Alarm Management Strategy for the technical optimization of a Power Plant Alarm System. Company Ansaldo Energia. POWER-GEN Middle East 2014

Transcription

1 Alarm Management Strategy for the technical optimization of a Power Plant Alarm System Author Fabio Piccardo Company Ansaldo Energia Country Italy POWER-GEN Middle East 2014 Abu Dhabi, 13 October 2014 Pag.

2 Alarm Management Strategy for the technical optimization of a Power Plant Alarm System Background Ansaldo s configuration model Alarm system optimization Conclusion Pag.

3 Background Alarm System assit the operator to - detect process problems - identify action requests - prioritize act Pag. 3

4 Background Awareness Situations EEMUA (191) ISA (S18) API (1167) NAMUR (NA102) Abnormal Alarm Situation Management Management Workgroup Consortium Best practices Alarm management guidelines Pag. 4

5 Alarm Management Strategy for the technical optimization of a Power Plant Alarm System Background Ansaldo s configuration model Alarm system optimization Conclusion Pag. 5

6 What is an ALARM? Alarm is a message about a deviation of the process from the desired state that requires an immediate response from the operator Ansaldo Energia s configuration model What are the goals of the alarms? Allow the Operators - to understand an occurrence in the way clearest possible - to have quickly decision on the action to undertake in order to safety complete the production programs Pag. 6

7 Plant Ansaldo Energia s configuration model Control Room Synoptic Alarm page Pag. 7

8 Ansaldo Energia s configuration model Alarm Group & Sub-Group Root visualization Customizable To simplify the context identification of the occurrence where each alarm is generated Pag. 8

9 Ansaldo Energia s configuration model Priority Graphic visualization (color) Standardized assignment Customizable Description 3 fields description Standardized words Customizable To quickly identify the action to undertake to safety complete the production programs Pag. 9

10 Ansaldo Energia s configuration model Priority Graphic visualization (color) Standardized assignment Customizable Description 3 fields description Standardized words Customizable To quickly identify the action to undertake to safety complete the production programs Pag. 10

11 Priority Ansaldo Energia s configuration model Pag. 11

12 Priority Ansaldo Energia s configuration model Priority 1 "Trip Causes" are classified the alarms on which typically the operator hasn t the opportunity of intervention. On this alarm type could be necessary a post event analysis. Even though the plant will be out of service, the operator will have the information necessary to understand what s happened and by an adequate graphic representation on the devoted supervision monitor (Log of Sequence of Events, graphic Representation of the Trip, "First Out" Function), to clearly understand the actual Plant status. These alarms must be visualized in "Alarms Page". Time for operator action: 0s Pag. 12

13 Priority Ansaldo Energia s configuration model Priority 2 and Priority 3 are classified the High Priority alarms. This typology of alarm must be immediately visible and the description must be auto-explanatory. All the pre-alarm, on the process variable which can be cause of Plant Trip, must classified to Priority 2. These alarms must be visualized in "Alarms Page Time for operator action: 1-3 min. Pag. 13

14 Priority Ansaldo Energia s configuration model Priority 4 are classified the Low Priority alarms. In case of an occurrence the production programs must be permitted without limitations also without operator s action. For an occurrence alarmed belonging to this category, the immediate solutions are acted autonomously by the automation system. These alarms can be visualized in "Alarms Page". Time for operator action: n.d. Pag. 14

15 Ansaldo Energia s configuration model Priority Priority 5 are classified the messages of hardware or software diagnostic and the messages that tell some meaningful change of state or condition of systems and components of plant. Generally they don't need action from the operator. These alarms are stored in the file, the chronological (historical) events and typically they haven t to be visualized in "Alarms Page" but exceptions are possible. The events to this class of messages, must be immediately visible to the operator through variations in the graphic representation in process video pages (for example changing the colour of a component or a changing a text). Time for operator action: n.d. Pag. 15

16 Priority Ansaldo Energia s configuration model Events are classified the messages that communicate the status change or the condition of systems and/or plant components. They don't require action from the operator. The belonging events to these classes must be recorded in the chronological events file and they aren t visualized in "Page Alarms." The events must be immediately visible to the operator through variations in the video graphic representation Time for operator action: n.d. Pag. 16

17 Priority Ansaldo Energia s configuration model Standardized assignment Default Priority Assignment for Software standard Macro Logics - MACRO for 2 and 3 states device - MACRO for PID and A/M station - MACRO for stand-by selection - MACRO for double/triple analogic signal treatment - MACRO for analogic measure - MACRO for digital status treatment Pag. 17

18 Priority Ansaldo Energia s configuration model Standardized assignment Default Priority Assignment for Software standard Macro Logics - MACRO for 2 and 3 states device - MACRO for PID and A/M station - MACRO for stand-by selection - MACRO for double/triple analogic signal treatment - MACRO for analogic measure - MACRO for digital status treatment Pag. 18

19 Priority Ansaldo Energia s configuration model - MACRO for 2 and 3 states device - Status discrepancy - Protection command - MACRO for PID and A/M station - Feedback bad quality - MACRO for stand-by selection - Command failed (after time out) - MACRO for double/triple analogic signal - Undervoltage treatment (for motor driver only) - Unavailability (electrical equipment racked out) - MACRO for analogic measure - Torque switch (for motor-actuated valves only) - MACRO for digital status treatment Pag. 19

20 Priority Ansaldo Energia s configuration model - MACRO for 2 and 3 states device - MACRO for PID and A/M station - Automatic to Manual mode switch - MACRO for stand-by selection - MACRO for double/triple analogic signal treatment - MACRO for analogic measure - MACRO for digital status treatment Pag. 20

21 Priority Ansaldo Energia s configuration model - MACRO for 2 and 3 states device - MACRO for PID and A/M station - MACRO for stand-by selection - Requested number of running device not - MACRO for double/triple analogic signal congruent treatment to the actual state (after time-out expired) - MACRO for analogic measure - MACRO for digital status treatment Pag. 21

22 Priority - MACRO for 2 and 3 states device - MACRO for PID and A/M station - MACRO for stand-by selection - MACRO for double/triple analogic signal treatment - MACRO for analogic measure - MACRO for digital status treatment Ansaldo Energia s configuration model - Cumulative - High deviation - 1ooX bad Pag. 22

23 Priority Ansaldo Energia s configuration model - MACRO for 2 and 3 states device - MACRO for PID and A/M station - MACRO for stand-by selection - MACRO for double/triple analogic signal treatment - MACRO for analogic measure - Threshold - MACRO for digital status treatment Pag. 23

24 Priority Ansaldo Energia s configuration model - MACRO for 2 and 3 states device - MACRO for PID and A/M station - MACRO for stand-by selection - MACRO for double/triple analogic signal treatment - MACRO for analogic measure - MACRO for digital status treatment - Threshold Pag. 24

25 Attributes Ansaldo Energia s configuration model Inhibition criterions on the visualization of the alarm in the Alarm Page SCOPE: to avoid the flood for irrelevant information that could confuse the Operators - Suppression for "Plant not in Operation - Time delay for transitory phenomena - Dead band Pag. 25

26 Description Ansaldo Energia s configuration model Criterions for Alarm Page the descriptive fields SCOPE: to understand an occurrence quickly and in the way clearest possible - Pre-defined fields collect the information - Closed dictionary for Words & Abbreviation Pag. 26

27 Description Ansaldo Energia s configuration model - Pre-defined fields collect the information - Closed dictionary for Words & Abbreviation Pag. 27

28 Description Ansaldo Energia s configuration model - Pre-defined fields collect the information - Closed dictionary for Words & Abbreviation - System/Component - Measure/Designation - Status Pag. 28

29 Description Ansaldo Energia s configuration model - Pre-defined fields collect the information - Closed dictionary for Words & Abbreviation - for systems and components - for process fluids - for measures - for digital status Pag. 29

30 Alarm Management Strategy for the technical optimization of a Power Plant Alarm System Background Ansaldo s configuration model Alarm system optimization Conclusion Pag.

31 Alarm System Optimization Awareness Situations EEMUA (191) ISA (S18) API (1167) NAMUR (NA102) Abnormal Alarm Situation Management Management Workgroup Consortium Best practices Alarm management guidelines Pag. 31

32 Measuring performance Alarm System Optimization EEMUA (191) ISA (S18) API (1167) NAMUR (NA102) EEMUA (191) - Average Alarm Rate - Maximum Alarm Rate Evaluations are performed on the Plant commissioned - Alarm Rates outside of acceptability target Checks are performed analyzing the alarm alerting for Alarm Group and Sub Alarm Group Any Alarm Group is object to a complete analysis to evaluate the alarming in operational conditions Pag. 32

33 Measuring performance Alarm System Optimization EEMUA (191) Average Alarm Rate target 1 alarm within 10 minutes per Operator Evaluations are performed on the Plant commissioned Checks are performed analyzing the alarm alerting for Alarm Group and Sub Alarm Group Any Alarm Group is object to a complete analysis to evaluate the alarming in operational conditions Pag. 33

34 Measuring performance Alarm System Optimization TARGET EEMUA (191) Stable Deviation from the final target is analyzed for any Alarm Group/Sub Alarm Group Pag. 34

35 Measuring performance Alarm System Optimization AUDIT wrong alarm priority assignation, threshold not properly set OPERATIVE CICLIC CHECK RELEASED Deviation from the final target is analyzed for any Alarm Group/Sub Alarm Group Pag. 35

36 Start Alarm System Optimization Does Alarm require Operator action? YES Can the Operator respond in the available time? YES Is the Alarm configurable by the Operator? NO Alarm is properly set NO NO YES Is Alarm warning of hazard? NO YES Does the the occurrence still defined still defined Alarm? Alarm? NO Plant Automation System (ESD) is devoted to undertake actions YES Decrease the designed prioritization of the alarm Change occurrence assignment from Alarm to Event Alarm is properly set Revise the logic configuration increasing the automatic action by Plant Automation System Check for alarm aggregation (new cumulative alarm) End, check another alarm Pag. 36

37 Start Alarm System Optimization Does Alarm require Operator action? YES Can the Operator respond in the available time? YES Is the Alarm configurable by the Operator? NO Alarm is properly set NO NO YES Is Alarm warning of hazard? NO Does the the occurrence still defined still defined Alarm? YES Alarm? NO Plant Automation System (ESD) is devoted to undertake actions YES Decrease the designed prioritization of the alarm Change occurrence assignment from Alarm to Event Alarm is properly set Revise the logic configuration increasing the automatic action by Plant Automation System Check for alarm aggregation (new cumulative alarm) End, check another alarm Pag. 37

38 Alarm Management Strategy for the technical optimization of a Power Plant Alarm System Background Ansaldo s configuration model Alarm system optimization Conclusion Genova Pag.

39 Summary Conclusion Alarm System is an essential part of the Plant interfaces and it has an important role to assist the Operators - to detect process problems that require his intervention - to prioritize his response Poor alarm management is a leading causes of unplanned downtime and industrial incidents Too many alarm annunciation is one of the main Plant operational issue Pag.

40 Summary Conclusion A good Alarm System is the application of instrumentation engineering, plant design and human factors Improving alarm handling is not a on-off project: it have to be managed in a systematic way as part of safety and quality assurance management system Pag.

41 Thank you for attention Pag. 41

42 Alarm Management Strategy for the technical optimization of a Power Plant Alarm System Author Fabio Piccardo Company Ansaldo Energia Country Italy POWER-GEN Middle East 2014 Abu Dhabi, 13 October 2014 fabio.piccardo@aen.ansaldo.it Pag.