Alarm Management Seminar

7/18/2019 Alarm Management Seminar

1/52

Bergen op Zoom Seminar

February 2011

Alarm ManagementPrinciples & Guidance


2/52

Next generation alarm management

Todays Seminar

Most of you here have a Plant, DCS system, ESD systemImproving the effectiveness of the alarm systems improvesoverall operation and increases safety

Todays seminar focuses on a good foundation to achieve this


3/52


Agenda

Introduction to Ueason

E!ample Cases

"larm Management Principals # $uidance

%o& Ueason can help 'ou(

)uestions # Discussion

*Every attendee &ill receive the presentation+


4/52


UReason is

"ngloDutch Company &ith offices in -eiden and Maidenhead

Delivers realtime applications and solutions in the area of .perationalE!cellence

Customers in Europe, /orth"merica and MiddleEast0Industries1 .il # $as, *Petro+chemical, Traffic, Energy and Utilities

23e Com4ine our E!pertise and

Technology &ith that of our

customers to improve .perational

E!cellence50


5/52


Operational Excellence

Operational Advisories:6 Sa4ic

6 DSM6 emote Surveillance1

7 Siemens Po&er $eneration7 8estolit7 Shell $lo4al Solutions9/"M

Alarm Management:6 :"S;

6 :P6 ?0@A Standard7 IS" S>?0@A T Development7 EEMU" >B> $uideline


6/52


Example: Northsea Gas producer

Scope of Supply:- Alarm Management Survey

- Philosophy Development

- Support Alarm Rationalization-Performance Auditing-Advanced Alarm Management System

for Onshore Centralized Control Room

DCS: o!"oro #A

A$% &istorian: 'iPS (ogMate

Alarm Reporting: OAS)S-AM

Advanced Alarm Management: OAS)S-AM

Alarm redution on platforms,8isionary "pproach for Centralied Control oom


7/52Next generation alarm management

.vervie& of the redutionrealied, varying 4et&een "0#6 $%#


Example: yondell!asell

Scope of Supply:

- Rule Discovery from &istorical Data

- Alarm Display Replacement

- Alarm Predictions in Control Room

Corporate Agreement Advanced Dynamic Alarm Management

DCS: %merson Delta*

Data: 'iPS (ogMate

%merson OPC

Advanced Alarm Management:

OAS)S-AM


8/52Next generation alarm management

Example: "hemical #lant Germany

Proactive A! informationon gas leaFs

8ision9Smell # SoundSensors Com4ined

.perators dont have to do a>A hours plant inspection

Important for Feeping licenceto operate

Operator Advisories

Interfaces: Emerson, ABB,

Siemens


9/52


Example: Re$nery Netherlands

Scope of Supply:

-Alarm $ %vent &istorization-Alarm $ %vent Reporting

- Alarm A+areness ,orshops-Alarm Philosophy Development

-Master Alarm Data"ase-Alarm MOC

DCS: &oney+ell 'DC. o!"oro

#A. )ooga+a CS

&istorian: S/( Server


10/52


Example: Re$nery Netherlands

Scope of Supply:

-Consultancy-Alarm A+areness ,orshops-Alarm Philosophy Development-Setup Master Alarm Data"ase

-*endor Selection-A$% &istorization-A$% Reporting-Master Alarm Data"ase $ MOC

DCS: &oney+ell 'DC.

MA0Mag(og %SD


11/52


Siemens % #rocess Real&Time 'istorian#()A*

SIS.$ PIM") System Em4eds."S'S"M

PIM") E!amples1 MaersF "lShaheen ;DP A@@@ MaersF "lShaheen ;DP A@@G MaersF %alfdan Petro4as ;PS. Piranema 8enture .il ;PS. %umming4ird Statoil Snorre ", Snorre : ConocoPhillips Eld;iFs %ydro /Hord " # :


12/52


Siemens & #()A*


13/52


Siemens & #()A*


14/52


"larm Management

Principles # $uidance


15/52


ust imagine J you drove to

this seminar and every A9Kminutes an alarm &ent off

:reaFs are overheating

-eft front tire pressure

is do&n.il Temperature

drifting to %igh

J0

Andyou &ere also e!pected to find your &ay, drive safefully,listen to the radio for traffic Hams and decide on alternative routesJ


16/52


00 our car and our driver


17/52


+hy ,ocus on Alarm )anagement -

"4normal conditions cost 4illions annually1

6 -oss of eLuipment and life

6 .ffspec Product and -ost Production *K? per year+

6 Environmental E!cursions and emediation

MaHor contri4uting factors include16 Information .verflo&

6 Poorly Designed .perator Interfaces

6 InadeLuate "larm Management System

Alarm Management is reogni&ed as a signi'iantplant reliability improvement


18/52


The Alarm System & .e$nition

The primary function of the alarm system is to &arn the

operatora4out a situation that is not normal

.perators esponse to

an alarm N action1

Source %%M1A 232

S l


19/52


Some Examples

Source &S% CRR 244

On 25th May 6776. pilot lights on the flare system at a chemical plant +eree!tinguished8 'his occurred "ecause there +ere fluctuations in the gas

supply to the flare8 A large gas cloud formed "ut. fortunately. did not ignite8

'he flare gas came from an installation +hich +as "eing restarted8

'he restart process produced 3,700 alarms so. not surprisingly. the

operators failed to detect the alarm for the flare8

&S% 9riefing ote o8 3

Al S " i/ S


20/52


Alarm System "ontri/utes to Stress

"larm annunciation is the 4iggest stress factor for operators

Picture Source: ASM Consortium

Stress is the maincause for human errors

Human errors are themost frequent cause forincidents and upsets

Human errors arecaused by ineectivesystems


' did t h -


21/52


'o0 did 0e get here -

.ld days 6 hard&ired 6

Ooptimied alarm system

*>@@ -ight ;i!tures+

DCS systems 6 Inflation of

num4er of configured alarmsper operator station1

+h t . ' -


22/52


+hat .o you 'a1e-

Seminar Attendees:

)uestion>1 %o& many configured alarmsdoes your plant have

)uestionA1 %o& many .perator stationsdoes your plant have

)uestionK1 %as an %"=.P ever revealedinformation overload and led toopera4ility improvements


23/52


Unfortunately incidents *re+focus attention

7 Esso -ong;ord

7 Total :unce;ield

7 :P efinery Te!as City

7 Te!aco efinery Milford %aven

Increased attention leads to regulation and

improvements

A E l )il2 d ' 3456


24/52


An Example & )il2ord 'a1en 3456

.n Ath uly >BB there &as a maHor e!plosion at the oil refinery at

Milford %aven Hointly o&ned 4y Te!aco and $ulf0 There &as plantdamage that cost a4out Q?M to repair0 There &as also t&o monthslost production from the complete plant and four months lostproduction from the area that &as damaged0 The plant o&ners &ereprosecuted and fined a total of QA@@,@@@ plus costs0

"larm system shortcomings &ere one maHor contri4utor to thisincident0 There &as a lightning striFe &hich caused a significant plantupset0 ;or several hours after the lightning striFe the operators &ere;or several hours after the lightning striFe the operators &ereheavily loaded &ith alarms at a rate estimated to 4e in e!cess of >heavily loaded &ith alarms at a rate estimated to 4e in e!cess of >every AK seconds0 During this period several operators failed toevery AK seconds0 During this period several operators failed toidentify the 4uild up of liLuid in a FnocFout vessel0identify the 4uild up of liLuid in a FnocFout vessel0 This eventuallyoverfilled and resulted in the e!plosion taFing place0 " num4er of

instrument faults contri4uted to the operating confusion0 " largenum4er of people *AR+ sustained minor inHuries as a result of thee!plosion, 4ut fortunately there &ere no maHor inHuries0

Source &S% CRR 244

A E l )il2 d ' 3456


25/52



Lesson 1 - Alarm System

6 The control displays and alarms did not aid operatives6 " process overvie& &ould have helped diagnosis

6 The alarms appeared faster than they could 4e responded toand Fey alarms &ere missed in the flood

6 ? of the A@@ alarms displayed as high priority, despitemany 4eing informative only safety critical alarms &ere not

distinguisha4le from the rest

Lesson 2 - Safety Management System (SMS)

SMS failures included1

6 The plant modification procedure did not prevent removal of

the flare FnocFout drum emptying facility6 The instrument maintenance system did not prevent @ of

instruments from 4eing defective

A E l )il2 d ' 3456


26/52



Lesson 3 - raining and competence

Training should include16 Clear guidance on ho& to manage unplanned events

6 Clear guidance on &hen to initiate emergency plant shutdo&n

6 Clear authority to initiate shutdo&n

Lesson !

6 Ultimate plant safety must not depend on operator response

)il2 d ' ' d T -


27/52


)il2ord 'a1en 'as ed To -

ecognition of the "larmManagement Pro4lem

Definition of "larm Metrics

EEMU" >B> *>BBB9A@@+

J0 and Many "larmImprovement Programs 4asedon EEMU" >B> $uidelines

9e careful +ith using this picture 88 Statistics and Averaging tend to hide real issues

Some EE)UA )etrics


28/52


Some EE)UA )etrics

Source %%M1A 232

Some EE)UA )etrics


29/52


Some EE)UA )etrics

Source %%M1A 232

Message: Start Measuring (our Alarm System!er'ormane )ompare and *a+e Ation


30/52


O,A( -..

/e +no at to measureand o to ompare

/e are engineers -

ets Start 3

4sing /at Frameor+ 5


31/52


6on7t start building your ouse itout a good

'oundation

Foundation:

"larm Philosophy *ules+ Management of Change

Monitoring # "ssesment


32/52


The S#78 % The Alarm )anagement i2ecycle

The lifecycle model is useful

in identifying thereLuirements andresponsi4ilities for

implementing an alarmmanagement system0

The lifecycle is applica4le forthe installation of ne& alarm

systems or managing ane!isting system0

Source #SA SP2;

The Alarm #hilosophy


33/52



Source #SA SP2;



34/52



The "larm Philosophy Document can 4e a small

document0


35/52


,irst ,ocus On-

3hen &riting an "larm Philosophy first ;ocus on1

>0 oles # esponsi4ilities

A0 "larm Prioritiation Method

K0


36/52


Roles 9 Responsi/ilities in Alarm)anagement


37/52


#re1ent (n2ormation O1ero0

"dopt a SinglePrioritiation Method1

>0 Classify the %ealth, Safety, Environment, ;inancial # eputationConseLuences

A0 Decide &hat .perator esponse Times you use to prioritie7 V K minutes N Immediate "ction7 K 6 >@ minutes N S&ift "ction

7 >@ minutes W N TaFe "ction

K0 Decide levels for ConseLuences of no esponse, f0e!017 Small Immediate "ction reLuired 4ut Small ConseLuence N -.3

Priority7 Moderate Immediate "ction reLuired 4ut Medium ConseLuence N

%I$% Priority7 8ig Immediate "ction reLuired 4ut Severe ConseLuence NEME$E/C' Priority

Example )atrix


38/52


Example )atrix

Set Targets


39/52


Set Targets

Set Targets for1

7 "verage "larm ate per time period*day9hour9minute+ X R per hour

7 Percentage of hours containing morethan WN / alarms 6 A N > hoursper month in flood condition

7 Percentage contri4ution of the top >@most freLuent alarms to the overallalarm load

7 /um4er of standing alarms on any day7 "nnunciated priority distri4ution

during alarm flood7 "nnunciated priority distri4ution in

steady operation7 The top >@ most freLuent

disa4led9ena4led alarms0

7 The top >@ most freLuent inhi4itedalarms0

< X R per hour

< A N > hours per month in floodcondition

< V G *other&ise many 4ad actors+

< V G

< XG, >G, ?@ *Emergency, %igh-o&+

< V>, >@, B@ *Emergency, %igh-o&+

< V> of total configured alarms

< V > of total configured alarms

)onitor 9 Ta;e Action


40/52


)onitor 9 Ta;e Action

Monitor 3eeFly9:i3eeFly9Monthly

;ollo&ed 4y LuicF 4adactor mitigation to improve

Actual

'arget

(denti2y 9 (mpro1e


41/52


(denti2y 9 (mpro1e

:ad "ctor Mitigation is a LuicF&in solution *fi!es the

alarms that are a pro4lem no&+0

"larm Performance Monitoring may have identifiedfollo&ing Issues1

Priority Distri4ution is .ff

Too many alarms in sta4le operation

Too many alarms during and follo&ing trips

-arge num4er of disa4led alarms

ationalie1 rethinF and document your alarms

.ocument 9 Rationali


42/52


.ocument 9 Rationali0 Unit4yUnit

A0 ;ullscale

educe scope1 .nly rationaliethe alarms that actuallytriggered during the last >Amonths

Document and ationalieaccording to your rules inyour "larm Philosophy0

Alarm Rationali


43/52


Alarm Rationali


44/52


+hat .o you 'a1e-

Seminar Attendees:

)uestion >1 Does your plant9site have an"larm Philosophy

)uestion A1 Do you have clear metrics &here4yyou can measure system performance 00 "nddo you freLuently monitor these

)uestion K1 Do you have an alarm historian

)uestion 1 Do you store and audit changes onyour alarm configuration data

+here to Start-


45/52


+here to Start-

8=!J > ?ust experiened an Alarm Management >n'ormation Over'lo -/ere to Start:

>0 "larm Philosophy Document

A0 Use Current Systems Improve Procedures1

DocumentMeasure"udit

TaFe "ctions *3eeFly9:i3eeFly+

K0 Invest in "larm Systems1

"larm # Event %istoriationMaster "larm Configuration Data4ase"larm M.C *Electronic+."S'S"M

State :ased "larming9Shelving .perator "dvisories1 supporting the non routine situations educing the alarm load

Prevent "larm Storms &ith "larm Predictions

%MI improvements 1 sounds and presentation(

Foundation

6oument@Measure >mprove

=our Goal ->


46/52


=our Goal ->

$ood "larm Management Practices1

>0 "llo& your operator to focus on improving the processinstead of responding to the system

A0 esult in less stress and reduction of human failure

K0 esult in less e!cursions to the safety and integritylimits of your operations and as a result fe&er trips

and reduction of do&ntime


47/52


Ueason can help you in the entire "larm Management

-ifecycle1

"larm "&areness 3orFshops

-"larm Philosophy Development

-"larm ationaliation # Documentation

-"larm M.C-Measuring # Improving "larm

Systems Performance

-"larm Management Systems1

- "#E %istorian, "#E eporting,

Master "larm Data4ase,"larm M.C

- "dvanced "larm eduction


48/52


*an+ (ou 'or your Attention 33

uestions 355


49/52


)ontat 6etails:

Ueason -eiden

Pompoen&eg B

AKA>D< -eiden

@>GA?>@@&&&0Ueason0com

Presenters1

-ieven Du4ois1 ldu4oisYureason0com

ules .udmans1HoudmansYureason0com

,uture de1elopments
mailto:[email protected]:[email protected]:[email protected]:[email protected]


50/52


p

The average age of control room operators is high 6

Fno&ledge retention is 4ecoming more and more ahot topic

There is a change in &orFforce1

>0 %igher educated control room operators staying shortperiod of time *A9K yrs in control room+

A0 -o&er educated control room operators reLuiringsmarter systems helping them

Improved .perational Information *at the fingertips+ and.perator Training (

,uture de1elopments


51/52


p

IS" S>? is released this &ill lead to updated .S%"regulations in turn leading to investments inImproved "M procedures, eporting and Improved"larm Management systems

/e& regulations to follo& J


52/52

Furter reading:

IS" SP>?1

http199&&&0isa0org9MSTemplate0cfmSiteNSP>?,ZInstrumentZSignalsZandZ"larms

EEMU" >B>1http199&&&0eemua0co0uF9pZinstrumentation0htm

%SE C >RR1 IS:/1 @>R>G>G

%uman ;actors # "larm Management1http199&&&0hse0gov0uF9humanfactors9topics9alarmmanagement0htm
http://www.isa.org/MSTemplate.cfm?Site=SP18,_Instrument_Signals_and_Alarmshttp://www.isa.org/MSTemplate.cfm?Site=SP18,_Instrument_Signals_and_Alarmshttp://www.eemua.co.uk/p_instrumentation.htmhttp://www.hse.gov.uk/humanfactors/topics/alarm-management.htmhttp://www.hse.gov.uk/humanfactors/topics/alarm-management.htmhttp://www.hse.gov.uk/humanfactors/topics/alarm-management.htmhttp://www.hse.gov.uk/humanfactors/topics/alarm-management.htmhttp://www.eemua.co.uk/p_instrumentation.htmhttp://www.isa.org/MSTemplate.cfm?Site=SP18,_Instrument_Signals_and_Alarmshttp://www.isa.org/MSTemplate.cfm?Site=SP18,_Instrument_Signals_and_Alarms

Documents

Alarm Management Seminar