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HMI SCADA-08 Best Practices for Alarm Management
Rob Kambach
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HMI/Supervisory Market Spectrum Plant Site Enterprise
• Ease of Use • Process Visualization • Basic Alarming • Short Term History • Device Connectivity
Key
N
eeds
/Asp
ects
• Larger Tag/Graphic Counts
• Graphic Standards • Extensible Vis (Client
Controls) • Basic Reporting • Basic Alm
Management
• Server Consolidation • Standard Equipment
Model • Thin Client • Centralized Historian • Fault Tolerance • Situational Awareness • Advanced Alarm
Management
• Multi-Plant HMI/Common Control Room
• Large Engineering Teams
• Common Standards
• Monitoring • Operational Centers • PIMS (Information
Management)
Scale/Cumulative
Process Machine Pr
oduc
ts
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Current state around alarming Configured alarms per operator
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Economical impact Affecting several crucial areas of plant operations: - Reduces the operational effectiveness - Economical impact: Unnecessary plant shutdowns (in the USA alone this
costs $20 Billion a year on productivity)
- Poor alarm management also causes losses in product quality, danger to population and environment and/or image loss of a respective company
Source : ASM Consortium Abnormal Situation Management
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Safety Impact
Piper Alpha North sea 1988
Texaco Pembroke 1994
Bunkfield Oil Depot
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Why did the number of alarms increase?
• Automation evolution (including fieldbus) brought more accessible
information per sensor/actuator
• Alarms are easily configurable now (no more wired) -> no real cost
at engineering or operating time to add alarms
• People (SI/EPC) tend to believe more is better : nothing can happen
without notice if everything has an attached alarm
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A set of standards and guidelines ● EEMUA 191, Alarm systems a guide to design ● Namur NA 102 Worksheet, Alarm Management ● NPD YA 711, Principles for alarm design (Norwegian petroleum doctorate
slowly adopted throughout Europe as the standard) ● VDI/VDE Guideline 3699 (process control using monitors) ● ISA S18.02, Management of alarm systems for the process industry ● IEC 62682 Alarm Management Standard
ANSI/ISA 18.2 Management
of Alarm Systems for the Process Industries
API RP-1167 Alarm
Management For Pipeline
Systems
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IEC 62682 Alarm Standard Worldwide ● Introduces vendor neutral terms
●Shelving, Initiated by Operator to temporarily suppress an Alarm ●Suppressed by Design, Mechanism implemented within that prevents the
transmission of the alarm indication to the operator based on Plant State ●Out of Service, is the state of a alarm indication that is suppressed, typical
manually, for reasons such as maintenance These map to our system as Shelving, Plant State and Inhibit or Disabled
●The standard requires that all alarms currently shelved, suppressed by design and out of service can be listed. Alarms must be under access control to be placed out of service. If an alarm is placed out of service it must be recorded.
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Situational Awareness HMI and Alarms Combined
Alarm
Impact
Time
Alarm Grid
What Happened ? Critical
Process Trends
Operational Limits
Alarm Boundaries
Tool
Tool
Knowledge Operator
Knowledge Operator
Traditional HMI
What is Happening ? SA Graphics
- 40 %
Interpretation time
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Advanced Graphics, EEMUA, ISO Identify what type of information and support people
need in order to be able to deal successfully with unanticipated events (Higher) Plant Operating Target
Plant Capacity Limit
(Fewer) Operational Constraints
(Fewer) Planning Constraints
Day
s pe
r Yea
r
95% 100% < 60%
Daily Production
Recovery of 3-8% of Capacity
APG Efforts
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2014 System Platform Alarm Enhancements
Released January 2014
Before 2014…….you could build your own alarm App…but you needed the know how.
Setup the logger Define Queries Configure/Connect Databases Have SQL Server SA Passwords Wire the Runtime to History Repeat all the same for Visualization Setup the logger as service
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2014 delivers this experience…
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Applying the guidelines
Define response times for each category
1.Alarm Priorities 2.The system shall only represent four active alarm priorities:
Priority 1 Critical (only Safety and Emergency related) Priority 2 High Priority 3 Medium Priority 4 Low Priority 5 Events and logging only no Alarms.
1.The four priorities and the impact to the business and operation. 2.Ranking and economical scale:
Operational risk of the Alarms
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Severity indication on alarm borders Severity 1 response time < 5min
Severity 2 response time < 30min
Severity 3 response time < 60min
Severity 4 response time < 120min
Wonderware Implementation
Specification
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Global Priority to Severity mapping
One location to change and customizable image…
Default Alarm Border Icons
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Global defined styles for alarm colors and borders
One place to change how graphics represent Alarms
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Alarm Border Animation Global Icons
Global Styles
Auto Configuration for Field_Attributes or Objects
Runtime
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Possible Alarm Border States on Graphics
In Alarm Acked Un-Acked Flashing
Was in Alarm Returned to Normal Un-Acked
Disabled or Inhibited (Engineering)
Shelved (Operator)
2014 R2
Silenced / Suppressed (Operator, PlantState)
Yes Yes No Yes Yes Transitions logged
Yes Yes No Yes, tab Shelved
No In Alarm Summary Display
Yes Yes Yes Yes Yes Indicated in
alarm border
Yes No No Yes Yes Aggregated/ Counted
Alarm Border Can represent multiple alarms Its show the Alarms in the following order of importance Using something we call “Most Urgent” Un_Acked Severity 1,2,3,4 Acked 1,2,3,4 Unacked RTN Normal 1,2,3,4 Shelved 1,2,3,4 Disabled, Inhibited 1,2,3,4 Silence 1,2,3,4
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Alarm Aggregation Counted and totalized by Area or Object
Active count On any level In the model
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2014 R2 Release System Platform
Releasing October 2014
If for 2014 we delivered this….
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2014 R2 delivers this: Scalability Factor times 10 Clients with out of the box experience Shelving and plant state suppression built-in
Alarm App
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Update Clients: Runtime • Tabbed filtering • Actual alarm indicators on Tabs • Ack buttons • And styles and themes setup as default
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Updated Clients: Historical • Defined with the standard Themes and Styles colors • Fonts best Practices HMI Standards • Dynamic Filter tabs • Group By functionality
History Blocks Extra Columns
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Severity Indication in Runtime and History mode within the Alarm Symbols
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Widgets for Alarming
Area Indicator Object or Device Indicator Navigation Badges
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Alarm Shelving Who Can Shelve?
What can be shelved?
Shelving from Alarm Client or Scripting Mandatory: a Reason and duration Audit trail logged to Historian Any configured alarm can be shelved Only enabled Alarms can be shelved Alarm Border integration
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Alarms Plant State-Based Suppression
●Global definition of plant states
●Area object based suppression of alarms ● Individual state on the area object has an I/O Extension
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Added Operational Permissions
●Who can Shelve ●Who can Inhibit / Disable ●Who can change Plant State ●Who can modify Alarm and Event configurations
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Operational organization of alarms
PLC
Operator
Engineering Inhibit / Disabled Based on Maintenance
Shelving Based on temporary conditions
Plant State Based on production Conditions
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Unified Attribute Editor Same UI on any object to manage alarms
Duplicate Function
Bulk Editing Smart Filter
Icons that show what Features are On or Off
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New High Performance Storage and Retrieval ●Choice upon install logging to legacy DB A2ALMDB
● 100 messages per second
●History Blocks same as process data ● 2000 messages per second
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Release of WW Alarm Analyst Q1 2015
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Wonderware Alarming 2.0 ●Easy to Use ●Compliance to regulations and best practices around alarming ●Alarm rationalization In context with Situational Awareness…OUT OF
THE BOX!!!!! ●Scalable by 10X , 2000 messages per second sustained ●Redundancy built-in as an option ●Most Robust system in the industry using Store & Forward ●Highest throughput in the industry ●Completely re-invented and revamped Alarm system to deal with the demands, flexibility and safety requirements of today’s and tomorrow’s projects
Differentiators
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Approach
Analysis of Current Situation Operator Input
Alarm Adviser
Alarm Philosophy
Review Alarms
Alarm Rationalization Active When
Alarm Design
Plant State
Plant State
Shelving
Why
Implementation Suppression Implement
Alarm Performance Assessment Determine Fleeting
Determine Standing
Determine Bad Actors
Determine Frequent Alarm Adviser
Determine Fleeting
Eliminate Noise
Standing Fleeting Frequent Bad Actors
Annual
Monthly
1
2
1
2
3
4
Operational Limits Document
Wonderware Software
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Alarm Adviser - Overview ●Common UI/UX ●Up to 10 years of historic alarm data ●Multiple sites/plants/systems ●Connects to
● Vijeo Citect ● InTouch ● System Platform ● ClearSCADA ● Foxboro
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Configuration – Priority & Severity
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Dashboard
The dashboard is available to all users
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Dashboard – User defined KPIs EEMUA 191 Standards
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Alarm Activity – Severity Distribution
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Frequent Alarms
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Long Standing Alarms - Longest
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This makes a strong case … to manage 95% of your alarms in System Platform
• Typical 80% is low, 15% is medium, 4% is High, 1% Critical • Meaning 95% of your alarms do not cause a shutdown • By moving these alarms out of the PLC, you create room and make management a lot easier Benefits:
Centralized Configuration One approach to Shelving and Plant State Redundancy Built-in Out-of-the box Styles and Alarm Borders Aggregation Built-in Counting Built-in Severities Built-in (used for rationalization)
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Where does this give you the advantage?
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Thank you!
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