results before and after dynamic alarm mgt emerson
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Results before and after dynamic alarm managementTRANSCRIPT
Results Before and After Dynamic Alarm Management
Dustin Beebe –ProSys
Bob Wingard – Huntsman Corporation
Bob Townley-Smith – Huntsman Corporation
Presenters
Dustin Beebe
Bob Wingard
Bob Townley - Smith
Huntsman Performance Products
Huntsman Performance Products
Morpholine
DGA
E7
Ethylene
Oxide
F4 & F6
Surfactants
E3 & E6
Propylene
Glycols
G2
Ethylene
Glycols
G1/3/5/6
Ethanol-
Amines
E4
Olefins
A3
PO/
MTBE
F5
Oxygen
Isobutane
Methanol
Ethane/Propane
FCCU Gas
Refinery Grade
Propylene
Oxygen
Ethylene
EO
Monoethanol Amine (MEA)
Diethanol Amine (DEA)
Triethanol Amine (TEA)
Triethanol Amine Residue
Ethylene
Water
MEG
TEG
DEG
Propylene Glycol (PG)
DiPropylene Glycol (DPG)
Sales
Morpholine
EO
EO
NH3
Nonyl Phenol Ethoxylates
Sodium Isethionate
Amine Ethoxylates
AD
C4’s
Propylene
PO
MTBE Alcohols
Amines
MNP
Biodiesel
Shipments
PO
Water
Normal C4
AFG
Linear Alcohol Ethoxylates
Shipments
NH3
Raw Materials
Pipeline Barge
Rail Trucks
Purchases
SO2
Propylene
EO
Huntsman Performance Products
Units Products Capacity Technology
A3 Ethylene 450 MMPPY 65/Stone & Webster
A3 Propylene 300 MMPPY 65/Stone & Webster
F4, F6 Ethylene Oxide 1000 MMPPY 63/68 Scientific Design
G1/3/5/6 Ethylene Glycol 890 MMPPY 47-89/In House
G2 Propylene Glycol 144 MMPPY 58/In House
E4 Ethanolamines 400 MMPPY 79/07 In House
E7 Specialty Amines 50 MMPPY 67/In House
E3/E6 Surfactants 470 MMPPY 52-71/In House
F5 PO 566 MMPPY 94/In House
F5 MTBE 1782 MMPPY 94/In House
Port Neches Control Systems
Approximately 10,000 analog IO 3000 Controllers 73 Control Processors More than 35,000 blocks with at least one alarm
configured. (Most have several alarms configured.) 36 PLC processors. Control is split between DeltaV and Foxboro IA
Pogo
We have met the enemy and he is us.
Oliver Hazard Perry
Common Mistakes / Proof that the enemy is was us.
Every SIS action was a critical alarm.– Removed alarms from individual trips.– One common low priority SD alarm per system.
• Operator action to check first out display.
– Save higher priority alarms for SIF failures. Every shutdown had a pre-alarm that was not suppressed
when the associated trip is active. – Delay pre-alarms and suppress when associated trip is active.
Almost every temperature on distillation column had an alarm and the pressure.– Choose single most critical temperature and the overhead pressure.
Common Mistakes / Proof that the enemy is was us. (cont)
Alarms were configured on individual pieces of redundant equipment.– Example: 6 redundant Fireye flame detectors generate 18
alarms each time the incinerator is shut down. One for each detector and one that indicated that both detectors agree or disagree that the fire is out.
• Remove alarms from individual Fireyes, suppress flame out alarm when gas valve is blocked in. Create flame detected alarm when gas valve is blocked in.
Low Flow alarms set at less than 10% of span.– Still have some of these but dynamic management reduces
chatter.
Alarm Philosophy
Philosophy development should be your first step on your road to alarm management.– There are a lot of good resources on what should be in your alarm philosophy,
make use of them. Spend time on it and generate a good document.
– You are not helping yourself if your philosophy is simply a checklist of the ISA 18.2 sections.
– Specific to your site. Will guide your teams through the rationalization process. Defines the life cycle processes use to maintain your alarm systems. Contains clear examples that your teams can refer to during
rationalization. Very important that your philosophy formalize alarm management
responsibilities within the operating units.
Alarm Management Champions
One for site and one for each operating unit. Creditability within the operating units. Leverage champions creditability to help reshape
wrong ideas about alarms. Train first, force multiplier.
Training
Train your teams on your Philosophy, before you start. Focus on understanding of the definition of an alarm and team members roles and responsibilities.
Ensure that each team member understands his/her role in alarm management.
Time spent on training up front will come back to you during your rationalizations.
Implementation
Do not put anything in front of your operators, until you are sure it is correct.– Spend extra time up front verifying your implementation, especially on your first
couple of units. If you lose creditability with you console operators, regaining that
creditability will be harder the second time. Bad news travels much faster than good. Don’t tie your operators hands, initially.
– At Huntsman we initially allowed our operators to continue suppressing alarms the old way in parallel with the new way. Once we are sure everything works as designed we remove the “old” ability.
It will be difficult to meet the ISA requirements without some form of dynamic management of your alarm settings.
Ongoing maintenance of your Alarm Systems
To be successful you must have accountability for alarm maintenance functions.
Management of alarms should become just another expected job function for the personnel assigned to your units.– At Huntsman our alarm performance reports are part of each
units weekly KPI meetings. Beware of your PHA/LOPA and Project teams, ensure
that they are trained on your alarm philosophy. One bad LOPA/Project can eliminate your gains.
Introduction
Define an Alarm Flood What Causes Floods? Impact of Alarm Floods on your plant Dynamic Alarm Management and its ability to
control alarm floods Results before and after Dynamic Alarm
Management
Definition of Alarm Flood
Alarm Flood defined by ISA 18.2 as -
“10 or more annunciated alarms in any 10 minute period per operator”
What causes a Flood?
Alarms are typically configured for run therefore many alarms are triggered upon a Change of Process State:• Run to Shutdown• Plant State 1 to Plant State 2
Impact of Alarm Floods
Plant Managers should be ready for alarm performance to be scrutinized during OSHA audits
Reports show that 70% of plant incidents occur on startup, shutdown or transitions.
Could incidents be caused by critical alarms being hidden under a flood? What about before alarms have cleared and operators are starting up the plant without alarms?
Even your SIS alarms are not immune to influence by alarm floods. Even special sounding alarms can be missed when hundreds of alarms are sounding.
Impact of Alarm Floods
What about product quality, plant profitability and equipment damage – have any of these suffered when alarm floods were a significant distraction for the operator?
Have you performed an incident review to find that a critical alarm was missed? Was a flood of alarms even considered as a distraction for the operator?
Do you have any data on how many alarms are missed due to distractions?
How many loss of containment incidents, injuries or worse can be tracked back to an alarm flood?
ANSI / ISA 18.2 Alarm Metrics
Metric Target Values
Average Annunciated Alarms per Hour 6
Average Annunciated Alarms per 10 minutes 1
Percentage of Hours containing more than 30
alarms<1%
Percentage of 10 Minute periods containing
more than 10 alarms<1%
Maximum number of alarms in 10 minute
period<=10
Percentage contribution of the top 10 most
frequent alarms to the overall alarm load<1% to 5% maximum, with action plans to address deficiencies
Percentage of time the alarm system is in
flood condition<1%
Quantity of Chattering and fleeting alarms Zero, with action plans to correct any that occur
Stale alarms < 5 present on any day, with action plans to address
Annunciated priority distribution 3 priorities - 80% Low, 15% Med, 5% High, or
4 priorities - 80% Low, 15% Med, 5% High, <1% Highest
Dynamic Alarm Management
Improved Quality of Alarms– Every alarm should:
• Be clear and relevant to the operator• Indicate an abnormal process condition that has consequences of
inaction and a defined response• Be unique
Correct Technology, Methodology and Resources– Plant is divided into systems and sub-systems– Complete and thorough review of:
• Plant operating procedures• P&ID’s• PHA documentation• Interviews with engineers and operators
– Quality of process rises and falls with the quality of the rationalization facilitator
• Experienced process engineer with P.E.• Alarm management experience• Capable of challenging participants to keep process on track
Dynamic Alarm Management
Dynamic rationalization is rationalization for more than one process state
Static rationalizations can become dynamic when the question “When” is added to the discussion for each point
Control of alarm floods is vastly more important than improving average alarm rates
Dynamic Alarm Management is the only way to control alarm floods
Dynamic Alarm Management– Transition manager configurable for every alarm– Smooth transitions from state to state– True Dynamic Alarm Management software able to handle 700+ dynamic
points per operator– No problem meeting or exceeding ISA 18.2 metrics
Online Solution
Results Before Dynamic Alarm Management
Peak Alarm Rate – 40 per 10 min Average Alarm Rate – 1.4 per 10 min % of Time in Flood Condition – 6.45% Chattering Alarms
– 78.3% of all alarms– G5-FC1505.PVHI – 85.9% of count and 88.9% of duration
Results Before Dynamic Alarm Management
Results Before Dynamic Alarm Management
Results After Dynamic Alarm Management
Results Before Dynamic Alarm Management
Results After Dynamic Alarm Management
Results After Dynamic Alarm Management
Results After Dynamic Alarm Management
Summary
Alarm System Design ChangesItem Before After % Diff
Alarms Configured 3745 1112 -70%
Log 0 767 +∞
Low 2003 917 -54%
Medium 1648 163 -90%
High 94 32 -66%
Summary
Alarm System Design ChangesItem Metric
Trip Point Changes 357
Priority Changes 970
Alarms Eliminated 2633
Dynamically Managed
143 (13%)
Dynamic Actions 510
Summary
Performance versus ISA 18.2 Metrics
Metric Before After Targets
Avg. Alarms/10 min >24 0.2 1
Peak alarms/10 min >200 18 10
% Time in Flood 19% 0.11% <1%
Stale Alarms 72.2 7 <5
% Hours > 30 alarms 18.4% 0.1% <1%
Results After Dynamic Alarm Management
Dramatic absence of redundant and unnecessary alarms
Operators expressed concern but when questioned - were receiving all legit alarms
No issues as a result of fewer alarms
Business Results Achieved
Lower risk with fewer floods Lower operator loading Better operator focus
Summary
Definition of alarm flood and causes Impact of alarm floods on your plant Alarm flood results before and after dynamic
alarm management Compliance with ISA 18.2 as a result
Where To Get More Information
ProSys Contact Info
prosys.com
225-291-9591 x225