Download - Six Sigma Project Six Sigma Project
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Six Sigma ProjectSix Sigma Project
Alarm ManagementAlarm Management
2005-2006
Brent J. ThomasBrent J. Thomas
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Define PhaseDefine Phase
Alarm Management Measure Analyze Improve ControlDefine
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IdentificationGreen Belt: Brent J. Thomas
Black Belt Advisors: Aimee S. Anani, Mark L. Olson
Plant / Location: Soda Springs, Idaho
Project Title: DCS Alarm Management
Champion / Management Sponsor: Paul H. Kraus
Plant Manager: Bruce E. Pallante
Accounting Contact: Helen K. Smith
Start Date: 11-01-04
Completion date: August 31, 2006
Measure Analyze Improve ControlDefineAlarm Management
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Alarm Management
Operator Intervention
DCS Intervention
Interlocks and emergency procedures
Normal Operation =Upset Condition =
Target Operation =
High =
Low =Alarm Boundaries:
Medium =
Process Description
Measure Analyze Improve ControlDefine
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Alarm Management Measure Analyze Improve ControlDefine
•Too Many Alarms•Alarms that don’t mean anything desensitize operators to real ones
•Too Many Alarms At Once•Alarm floods allow no reaction time
•Too Many Alarms Have No Defined Response•Operators sometimes have no way of reacting to an alarm
•Poor Alarming Practices Blamed For Several Incidents•Three Mile Island and Chernobyl are examples
Problem Description
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Monsanto Alarm Management Team: Matt Rollinson Luling, Team Lead
Mark Gamel Luling
Andrew Johnson Luling
Edward McGinnis Luling
Jack Ahlers Muscatine
Kurt Schlawin Muscatine
Andre Divino Sao Jose dos Campos
Luiz Dourado Camacari
Jose Neto Camacari
David Mourino Zarate
Johnny Ollivier Antwerp
Brent Thomas Soda Springs
Measure Analyze Improve ControlDefine
Human ResourcesSoda Springs Alarm Management Team:
Doug Beauregard Manufacturing, Team Lead
Aimee Anani p4 production
Brian Kemmerer Burden Prep
Reggie Kuzet Maintenance
Brent Thomas Process Control
Soda Springs Alarm Rationalization Team: Aimee Anani p4 Production, Team Lead
Troy Carver Furnace Operations Specialist
Matt Kirby Furnace ESH Representative
Brock Sherman Furnace Process Engineer
Kenny Rasmussen Furnace Control Operator
Vaughn Mickleson Furnace Control Operator
Rick Hendricks Furnace Control Operator
Aaron Tarbet Furnace Control Operator
Brent Thomas Process Control
Alarm Management
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Measure Analyze Improve ControlDefineAlarm Management
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Solution1) Develop an Alarm Management Philosophy
2) Select alarm metrics
3) Assess present alarm system (Measure - Analyze phases of this project)
4) Reduce nuisance alarms (Analyze - Improve phases)
5) Rationalize alarms by need and priority (Improve phase)
6) Develop alarm configuration database (Improve – Control phases)
7) Implement knowledge-based alarming where appropriate
Alarm Management Measure Analyze Improve ControlDefine
Conclusions of Cause and Effect Analysis• We do a good job of selecting and maintaining instrumentation.
• Our methods were the root cause of the alarm system state – we had no philosophy or guidelines for configuring alarms
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Steps in an Alarm Management Project
1) Develop an Alarm Management Philosophy1) Every alarm will be rationalized by need and priority
2) Every audible alarm will have a defined response
3) Each response will have an appropriate response time
4) Alarm system metrics will be defined, measured, and reported
5) A continuous improvement process will monitor alarm system performance, identify meaningful opportunities for improvement and implement them
Alarm Management Measure Analyze Improve ControlDefine
Project Planning
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2) Select Alarm MetricsMonsanto established a corporate wide initiative to improve alarm system
performance at all locations after an incident occurred that was partly due to a
poor alarm system design. A corporate alarm team was chartered which agreed on
a set of metrics. The Average Alarm Rate is used most in this project.
Average Alarm Rate: Average number of alarms per hour per day.
Operator Loading: Number of 10 minute periods per day with 10 or more alarms.
Also reporting:Standing Alarms – alarms that exceed 24 hours in duration.
Alarms per console point count
Alarms per plant process area
Steps in an Alarm Management Project
Alarm Management Measure Analyze Improve ControlDefine
Project Planning
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Project Scope: The scope of this project will be limited to alarms generated by the electronic Distributed Control Systems at Soda Springs. It will not include hardwire panel alarms although those are addressed by the Alarm Team. It will be limited to the #9 furnace area of the Soda Springs process. #9 furnace was chosen because it is scheduled for conversion from PRoVOX to DeltaV control in early 2006. DeltaV has a number of alarm management tools that would facilitate the redesigned alarm management process.
Customers: Internal: Paul Kraus, P4 Production process owner, furnace operations, and furnace maintenance.
Customer CTQ: Alarms that are meaningful and help operators avoid upsets that impact safety, quality, and production.
Alarm Management Measure Analyze Improve ControlDefine
Project Planning
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Measure PhaseMeasure Phase
Define Measure Analyze Improve ControlAlarm Management
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3) Assess present alarm system
Steps in an Alarm Management Project
Alarm Management
Assessment
First the present alarm management system needed to be upgraded. LogMate, from TiPS, Inc., had been in use since 1992 but was little more than an event historian. It was not compatible with DeltaV or the new DVOP (DeltaV Operate for PRoVOX) consoles that were in development.
A new network-based version compatible with PRoVOX, DVOP, and DeltaV was available. The new version also posessed considerable analysis capability and the ability to document and manage the alarm configuration in the control system.
Resources from TiPS, Inc., the company that produces LogMate were used often during the project. Training was conducted for the Alarm Management Steering Team in March of 2005 and March of 2006. The product was upgraded three times during the project to enable it to provide tools for the analysis, improvement, and control phases. Some tools were added to LogMate by TiPS, Inc. at Monsanto’s request.
Define Measure Analyze Improve Control
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DVOP Console*.csv files
Event_Journal (Access database)
ASCII Capture port
LogMATE Capture
NetView – SOE (sequence of
events)
TRAC - Data Historian
Integration
TRAC – Key Performance
indicators
Alarm Rationalization
ACE – Bad Actors (80/20 Rule)
OPC Capture port
Alarm Generated in PRoVOX
Alarm Generated in DeltaV
PRoVOX and DeltaV
configuration databases
Alarm Knowledge
Base
Automated Alarm Activity Reports –
Email Notice
Measurement System
Alarm Management Define Measure Analyze Improve Control
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Define Measure Analyze Improve ControlAlarm Management
Measurement System
Define Measure Analyze Improve Control
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Process Characterization
Define Measure Analyze Improve ControlAlarm Management
Furnace roof pressure
5 of the 10 most common events are network
integrity errors
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Define Measure Analyze Improve ControlAlarm Management
Measurement System
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Process Characterization
Define Measure Analyze Improve ControlAlarm Management
Furnace roof pressure
Duplicate point
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Count 108 65 58 1551888 355 313 153 152 146 140 112Percent 3.0 1.8 1.6 4.351.8 9.7 8.6 4.2 4.2 4.0 3.8 3.1Cum % 92.4 94.2 95.7 100.051.8 61.5 70.1 74.3 78.5 82.5 86.3 89.4
Coun
t
Perc
ent
TagsOthe
r
TI93
5-3
LI949
-1
PI956
-3
ZS93
7-6
ES97
2-1
PC96
0-1
EI935
M-5
EI935
-5
PI956
6-4
TI96
00-7
PC93
6-1
4000
3000
2000
1000
0
100
80
60
40
20
0
Pareto Chart of Furnace 9 Alarms
Define Measure Analyze Improve ControlAlarm Management
More than half are furnace roof pressure
Duplicate point
Process Characterization
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Define Measure Analyze Improve ControlAlarm Management
pressure deviation activated 83 times
of those 83, the high alarm activated 61 times within 10
seconds
furnace pressure A alarm (deviation)
Process Characterizationfurnace pressure C
alarm (high)
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Define Measure Analyze Improve ControlAlarm Management
furnace pressure A alarm (deviation)
furnace pressure C alarm (high)
Process Characterization
duplicate point
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Count 112 108 65 58 1551083 795 355 313 153 152 146 140Percent 3 3 2 2 430 22 10 9 4 4 4 4Cum % 89 92 94 96 10030 52 61 70 74 78 82 86
Coun
t
Perc
ent
TagsOthe
r
TI93
5-3
LI949
-1
PI956
-3
ZS93
7-6
ES97
2-1
PC96
0-1
EI935
M-5
EI935
-5
PI956
6-4
TI9600
-7
PC93
6-1.h
igh
PC93
6-1.de
v
4000
3000
2000
1000
0
100
80
60
40
20
0
Pareto Chart of Furnace 9 Alarms
Define Measure Analyze Improve ControlAlarm Management
roof pressure high and deviation alarms
separated
Process Characterization
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Define Measure Analyze Improve ControlAlarm Management
roof pressure alarms removed
from data
Count 58 54 51 50355 313 152 146 140 112 108 65Percent 3.6 3.4 3.2 3.122.1 19.5 9.5 9.1 8.7 7.0 6.7 4.1Cum % 90.3 93.7 96.9 100.022.1 41.6 51.1 60.2 69.0 75.9 82.7 86.7
Coun
t
Perc
ent
TagsOthe
r
II959
A-1
LI944
-1
TI93
5-3
LI949
-1
PI956
-3
ZS93
7-6
ES97
2-1
PC96
0-1
EI935
M-5
PI956
6-4
TI9600
-7
1800
1600
1400
1200
1000
800
600
400
200
0
100
80
60
40
20
0
Pareto Chart of Furnace 9 Alarms
Process Characterization
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Analyze PhaseAnalyze Phase
Alarm Management Define Analyze Improve ControlMeasure
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DVOP Console*.csv files
Event_Journal (Access database)
ASCII Capture port
LogMATE Capture
NetView – SOE (sequence of
events)
TRAC - Data Historian
Integration
TRAC – Key Performance
indicators
Alarm Rationalization
ACE – Bad Actors (80/20 Rule)
OPC Capture port
Alarm Generated in PRoVOX
Alarm Generated in DeltaV
PRoVOX and DeltaV
configuration databases
Alarm Knowledge
Base
Automated Alarm Activity Reports –
Email Notice
Analysis System
Alarm Management Define Analyze Improve ControlMeasure
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Define Analyze Improve ControlMeasureAlarm Management
Process Capability
907560453015
Median
Mean
6462605856
1st Q uartile 49.306Median 59.0283rd Q uartile 74.306Maximum 100.000
58.944 63.600
56.944 61.806
18.732 22.036
A -Squared 2.04P-V alue < 0.005
Mean 61.272StDev 20.249V ariance 410.024Skewness 0.049607Kurtosis -0.235195N 293
Minimum 13.194
A nderson-Darling Normality Test
95% C onfidence Interv al for Mean
95% C onfidence Interv al for Median
95% C onfidence Interv al for StDev95% Confidence Intervals
Summary for Furnace 9 Alarms
Project: Alarm-management-04.MPJ; Worksheet: Worksheet 1; 6/5/2006
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Define Analyze Improve ControlMeasureAlarm Management
Lag
Aut
ocor
rela
tion
18161412108642
1.0
0.8
0.6
0.4
0.2
0.0
-0.2
-0.4
-0.6
-0.8
-1.0
Autocorrelation Function for Furnace 9 Alarms(with 5% significance limits for the autocorrelations)
Process Capability
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Define Analyze Improve ControlMeasureAlarm Management
Index
%pe
riod
s
2902612322031741451168758291
100
90
80
70
60
50
40
30
20
10
Project: Untitled; Worksheet: Worksheet 1; 6/5/2006
Time Series Plot of Furnace 9 Alarms
Process Capability
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Define Analyze Improve ControlMeasureAlarm Management
Observation
Indi
vidu
al V
alue
2912622332041751461178859301
90
60
30
_X=61.27
UCL=84.28
LCL=38.26
Observation
Mov
ing
Ran
ge
2912622332041751461178859301
45
30
15
0
__MR=8.65
UCL=28.27
LCL=0
1
1
11
1
1
111
111
111
1
11
111
1111
111
111111
11111111
111
11
111
11
1111
11111
111
1
11111
11111111
1
1
11
111
1
11
1
1
11
1
Project: Alarm-management-04.MPJ; Worksheet: Worksheet 1; 6/5/2006
I-MR Chart of Frunace 9 Alarms
Process Capability
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Define Analyze Improve ControlMeasureAlarm Management
105907560453015
USL
LSL 0Target *USL 71Sample Mean 61.2723Sample N 293StDev (Within) 7.67023StDev (O v erall) 20.2664
Process Data
C p 1.54C PL 2.66C PU 0.42C pk 0.42
Pp 0.58PPL 1.01PPU 0.16Ppk 0.16C pm *
O v erall C apability
Potential (Within) C apability
% < LSL 0.00% > USL 27.99% Total 27.99
O bserv ed Performance% < LSL 0.00% > USL 10.24% Total 10.24
Exp. Within Performance% < LSL 0.12% > USL 31.56% Total 31.69
Exp. O v erall Performance
WithinOverall
Process Capability of Furnace 9 Alarms
Process Capability
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Improve PhaseImprove Phase
Alarm Management Definition Analysis Improve ControlMeasure
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DVOP Console*.csv files
Event_Journal (Access database)
ASCII Capture port
LogMATE Capture
NetView – SOE (sequence of
events)
TRAC - Data Historian
Integration
TRAC – Key Performance
indicators
Alarm Rationalization
ACE – Bad Actors (80/20 Rule)
OPC Capture port
Alarm Generated in PRoVOX
Alarm Generated in DeltaV
PRoVOX and DeltaV
configuration databases
Alarm Knowledge
Base
Automated Alarm Activity Reports –
Email Notice
Improvement System
Alarm Management Definition Analysis Improve ControlMeasure
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Rationalization Step 1
Alarm Management Definition Analysis Improve ControlMeasure
Soda Springs Alarm Rationalization Team:Aimee Anani Furnace Process Engineer, Team Lead
Troy Carver Furnace Operations Specialist
Matt Kirby South Area Compliance Representative
Brock Sherman Furnace Process Engineer
Kenny Rasmussen Furnace Control Operator
Ray Shurtz Furnace Control Operator
Rick Hendricks Furnace Control Operator
Aaron Tarbet Furnace Control Operator
Brent Thomas Process Control Engineer, MT
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Definition Analysis Improve ControlMeasure
Rationalization Process
Alarm Management
Identify top ten worst
alarms
Review with Rationalization Team
Submit MOC for changes
MOC approved
?
Implement changes in control system, alarm database, and alarm catalog
Y
N
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0
2000
4000
6000
8000
10000
12000
Integrity Errors Audible Alarms
March-06August-06
Alarm Management
Improvements
86% reduction in integrity errors
61% reduction in audible alarms
Definition Analysis Improve ControlMeasure
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Definition Analysis Improve ControlMeasureAlarm Management
Improvements
6004803602401200
USL
LSL *Target 52USL 240Sample Mean 124.78Sample N 82StDev (Within) 92.1329StDev (O v erall) 210.64
Process Data
C p *C PL *C PU 0.42C pk 0.42
Pp *PPL *PPU 0.18Ppk 0.18C pm 0.28
O v erall C apability
Potential (Within) C apability
% < LSL *% > USL 18.29% Total 18.29
O bserv ed Performance% < LSL *% > USL 10.55% Total 10.55
Exp. Within Performance% < LSL *% > USL 29.22% Total 29.22
Exp. O v erall Performance
WithinOverall
Process Capability of March Integrity Errors
6004803602401200
USL
LSL *Target 52USL 240Sample Mean 16.4146Sample N 82StDev (Within) 5.63655StDev (O v erall) 8.47927
Process Data
C p *C PL *C PU 13.22C pk 13.22
Pp *PPL *PPU 8.79Ppk 8.79C pm 1.70
O v erall C apability
Potential (Within) C apability
% < LSL *% > USL 0.00% Total 0.00
O bserv ed Performance% < LSL *% > USL 0.00% Total 0.00
Exp. Within Performance% < LSL *% > USL 0.00% Total 0.00
Exp. O v erall Performance
WithinOverall
Process Capability of August Integrity Errors
Scaled to 1/10
Data from March, 2006 compared to data from August, 2006
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Definition Analysis Improve ControlMeasureAlarm Management
100806040200
USL
LSL *Target *USL 45Sample Mean 28.122Sample N 82StDev (Within) 13.3635StDev (O v erall) 17.2955
Process Data
C p *C PL *C PU 0.42C pk 0.42
Pp *PPL *PPU 0.33Ppk 0.33C pm *
O v erall C apability
Potential (Within) C apability
% < LSL *% > USL 14.63% Total 14.63
O bserv ed Performance% < LSL *% > USL 10.33% Total 10.33
Exp. Within Performance% < LSL *% > USL 16.46% Total 16.46
Exp. O v erall Performance
WithinOverall
Process Capability of March Alarms
100806040200
USL
LSL *Target *USL 45Sample Mean 10.8293Sample N 82StDev (Within) 7.33298StDev (O v erall) 9.5159
Process Data
C p *C PL *C PU 1.55C pk 1.55
Pp *PPL *PPU 1.20Ppk 1.20C pm *
O v erall C apability
Potential (Within) C apability
% < LSL *% > USL 0.00% Total 0.00
O bserv ed Performance% < LSL *% > USL 0.00% Total 0.00
Exp. Within Performance% < LSL *% > USL 0.02% Total 0.02
Exp. O v erall Performance
WithinOverall
Process Capability of August Alarms
ImprovementsAlarm activations in March, 2006 compared to August, 2006
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Alarm Management
Confidence of Improvement
No question that the network integrity errors
were reduced
No question that audible alarms are
fewer
Definition Analysis Improve ControlMeasure
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Alarm Management
Integrity Errors
Audible Alarms
Definition Analysis Improve ControlMeasure
Confidence of Improvement
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Control PhaseControl Phase
Definition Analysis Improve ControlMeasure
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Control System
Definition Analysis Improve ControlMeasureAlarm Management
DVOP Console*.csv files
Event_Journal (Access database)
ASCII Capture port
LogMATE Capture
NetView – SOE (sequence of
events)
TRAC - Data Historian
Integration
TRAC – Key Performance
indicators
Alarm Rationalization
ACE – Bad Actors (80/20 Rule)
OPC Capture port
Alarm Generated in PRoVOX
Alarm Generated in DeltaV
PRoVOX and DeltaV
configuration databases
Alarm Knowledge
Base
Automated Alarm Activity Reports –
Email Notice
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Control Plan
•Long term control will be achieved by the following:•Comprehensive alarm philosophy (completed by AMST)
•Established alarm knowledge base
•Configuration for DCS alarms and locations and access of hardwired alarms (done)
•Automatic nightly update from DeltaV (done)
•MOC approval system (done)
•Defined action for each audible alarm (AMST work in progress)
•Assigned responsibility for action required:•The CIM Group will be responsible for maintaining the tools
•Engineering and manufacturing will ensure adherence to policies and philosophy
Definition Analysis Improve ControlMeasureAlarm Management
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Alarm Management Definition Analysis Improve ControlMeasure
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Alarm Management Definition Analysis Improve ControlMeasure
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Alarm Management Definition Analysis Improve ControlMeasure
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Questions?
Alarm Management Measure Analyze Improve ControlDefine
Project Title: DCS Alarm ManagementPlant / Location: Soda Springs, Idaho
Presently implementing the same improvements for 7 and 8 furnaces and working on additional improvements for all three.
Project to be completed August 31, 2007
Burden prep will be addressed when furnaces are complete