alarm management seminar
DESCRIPTION
Alarm Management SeminarTRANSCRIPT
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Bergen op Zoom Seminar
February 2011
Alarm ManagementPrinciples & Guidance
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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
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Agenda
Introduction to Ueason
E!ample Cases
"larm Management Principals # $uidance
%o& Ueason can help 'ou(
)uestions # Discussion
*Every attendee &ill receive the presentation+
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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
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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> $uideline
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Example: Northsea Gas producer
Scope of Supply:- Alarm Management Survey
- Philosophy Development
- Support Alarm Rationalization-Performance Auditing-Advanced Alarm Management System
for Onshore Centralized Control Room
DCS: o!"oro #A
A$% &istorian: 'iPS (ogMate
Alarm Reporting: OAS)S-AM
Advanced Alarm Management: OAS)S-AM
Alarm redution on platforms,8isionary "pproach for Centralied Control oom
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.vervie& of the redutionrealied, varying 4et&een "0#6 $%#
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Example: yondell!asell
Scope of Supply:
- Rule Discovery from &istorical Data
- Alarm Display Replacement
- Alarm Predictions in Control Room
Corporate Agreement Advanced Dynamic Alarm Management
DCS: %merson Delta*
Data: 'iPS (ogMate
%merson OPC
Advanced Alarm Management:
OAS)S-AM
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Example: "hemical #lant Germany
Proactive A! informationon gas leaFs
8ision9Smell # SoundSensors Com4ined
.perators dont have to do a>A hours plant inspection
Important for Feeping licenceto operate
Operator Advisories
Interfaces: Emerson, ABB,
Siemens
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Example: Re$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
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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
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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 " # :
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Siemens & #()A*
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Siemens & #()A*
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"larm Management
Principles # $uidance
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ust imagine J you drove to
this seminar and every A9Kminutes an alarm &ent off
:reaFs are overheating
-eft front tire pressure
is do&n.il Temperature
drifting to %igh
J0
Andyou &ere also e!pected to find your &ay, drive safefully,listen to the radio for traffic Hams and decide on alternative routesJ
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00 our car and our driver
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+hy ,ocus on Alarm )anagement -
"4normal conditions cost 4illions annually1
6 -oss of eLuipment and life
6 .ffspec Product and -ost Production *K? per year+
6 Environmental E!cursions and emediation
MaHor contri4uting factors include16 Information .verflo&
6 Poorly Designed .perator Interfaces
6 InadeLuate "larm Management System
Alarm Management is reogni&ed as a signi'iantplant reliability improvement
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The Alarm System & .e$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
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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
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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
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' did t h -
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'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 . ' -
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+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
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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
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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
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An Example & )il2ord 'a1en 3456
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
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An Example & )il2ord 'a1en 3456
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 -
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)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
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Some EE)UA )etrics
Source %%M1A 232
Some EE)UA )etrics
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Some EE)UA )etrics
Source %%M1A 232
Message: Start Measuring (our Alarm System!er'ormane )ompare and *a+e Ation
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O,A( -..
/e +no at to measureand o to ompare
/e are engineers -
ets Start 3
4sing /at Frameor+ 5
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6on7t start building your ouse itout a good
'oundation
Foundation:
"larm Philosophy *ules+ Management of Change
Monitoring # "ssesment
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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
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The Alarm #hilosophy
Source #SA SP2;
The Alarm #hilosophy
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The Alarm #hilosophy
The "larm Philosophy Document can 4e a small
document0
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,irst ,ocus On-
3hen &riting an "larm Philosophy first ;ocus on1
>0 oles # esponsi4ilities
A0 "larm Prioritiation Method
K0
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Roles 9 Responsi/ilities in Alarm)anagement
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#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
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Example )atrix
Set Targets
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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
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)onitor 9 Ta;e Action
Monitor 3eeFly9:i3eeFly9Monthly
;ollo&ed 4y LuicF 4adactor mitigation to improve
Actual
'arget
(denti2y 9 (mpro1e
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(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
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.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
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Alarm Rationali
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+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-
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+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 ->
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=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
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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
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*an+ (ou 'or your Attention 33
uestions 355
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)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] -
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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
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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
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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