PTP-Global. Alarm Management An Introduction

Transcription

1 Alarm Management An Introduction

2 Presentation Contents 1. The Old and the New 2. Importance of Alarm Management & Historical Context 3. Guides, Standards and Regulations 4. Benefits & Design of Alarm Management 5. Alarm Issues

3 The Old Simple and clear alarms Alarm annunciators Hard wired alarms PTP-Global

4 The Scope of the Problem Operators typically monitor more than 5,000 devices Each device typically has 4 to 5 alarms configured on it Devices x alarms results in Operators having to manage 20,000 to 25,000 alarms The average Operator gets 1,200 alarms per day, approximately 1 per minute! Engineering Equipment & Materials Users Association (EEMUA) recommends no more than 6 alarms per hour PTP-Global

5 The Causes of the Problem Historically, alarms were expensive and difficult to add resulting in careful review before implementation Each had to be hardwired Limited space in control panels Today, hardware and software advances has made it possible to alarm most devices at minimal cost Large increase in the quantity of alarms Less review resulting in reduced quality

6 Fundamental ASM Problem

7 Why Grey Scale Graphics Directing operator s attention to the most critical information with the least possibility for confusion, slow response, or errors in detection or interpretation. addressing concerns with respect to individuals that might have color vision deficiencies reducing glare so ambient light levels are high enough to support both visual acuity for non-display tasks (e.g., reading paper copy) and also biological clock adjustments for the appropriate day or night shift PTP-Global

8 Basic principles of human sensation and perception To enhance situation awareness, techniques to enhance the salience of the associated display elements. An object is more salient than another object if it stands out or grabs one s attention. Important to emphasize abnormal states, off-normal conditions and dynamic data. If red means critical alarm state then it should not also mean a pump is off. The background display color in combination with the ambient light level of the control room can impact the probability of eye strain and fatigue as well as visual acuity. PTP-Global

9 Sources of Abnormal Events

10 Human Limitations

11 ASM Grey Scale

12 HMI Individual Graphic Migration PTP-Global Initial Process Graphic Enabling Scope Execution Migrated Statics Graphic Workpack Execution (Note: More than one Workpack will be required to complete dynamic element migration when elements from more than 1 Process System are present) 1234 Current MB300 dynamic elements Stage 1 Stage Partially Migrated Dynamics Graphic Stage N Migrated Process Graphic 15/07/2013 Rev

13 The Causes of the Problem Alarms are continuously added Often after incident reviews Changes in process After de-bottlenecking projects Equipment changes and degrades Different vendors with different normal operating conditions Wear resulting in reduced efficiency Seasonal changes to process

14 Common Problem Alarm Types Standing No dynamic process logic Nuisance Alarms Frequent Poor Set value/s Possible control problem Redundant Equipment out of service Alarms still functional Improperly Prioritised EEMUA recommends process alarm priorities of: 80% low, 15% medium and 5% high PTP-Global

15 ..and the New DCS systems installed Numerous free alarms Everything is turned on

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17 Alarm Timeline

18 Why is Alarm Management Important? Accident investigations have identified that: inadequate alarm system performance contributed to a significant number of industrial accidents Three Mile Island Piper Alpha Milford Haven Refinery Buncefield Oil Storage

19 Three Mile Island A series of of failures and operational errors occurred that resulted in the release of a measurable amount of radio active material into the air. Alarms are not applied properly The use of alarms is not fully understood Alarm systems can avoid these incidents

20 Piper Alpha Oil Rig An accumulation of errors and questionable decisions caused a catastrophic fire on the offshore platform causing 167 deaths and billions of dollars worth of damage PTP-Global Inadequate shift handovers Issues with false alarms

21 Texaco Milford Haven Refinery PTP-Global A severe electrical storm caused plant disturbances. An explosion that occurred five hours later was a combination of failures in management, equipment and control systems during the plant upset. Twenty-six people were injured and damage of 48 million was caused. Too many alarms that were poorly prioritised Control room displays did not help the operators to understand what was happening During the last 11 minutes before the explosion, the two operators had to recognise, acknowledge and act on 275 alarms

22 Buncefield Oil Storage PTP-Global In December 2005, a number of explosions occurred. A large fire engulfed a high proportion of the site. Over 40 people were injured; fortunately there were no fatalities. Alarms were not tested regularly

23 EMMUA 191 PTP-Global Alarm Systems: A Guide to Design, Management, and Procurement Not a standard or regulation Globally accepted as the benchmark for best practice Guidance on designing, managing and procuring alarm systems

24 ISA PTP-Global Management of Alarm Systems for the Process Industries Based upon the EEMUA 191 recommendations To address development, design, installation and management Aims to improve safety within process industries.

25 Alarm management is a process, not Alarm Philosophy Alarm Rationalization Implementation & Execution a product. Benchmarking &Assessment Analyze your system and understand your problems Maintenance Determine key performance metrics Operator workload Problem alarms Compare facility performance Gap analysis (you cannot improve what you cannot measure) Continuous Improvement

26 Alarm Management Lifecycle Benchmarking &Assessment Alarm Philosophy Alarm Rationalization Implementation & Execution Maintenance Continuous Improvement Corporate document that specifies Objectives of alarms Assign roles & responsibilities Procedures for defining alarms How to assign priorities Expected Operator responses Management of change

27 Alarm Management Lifecycle Benchmarking &Assessment Alarm Philosophy Alarm Rationalization Implementation & Execution Maintenance Continuous Improvement Systematic review and documentation of each configured/engineered alarmable tag in the DCS Store information in Alarm Database Objective is to optimize alarm quantity and quality Ongoing process, target 50 to 100 worst alarmable tag per day PTP-Global

28 Alarm Management Lifecycle Benchmarking &Assessment Alarm Philosophy Alarm Rationalization Implementation & Execution Maintenance Continuous Improvement Implement alarm strategy on DCS Implement advanced alarming strategies Alarm shelving Temporary disabling of alarms depending on process state Dynamic alarming Change alarm limits depending on process state Alarm grouping Use top level alarm to summarize multiple ones (with drill-down capability) Alarm eclipsing Disable an H alarm if the HH alarm limit is reached

29 Alarm Management Lifecycle Benchmarking &Assessment Alarm Philosophy Alarm Rationalization Implementation & Execution Integrate into work practices and embed into company culture Prevent unauthorized changes Track changes made Monitor performance Maintenance Continuous Improvement

30 Alarm Management Lifecycle Benchmarking &Assessment Alarm Philosophy Alarm Rationalization Implementation & Execution Analyze alarm floods during upsets Frequent intervention analysis Identify opportunities for additional process automation (supervisory control) Maintenance Continuous Improvement

31 Benefits of Alarm Management Compliance with best practice Improved safety measures Reduced maintenance costs and better plant operation Improves production and Human performance Reduces operator workload Improved shift handovers Reduced insurance rates

32 Well Designed Alarm Management The purpose of an alarm system is to direct the operator s attention towards plant conditions requiring timely assessment or action Alert, inform and guide the operators Prevent unnecessary shutdown Only present the operator with useful and relevant alarms Use prioritisation to highlight critical alarms Have a detailed response to each alarm Allow enough time for the operator to respond

33 Number of Alarms Number of Installed Alarms per operator Number Configured Under Over 1000 Simple A major technology. alarm system, Risk which that the will operator require significant and the Mixed Sophisticated annunciator computer and computer-based alarm handling alarm with display alarm investment systems throughout may have its a life safety cycle role and that which is not needs fully to can powerful be effective. tools for If logical purely processing computer based and suppression displays are of appreciated. Also poor alarm system performance may alarms is very desirable - possibly in combination with Common sense suggests that, in general, the more alarms installed per operator, the greater be developed the likelihood and maintained of problems to the with best spurious practices used, then the alarm system may not have to be alarms, high alarm rates, not available be etc. recognised within On the industry and other given if hand, it is management to a work small well. number priority sophisticated, individual displays but is of does critical need alarms. good Significant tools for dealing effort of alarms should not be with has viewed to basic be as expended problems, necessarily on e.g. ensuring desirable repeating a consistent alarms, as this alarms may and mean that the operator from will out be of unaware service plant. of important Effort should events. be put A into balance has to be struck, identifying and it key is inevitable alarms and that ensuring on a that large they complex are clearly require displayed. involvement Management of a team of commitment engineering needs and to plant a large number of alarms will be required. (7) considered approach to the design of individual alarms. The optimisation of operational performance is likely to be operational made to staff solve for operational several months. problems, but much may often be achievable with relatively little effort

34 Average Alarm Findings EMMUA Oil & Gas PetroChem Power Other Average Alarms per Day Average Standing Alarms Peak Alarms per 10 Minutes Average Alarms/ 10 Minute Interval Distribution % (Low/Med/High) /15/5 25/40/35 25/40/35 25/40/35 25/40/35

35 Alarm Issues Priority (1) Priority of Alarm Critical (emergency) Number Configured 20 (Total) High 5% Medium 15% Low 80% EMMUA Oil & Gas PetroChem Power Other Distribution % (Low/Med/High) 80/15/5 25/40/35 25/40/35 25/40/35 25/40/35

36 Alarm Issues Flooding Alarm activations occur so fast that the operator becomes flooded by them and is unable to distinguish useful information, which can cause: The operator may work on a less important alarm, or Attempt to struggle with all of the alarms, or Give up completely on the alarm system

37 More Alarm Issues Chattering Alarms Comes in and clears at least three times in one minute Nuisance Alarms bad actors Where a few number of alarms cause significant amount of alarm activations. Masking Where an alarm sound cannot be heard above typical noise levels

38 What Companies are Currently Providing Very limited analysing alarm log on DCS Data being stored in Printer replacement products Issues limit access to data, normally 1-2 weeks history Extracting data to Excel and performing frequency DCS Limited systems Analysis are designed Frequency to run the process not generate alarm Very reports Collection Slow to of access data required can be manual; data going to the data source Database If data logs, can be data limited has to size, be only conditioned several very months complex history Very time consuming, can take several hours

39 What is an Analyser Displays Real-time Key Performance Indicators (KPI) KPI display for Systems, Area s and Connectors Seamless integration between displays Handover End of Shift Reports Improved Performance for Frequency Analysis Pre-formatted Reports Simple to use

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41 Impact on data processing 2 We might forget or fail to remember important information 2 referring to our memory store 1 We might misread something, we might miss something important, we might choose to focus on certain things rather than others 3 We process the information and make decisions 3 We might make the wrong connections, we may not have all of the facts, we might make the wrong assumptions 4 We act accordingly in line with the decision made 1 We take in information through our senses 4 We might select the wrong response, we might set out to act in one way but get clumsy

42 Conclusion Understanding ASM. Focus on issues that provide a better understanding of ASM, insight into reducing future incidents and prepare ops teams to handle abnormal situations as they do occur. Training and skill development. Focus on anticipating and coping with abnormal situations. Communications. Critical to communicate issues to plant personnel using technology during normal, abnormal and ER situations. Procedural Operations. Focus on procedures to accomplish important tasks particularly during start-up and shut-down. Process Monitoring and control. Focus on automation technologies for effective operations. PTP-Global

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