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Purpose of Alarm Management Reduce factors that causes incidents and escalations Reduce risk to personal safety, financial loss and Environment impact Set focused attention on issues of process and equipment control &
defects Improve operators abilities to prioritize based on alarms priority,
filtering and shelving Improve efficiency and effectiveness of intervention Improve interface with HMI and thus less human error Improve lifecycle performance as alarm analyzed and resolution action
applied
3
Facilities should have NO alarms or VERY LOW alarms if they are;Well DesignedWell ImplementedWell OperatedWell Maintained
4
Key Objectives of Alarm Management
Milford Haven Explosion, July 1994, UKMilford Haven Explosion, July 1994, UK
Langford Gas Plant Incident,1998, AustraliaLangford Gas Plant Incident,1998, Australia
Burchfield Incident, 2005, UKBurchfield Incident, 2005, UK
Texas City BP Amoco explosion, March 2005, USATexas City BP Amoco explosion, March 2005, USA
Excessive number of alarms in emergency situation reduced the effectiveness of operator response
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Alarm Management Standards
PDO is following developments around the world in the area of Alarm Management and capturing lessons learnt.
AuditAudit
PhilosophyPhilosophy
ImplementationImplementation
(MO
C)M
anagement of Change
(MO
C)M
anagement of Change
IdentificationIdentification
RationalizationRationalization
DesignDesign
OperationOperation
MaintenanceMaintenance
Monitoring &
Assessm
entM
onitoring &
Assessment
PhilosophyDefine processes for Alarm Management and Alarm System Requirement Specification (ASRS) as per Objective and StandardsIdentificationDefine potential Alarms. (Process Hazard Analysis PHA, P&ID, Plant Operating Manual, Cause & Effect and Alarm & Trip setting drawings) RationalizationRationalization, Classification, Prioritization and documentationDesignBasic alarm design, HMI design and advanced alarm designImplementationInstall alarms, initial testing and trainingOperationOperator responds to alarms , refresher and trainingMaintenanceMaintenance repair and replacement, periodic testingMonitoring & AssessmentMonitoring Alarm data and report performanceManagement of Change Processes to authorize additions, modifications and deletion of alarmsAuditPeriodic audit alarm management process
PhilosophyDefine processes for Alarm Management and Alarm System Requirement Specification (ASRS) as per Objective and StandardsIdentificationDefine potential Alarms. (Process Hazard Analysis PHA, P&ID, Plant Operating Manual, Cause & Effect and Alarm & Trip setting drawings) RationalizationRationalization, Classification, Prioritization and documentationDesignBasic alarm design, HMI design and advanced alarm designImplementationInstall alarms, initial testing and trainingOperationOperator responds to alarms , refresher and trainingMaintenanceMaintenance repair and replacement, periodic testingMonitoring & AssessmentMonitoring Alarm data and report performanceManagement of Change Processes to authorize additions, modifications and deletion of alarmsAuditPeriodic audit alarm management process
Alarm Management LifecycleAlarm Management Lifecycle
EEMUA 191
ISA 18.2
DEP 32.80.10.14
GU 513
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Step 3:Step 3:Step 3:Step 3:• Perform Bad Actor Alarm Resolution
Step 4:Step 4:Step 4:Step 4:• Implement Real-time Alarm Management
Step 5:Step 5:Step 5:Step 5:• Perform Alarm Documentation and Rationalization (D&R) [Critical:5%, High:15%, Low:80%]
Step 6:Step 6:Step 6:Step 6:• Implement Alarm Audit & Enfonce Techniques (A&E)
Step 7:Step 7:Step 7:Step 7:• Control & Maintain the Improved Systems
Step 2:Step 2:Step 2:Step 2:• Collect Data & Benchmark system
Step 1:Step 1:Step 1:Step 1:• Develop, Adopt & Maintain an Alarm Philosophy
Process of Alarm Management
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Alarm Rationalization Alarm Rationalization Workshop
Applicable for Green Field/Brownfield/FCP/Expansion Projects Complete Variable Table (VT) Utilize PDO Approved Facilitators for Rationalization. Rationalization Workshop Requirements
o Documentation: POM, Alarm & Trip Setting, PEFSo Workshop Participants: PDO Approved Facilitator, Operations, Maintenance,
Process Engineering, C&A, Rotating/Static/Other Constraint Owners Only the following Priorities in the System
o CRITICALo HIGHo LOWo JOURNAL
Issue Workshop Closeout Report Forward Variable table to ONO63/Function (UEOA31/33)
PDO Approved Facilitators Saif Al Berwani Dalmar Jama Mohsin Alharthy Biplap Mazumdar Kannan, Palaniappan UEOA28 Contact function (UEOA31/33) for latest list
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Rationalization Implementation Implementation
Ensure Implementation of Rationalization Workshop Outcome in the system OEMs made aware of implementation Requirement NO ALARMS TO BE CONFIGURED IN THE SYSTEM UNLESS IT IS IN VARIABLE
TABLE System Requirements
PDO uses Alarm Management Software called PAS. Currently 55 facilities connected to PAS system.
PAS License required for each new facility (if not currently connected) are;o Data Connection Licenseo Audit & Enforce License
DCS Licenses required (if not currently available) are:o OPC A&Eo Alarm Suppressiono Alarm Shelving
Contact Function (UEOA31/33) for License requirements.
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Alarm Management KPIs & Reporting Alarm Management KPIs
1. Average Alarm Rate / Hour (per operator console): OI: : 12 Alarms / Hour DEP/GU : 06 Alarms / Hour Project : <3 Alarms / Hour (Blade 24 Top Quartile)
2. Standing Alarms (Future - 2015)3. Peak Alarms (Future - 2015)
Project Acceptance Criteria Acceptable KPIs for 3 months period before acceptance
Commissioning Alarms Alarms during commissioning (prior to handover) should NOT go to the
operator. Commissioning alarms should go to dedicated “commissioning” workstations. Vendors made aware of commissioning alarms management as above
Reporting Monthly Reporting Commissioning alarm to be excluded from reporting (only if going to
commissioning workstation) Manual exclusion using Web Based AM dashboard at this time. Project to
support ONO63/AM focal points.
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Bad Actor Fix Progress Monitoring
Overall Bad Actor Fix %age w.r.t. Baseline (Asset A) = 73%Overall Bad Actor Fix %age w.r.t. Baseline (Asset B) = 49%Overall Bad Actor Fix %age w.r.t. Baseline (Asset C) = 66%
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Alarm QualificationIt shall require a defined Operator Response
It shall not
duplicate other
alarms
It sh
ould
indi
cate
wha
t
Pri
ority
Ope
rato
r
shou
ld a
ssig
n to
it
NOT too early that no operator response is required
NOR too late that no time left to respond
It shall have an appropriate
message that is easily
understood
It sh
all h
ave
signi
fican
t
oper
ation
al v
alue
15
Conclusion High alarm rate signifies shortfall of one or more of the following:
Design. Implementation of design intent. Operation effectiveness. Maintenance effectiveness
Alarm Management performance improvement needs: Motivated concerted team effort Sustainability of achievement Reiteration and goal post changing Culture embedding at all level Documentation for consistency Analysis tool i.e. data/dashboard
Targets achievable when focus is maintained by: Daily monitoring at facility level Weekly review by Integrity Engineering Monthly review and reporting at Asset Leadership level Quarterly corporate level review
Leadership support is required to successfully achieve and sustain Alarm Management
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