3. Alarm reduction service (10min)
4. Application example (20min)
5. Integrated plant safety mgt. solution (5min)
6. Conclusion (10min)
7. Q&A Discussion (5min)
Company Confidential Page.3<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
1. Why now alarm mgt. ?
Company Confidential Page.4<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
3 Reasons
Why Yokogawa Now Focuses on Alarm Mgt. ?
1. Most customers increase a budget for safety ensuring
Company Confidential Page.5<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
A Refinery– The plant trip caused US$24M of production loss
and plant damage– Alarm flooding occurred for 5 hours prior to the
plant trip caused an oversight of important alarm by operators
B Chemical plant– The plant trip caused 5 days production loss
(US$1.5M)– An operator accepted a low flow alarm without
appreciating its significanceC Petrochemical plant– The compressor trip caused 2 days production loss
(US$0.5M) and huge plant damages– Six weeks prior to the trip there had been an alarm
on high axial displacement which the operators accepted but did not investigate. Three days prior to the trip there was a second similar alarm which also was not investigated.
Many plant hazards happen due to alarm related problems,and most customers increase a budget for alarm management
Ref. CRR166, Health & Safety Executive, 1998
1. Most customers increase a budget for safety ensuring
Company Confidential Page.6<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
1. Most Customers Increase a Budget for Safety Ensuring
Popularization of Six Sigma philosophyA loss caused by plant trip/damage is greater than a profit achieving by improvement of plant throughputReduce nuisance alarms to avoid hazardous plant situations
Labor cost
Law materialCost Utility cost
Inventorymanagement
cost
Cost ofapology AD
Cost ofcompensation
for damage
Cost forproduct
inspection
Collectioncost
Cost oftransportation
Consolationmoney
Cost of plantmodification
Cost forDisaster restoration
works
Cost ofinsurance
Direct and indirect losses by plant trip
Company Confidential Page.7<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
3 Reasons
Why Yokogawa Now Focuses on Alarm Mgt. ?
1. Most customers increase a budget for safety ensuring
2. Major customers lead alarm mgt.
Company Confidential Page.8<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
1. Published in March 1999
2. A guide to design, management and procurement
3. For safer and more cost-effective operation
4. Major customers-led philosophy• BP, Shell, ExxonMobil, ChevronTexaco, Dow,
BASF, etc.
5. Desirable # of alarms : 1alarm/10min-operator• European average : 1 alarm/2min-operator
EEMUA = The Engineering Equipment and Materials Users Association
EEMUA No.191 Alarm Systems
2. Major Customers Lead Alarm Mgt.
Company Confidential Page.9<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
# of Alarms at Your Customer’s Site
ExxonMobil, Singapore (YEA)
16794alarms/day1alarm/5.1sec
Aramco Riyadh, Saudi Arabia (YME)
9100alarms/day1alarm/9.5sec
Kalgoorlie Gold Mines, Australia (YAU)
5055alarms/10hrs1alarm/8.1sec
Posco BTX, South Korea (YKO)
6213alarms/day1alarm/13.9sec
Company Confidential Page.10<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
3 Reasons
Why Yokogawa Now Focuses on Alarm Mgt. ?
3. Only Yokogawa has unique and practical weapons
2. Major customers lead alarm mgt.
1. Most customers increase a budget for safety ensuring
Company Confidential Page.11<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
3. Yokogawa Has Unique and Practical Weapons
1. We have full-automatic alarm mgt. tool
SixSigmaDMAIC + +
Sexymethodology
Full solutions(from field to MES)
Experiencedconsultancy/engineering
2. We have alarm reduction service
3. We have integrated safety mgt. solution
+ +
Company Confidential Page.12<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Our Competitors like Matrikon, PAS, etc.
1. They have manual alarm mgt. tool only
SixSigmaDMAIC + +
Sexymethodology
Full solutions(from field to MES)
Experiencedconsultancy/engineering
2. They have methodology and report tool only
3. They can’t provide integrated safety mgt. solution
+ +
which imposes tedious engineering works on customersto reduce nuisance alarms
Company Confidential Page.13<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Appendix
1. Competitive alarm reporting tools never solve the alarm flooding situation !
EventAnalyst (Honeywell), ProcessGuard (Matrikon), AMO Plus (PAS), etc.
2. Competitive alarm management tools impose tedious re-engineering works on production people !
ACM (Honeywell), ACE (PAS), etc.
3. Competitor does not have total solutionsto solve the root cause of alarm occurrence !
Company Confidential Page.14<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Message from Konishi-san
Nobuaki KonishiGeneral Manager
System Marketing Centre
Timing couldn’t be better !
All system sales should utilize our uniqueness and innovativeness of alarm management solutions to win the competitions.
Company Confidential Page.15<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
2. AAASuite
See IA Booklet #17Yokogawa’s AlarmManagement Solutions
Company Confidential Page.16<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
What is AAASuite ?
3. Alarm enhancementRealize safer and morecost-effective operation
AAASuite only shows operators meaningful alarms.
# of
ala
rms
AAASuiteimplementation procedure
2. Alarm Optimization
1. Automatic Nuisance Alarm Suppression
3. AlarmEnhancement
2. Alarm optimizationOptimize alarm settings based on a change of process conditions
1. Automatic nuisance alarm suppressionSuppress the repetition of nuisance alarms using existing DCS functions
Company Confidential Page.17<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
2.1 Automatic Nuisance Alarm Suppression
Typical Nuisance Alarms suppressed by AAASuite
Time
ANN
ON
OFF5.
4. Repeating Input Open alarm– Over range– Minor transmitter problem
5. Chattering Annunciator– Insufficient DCS sequence program
Time
PV
HI
LO
3.3. Oscillating HI and LO alarm
– Sub-optimal PID parameter settings
Time
PV
HI
Hysteresis
Not recovered2.2. Longstanding false HI or LO alarm
– Sub-optimal alarm hysteresis setting
Time
HI
PV
1.1. Repeating HI or LO alarm
– Tight alarm threshold setting– High-frequency fluctuations on a PV– Noise on a PV– Repeated action of on-off control loops– Device malfunction
Company Confidential Page.18<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
How AAASuite suppresses the repetition ?
Time
ANN AON AOF AONAOF
ON
OFF
Tag is registered
AON
5.
4. Repeating Input Open alarm– Set Alarm Off (AOF) to corresponding alarm– Set Alarm On (AON) to corresponding alarm
5. Chattering Annunciator– Set Alarm Off (AOF) to corresponding Ann– Set Alarm On (AON) to corresponding Ann
Time
PV
PH
PL
AON AOF (HI&LO) AON
3.
3. Oscillating HI and LO alarm– Set Alarm Off (AOF) to corresponding alarm– Set Alarm On (AON) to corresponding alarm
Scale HI
Time
PV
PH
Hysteresis
2.
2. Longstanding false HI or LO alarm– Change a threshold to SH/SL temporarily– Revert a threshold to original value soon
PH
Time
PV
1.
1. Repeating HI or LO alarm– Change a threshold to stricter value– Revert a threshold to original value
Company Confidential Page.19<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
2.2 Alarm Optimization (Optional)
Time
PV
StartUp
GradeA
GradeChange
GradeB
ShutDown
PH
PL
1. Dynamic alarm settingsDownload optimum alarm thresholds to FCSUpload current alarm thresholds to AAASuite
2. Static alarm suppressionSet Alarm Off (AOF) to specific tag group when process is upsetSet Alarm On (AON) to specific tag group when process is recovered
AON AOF AON
Time
PV
PH
PL Upset
Company Confidential Page.20<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
2.3 Alarm Enhancement
Longstanding Input Open Alarm
Longstanding HI Alarm
SL
IOP-
RAW
NR
LLPL
Time
PV
Alert Alert Alert
HINR
PH
HH
Time
PV
Alert Alert AlertAlert
1. Automatic re-notification alert for longstanding true alarms– Prevent possible oversight– Longstanding HI or LO alarm– Longstanding Input Open alarm
2. Automatic predictive alert for critical HH or LL alarms– Prevent ESD situations
Company Confidential Page.21<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
3. Alarm Reduction Service
See IA Booklet #11Yokogawa’s Total Solutionsfor Alarm Reduction
Company Confidential Page.22<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Six SigmaDMAIC
Methodology : Six Sigma DMAIC Step
Set the goals should be achieved.1 alarm/5min-operator# of operator actions/5min-operator
Measure Alarm&Eventsand relevant process datain order to assessthe current situation andidentify the root cause ofalarm occurrence.
Analyze the acquired datato identify the root causeand improvements should be takenfor alarm reduction.
Execute the improvement actions.
Control the results ofthe improvementto maintain them.If the goal has not beenachieved yet,Go to the Define step again.
Best practical and effective methodologyto realize “No alarm, No manipulation plant”
Company Confidential Page.23<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Root Causes and Improvement Actions
Company Confidential Page.24<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
How to Convince Your Customer ?
Show possible benefits– Risk prevention
• Estimate possible risks from HSE report
– Manpower saving• Operators, engineers
– Improvement of work environment
Contact to customer’s mgt. level– Need top-down method
Company Confidential Page.25<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
HSE CRR166 Incident Report
Company Confidential Page.26<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
4. Application Example
See ARC Web Pagehttp://www.arcweb.com/Events/webforums/archive.asp
Company Confidential Page.27<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
EVAL Company of America
EVAL Company of AmericaFounded in 1983, Pasadena, Texas facility start up in 1986Wholly Owned subsidiary of Kuraray Company Ltd.Manufacture and market EVAL Resins(Ethylene Vinyl Alcohol copolymer resins)
The PlantContinuous & Batch chemical plant3 Polymer Lines and Distillation SectionsRegular product grade changeoversYokogawa CENTUM CS installed4 Shifts of operators, 24hrs/7days operation2 board operators/shift6900 analog+digital inputs/operator– 5,000 I/O per DCS Board Technician– 1,900 PID Control loops per DCS Board Technician
Company Confidential Page.28<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
The Problem
Many controllers are controlled within 1% of the set point, for the high and low alarm settingsOther controllers are controlled within 5%
Target Typical bench mark in Europe
Typical bench mark in Japan
Manageable One alarmin five minutes per operator
One alarmin two hours per 100 inputs
Desirable Less than one alarmin ten minutes per operator
Less than one alarmin four hours per 100 inputs
Bench marks
Audible alarms disabled– Operators were missing critical alarms– Alarms were disappearing from display– Increased safety hazards
19,241 average alarms per day (11,378 analog, 7863 digital)33.4 alarms/5min-operator (European bench mark)11.6 alarms/2hrs-100inputs (Japanese bench mark)
Company Confidential Page.29<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
The Approach
DMAIC
Refer to Six Sigma DMAIC Methodology
Use Yokogawa solutions– Experienced consultancy– Exaplog: Event analysis package
• Alarm KPI reporting• Alarm interactive analysis
– AAASuite: Online execution engine• Automatic alarm repetition suppression• Dynamic alarm optimization
– CENTUM re-engineering• Unnecessary alarm elimination• Alarm settings modification
Alarm suppression
Analysis tool
Involve all related people– Experienced operator– Process/Control engineer– DCS/Instrumentation engineer– Maintenance engineer
Company Confidential Page.30<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Define Step
Original: 33.4 alarms/5min-operator (9,621 alarms/day-operator)
Target: 1 alarm/5min-operator(288 alarms/day-operator)
Means 97% alarm reduction
Target Typical bench mark in Europe
Typical bench mark in Japan
Manageable One alarmin five minutes per operator
One alarmin two hours per 100 inputs
Desirable Less than one alarmin ten minutes per operator
Less than one alarmin four hours per 100 inputs
Bench marks
Company Confidential Page.31<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Decide on a solution based on difficulty, manpower and cost– Fundamental improvement
• Re-engineering– Immediate improvement
• Automatic suppression by AAASuite
Measure and Analyze Step
Identify the root causes– Field related– Alarm settings and control strategy
related– Operator skill related– Process design related
Field related5%
Alarm settings20%
Sequence table20%
PID tuning10%
Process45%
Top20 alarms
Next20 alarms
Field related
30%
Alarm settings
40%
Sequence
Table
30%
PID tuning
0%Process
0%
Analyze top 40 alarms using Exaplog
Company Confidential Page.32<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Improve Step (Fundamental re-engineering)
Field related04NAN203 (Digital): Bad sensor, Alarm Off was setT132023B (Analog): Out of service, Tag was eliminatedF51040 (Analog): Out of service, Alarm Off was setIA-DEWPT-HIGH (Digital): Bad sensor, Alarm Off was set02NAN205 (Digital): Bad sensor, Alarm Off was setL31220 (Analog): Out of service, Function block was disconnected
Alarm settings and control strategy relatedF1103A: Change deviation parameterF1103B: Change deviation parameterF12030: Change deviation parameterF13031: Change deviation parameterF13032: Change deviation parameter
Company Confidential Page.33<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
0
5000
10000
15000
20000
25000
30000
35000
6/19ExaplogStarted
6/30FundamentalImprovement
Average 19241 (before improvement)
Average 1885 (after improvement)
26714
30000+
8264
5825
8/15 8/28
1007
Process Changeover
Improve Step (Fundamental re-engineering)
90% alarm reduction
Company Confidential Page.34<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Longstanding false HI (LO) alarms suppressionF11380 LOT11060 HI, LOF11070 HI
Oscillating HI-LO alarms suppressionCN1109BA (19 days)F1311A (9 days)CNR1101MEOH (22 hours)CN1108KNA (2hours)F13031 (30 min)
Repeating Input open alarms suppressionF12280
Repeating digital alarms suppression02NAN13102NAN198
Repeating HI (LO) alarms suppressionTuning AAASuite
Improve Step (Suppression by AAASuite)
Company Confidential Page.35<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
0
500
1000
1500
2000
2500
3000
3500
4000
4500
Average 1885(Fundamental improvement)
3807 3896
9/07Automatic
SuppressionStarted
Process Changeover
Average 1312(Automatic suppression)
Improve Step (Suppression by AAASuite)
30% alarm reduction
Company Confidential Page.36<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Control Step
AAASuite continues to manage alarms
– Tune the AAASuite settings for our process
Repeat process with the next highest set of alarms
Re-evaluate alarm settings for control loops
Repair instrumentation where problems were identified
Evaluate dynamic alarm settings for control loops (process changeover)
Company Confidential Page.37<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Conclusions
93% alarms reduced– 33.4 -> 2.28 alarms/5min-operator
not yet at goal of 1 alarm/5min-operator
– Looking to achieve with implementation of dynamic alarm settings for control loops (process changeover)
Alarm management does work
Has allowed EVALCA to analyze and correct alarms
Management now understands and fully supports the value of alarm management and that it is a continuous on-going process
This service achieves credibility with customer and triggers a replacement to CS3000
Company Confidential Page.38<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Achieved Benefits
AAASuite has allowed the operators to not turn alarms off, alarms have become more meaningful.
Monetary losses are always a concern but a safety or environmental event could be a life time of pain and costs.
Operators now have more time to attend to true process concerns.
Don’t have to deal with nuisance alarms saving resources both monetary and personnel.
The problem of important alarms being turned off has been alleviated reducing potential risk.
The alarm analysis application has allowed us to reduce the paper trail we used to track the alarm events.
Company Confidential Page.39<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
5. Conclusion
Company Confidential Page.40<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
What Alarm Reduction Service Brings Us ?
1. New sales toolfor existing customers to make new business opportunity logically and proactivelyfor non-Yokogawa customers to show Yokogawa’s uniqueness and innovativeness
2. Achieve credibility with customers
3. Make new profit as consultancyUtilizing remaining manpower in SSB/Operations
Company Confidential Page.41<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
What is Required ?
Description Responsibility
Clear packaged solutions consisting of products and consultancy services
Marketing/Business Development
Active sales as a part of solution selling
Sales
Commitment from SSB/operations to provide the manpower to execute the alarm management studies/projects
SSB/Operations
Company Confidential Page.42<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Reference Pricing
One day analysis service (Feasibility Study)– Price: $2,000 (CENTUM, mXL), $3,000 (Others)– Gather historical messages (1 week data)– Analyze messages using Exaplog– Submit a report which shows
• Alarm performance based on EEMUA benchmark• Alarm reduction possibilities
Alarm reduction consultancy (Pay first)– Price: From $20,000 (5 days=40 hrs)– Give consultancy based on Six Sigma DMAIC step– Package, installation, engineering and training are not
included
Package selling with consultancy (Pay later)– Price: Package fee + 20%
Company Confidential Page.43<ISD-MASP-S04029>Copyright © Yokogawa Electric Corporation<25 Nov. 2004>
Thank you for your attention.
Commitment means building the future to last.
No Alarm, No Manipulation !