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Standards
Certification
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Alarm ManagementSolutions
Enabling Operator Effectiveness byImproving Alarm Management Strategy
2014 ISA Water / Wastewater and Automatic Controls SymposiumAugust 5-7, 2014 – Orlando, Florida, USA
Speaker: Tom Maczuzak
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA 2
Presenter: Tom Maczuzak
• Over 20 years of I&C experience.
• Various types of plants in municipal water,
electric generation and industrial sectors.
• Specializes in Advanced Alarm Management.
• MA, MBA, JD degrees.
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA 3
Presentation Outline
• How big is the problem?
• How the problem came to be
• ISA 18.2
• Alarm management solutions
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
• Do you recognize any of these behaviours?
– Operators acknowledge / silence alarms without lookingat or acting on them?
– Alarm horns turned off?
– Operators don't know what a particular alarm means?
– Alarms disabled / suppressed for long periods withoutreview?
• Do you measure?
– Number of alarms / hour?
– Number of alarms disabled / suppressed?
– Time to silence / acknowledge?
How is your Alarm System Performing
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
10) You always need to scroll your alarm list9) Your SOP only says “Acknowledge the alarm”8) Constantly pressing the “Silence” button7) Use the “Ack All” feature way too often6) A&E historian fills up every 3 months5) You have one value for H, HH and HHH limits4) All alarms are ‘High’ priority3) Nervous when the ‘usual alarms’ are missing2) Make bets on what the next alarm will be!1) Active alarm dated 8-Aug-2009 09:34:00
Top 10 signs you may have problem
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Example Alarm Issues Found at Sites
120 Alarms/hr385 standingalarms
>100 alarms inalarm summaryAlarm prioritiesare mixed (sortedon time)
No formal changecontrolWho canchange? Whocan approve?No formal
rationalizationprocess -Should it even bean alarm?
Manually writtenreports in logbookNo periodicreports
Missing orincomplete alarmresponseNo SOP
Alarm burstshappenfrequently
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Alarm Management - Then and Now
Then: number of alarmswas limited by the physicalspace in the control room
• Discrete panel boards
• More important alarms,closer to the operator
Now: DCS & SCADA –virtually no limit to the numberof alarms
“Alarms are presumed free”results in tidal waves ofalarms
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
What is alarm system management?
• Alarm management is not a product, feature set, or a onetime implementation activity
• Alarm management is part of a site strategy
– Established by company management
– Starts with an alarm philosophy
– Must include a clear owner, procedures, and the rolesand responsibilities of all involved
– Extends to the system configuration, maintenanceand resolution of issues
– Ensuring the strategy is followed - enforcement
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
ISA 18.2 Alarm Management Lifecycle
Establish terminologyand practices for alarmsystems to effectivelymaintain an alarmsystem over time
Key PerformanceIndicators (KPI) -measure the quality ofthe alarm system
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Alarm Philosophy Document (ISA 18.2)
The first step
Document thatdescribes howalarms shouldwork in a plant
Defines aconsistent alarmphilosophy for allsystems
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Alarm Philosophy Document (ISA 18.2)
Process ofconfiguring andreviewing alarmsagainst theprinciples of thealarm philosophy
Determining anddocumenting therationale anddesign
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Alarm Philosophy Document (ISA 18.2)
Continuousmonitoringmechanism needsto be implemented
Compares thecurrent with thedesired quality
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Alarm Philosophy Document (ISA 18.2)
Most-frequent alarms
Longest-standingalarms
Average time toacknowledge
Alarm prioritydistribution
Number of alarmsdisabled, inhibited,shelved andhidden…
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Tools to Identify Problem Areas
Alarm & Events Over time and Alarm & Event FrequencyReports identify problem area
Alarm rate as f(t)
Alarmsordered byfrequency
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Identify ‘Bad-Actor’ Alarms
Use an Alarm and/or Event Frequency tool to view the mostfrequent alarms - Simply specify a time period and run areport…
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Acceptable Alarm Rates KPI
Measure the quality of the alarm system - benchmarksAlarm Rates / Time
X
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Priority Distribution KPI
Measure the priority distribution against the prioritydistribution guidelines
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
• How many standing alarms do I have atany given time?
• What do I do in an alarm burst situation?• Do I have well defined SOPs for alarm
response?• Do I keep track of your alarm setpoint
changes?• What is the priority distribution of my
alarms?• Are my alarms rationalized?• What’s my average alarm rate?• How do my operators react when they see
a high priority alarm pop up?
Summary - Recognizing the Problem
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
• Understand the whole picture– Map goals to the ISA standard– Map your organization to processes– Map Goals DCS capabilities
• Maximize use of HMI tools and capabilities
• Follow a structured approach
Summary - Reaching a Solution
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Example alarm analysis tools
• Instantaneous reports
• Alarm / Event frequency
• Alarms over time
• Priority distribution
• Alarm duration
• Time to acknowledge
• Alarm performance
• Operator actions
• Standing alarms
• Co-occurences
Summary - Use Modern Tools
2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA
Contact information
If you have further questions , please contact me at:
PRESENTER Tom Maczuzak
COMPANY ABB, Inc.
CONTACT PHONE (440) 585-6862
CONTACT E-MAIL [email protected]