smart alarm hiding makes plant smarter
TRANSCRIPT
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Automation SummitA User Conference Orlando, FL, June 23 – 26, 2014
Smart Alarm Hiding Makes Plant Smarter
Harry Pigler Pigler Automation, LLC
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2014 Automation Summit
Title: Smart Alarm Hiding makes Plant smarter
Track: Novel approaches to problem resolution, including
tips and tricks
Topic: Smart Alarm Hiding
Presenter: Harry Pigler
Company: Pigler Automation, LLC
Connect Event badge ID (use this # to connect with me):
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• Pigler Automation, LLC was founded in 2005
• We are a Siemens Solution Provider for PCS7 with currently 3
Siemens PCS7 certified Engineers (2 more to come this
summer).
• Located in Longmont, Colorado -- 30 miles north of Denver
• 8 Employees and Growing
• Industries Served: Chemical, Power and Mining
For more information please visit:
www.piglerautomation.com
Or call : (866) 871-1456
Pigler Automation, LLC
Providing Excellence in Process Automation
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Harry Pigler
Education and Employment
• Born and raised in Germany
• Electrical Engineering Degree from Universität Erlangen-
Nürnberg, Germany
• 20+ years employment with Siemens in Germany and the US
• Chief Operating Officer with Pigler Automation, LLC since 2005
• PCS7 Certified Process Control Engineer
PCS7 Experience
• Developing add-ons for PCS7 to be applied in the Power
Industry (PCS7 V3 -1996)
• Lead System Engineer in the TVA Hydro Automation Project
• Chief Operating Officer with Pigler Automation
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Challenge: Improve Alarm System
• Migrate Hydrogen Plant from PCS7 V6.1. SP1 to PCS7 V8.0
SP1 Upd 1.
• Plant commissioned in 2006, 24/7 operation and staffed
• Utilizing PCS7 features to improve Operations:
APL-Interlock and
Smart Alarm Hiding.
Issue:• Alarm Flooding: Too many alarms in critical situation.
• The alarm system design pre ISA 18.02
• No process triggered alarm suppression in place.
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Alarm System Management: ISA 18.02-2009
Alarm System Management
per ISA 18.02-2009
The life cycle of an alarm system
in a perfect world
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Retrofit of the Alarm System
Automatic Smart Alarm Hiding:
• Add to existing system without impacting the control logic:
New CFC chart per Area to trigger Smart Alarm Hiding.
• Process Object View offers easy interface to configure which
plant state will hide what alarm.
• List of hidden alarms and alarms that will be hidden is available
to the Operator.
• ‘Fine tuning’ available with Download Changes to the OS.
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Automatic Smart Alarm Hiding Overview
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Automatic Smart Alarm Hiding: Step by StepStep 1
Define Alarm Groups (Block Groups):• Compressor_1
• Compressor_2
• Reformer Shutdown: Step 8 in BMS sequence
Define the Plant States as Operating State:
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Automatic Smart Alarm Hiding: Step by StepStep 2
Assign Blocks to Block Group:• Use same name as Alarm Groups (i.e. STEP8)
• Process Object View allows for bulk engineering
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Automatic Smart Alarm Hiding: Step by StepStep 3
Build Trigger for Alarm Hiding:• Function Block “STRep” controls which Filter of the Alarm
Hiding becomes active.
• Input activates/de-activates Alarm Hiding Filter
1 – STOP
2 – STEP8
• Trigger will impact Alarms from multiple Controllers and Areas
(i.e. DSC and SIS)
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Automatic Smart Alarm Hiding: Step by StepStep 4
Configure Alarms to be controlled by Alarm Hiding:• Process Object View – Message Tab
• One column per Plant State
• Check box checked: Filter is applied, Alarm will be hidden
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Alarm Hiding in Action
• Alarm Hiding does not suppress Alarms. All alarms are logged
in the Event Journal but hidden from all other lists.
• Hidden Alarms will be auto-acknowledge when they clear while
hidden.
• Incoming Alarm while Alarm Hiding is active becomes visible to
the operator when Alarm Hiding is deactivated.
• Information in runtime on Alarm Hiding:
• List of active alarms that are hidden
• List of alarms that potentially will be hidden.
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Alarm Lists for Smart Alarm Hiding
• Hidden Alarm List
• List of Messages to be hidden
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Alarm Lists for “Dummies”
• Test Chart with just one MEAS_MON
• Separate Block Group USERCONFERENCE
• Hide Warnings when Smart Alarm Hiding is active
• Activate Smart Alarm Hiding and trigger High Alarm
• This alarm is actually in
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Real Life Example:Compressor Shutdown
• Screen to mark boundary for Alarm Hiding and used Plant Hierarch
• Export list of alarms off the Process Object view
• Operation marks alarms that should be hidden
• Update in project via Process Object view
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• Export alarm journal of a plant event: here Reformer Trip
• Mark alarms that can be hidden
• Utilize the Process Object View to:
• Set Block Group for Blocks that are impacted
• Ensure the messages to be hidden are checked for the state
Real Life Example:Reformer Shutdown (Step 8)
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Customer Feedback
“For the compressors, we have noticed that we received
considerably less alarms now, and it has helped somewhat;
however, I will be honest, if I had to do it over again, I probably
would have only applied the alarm hiding to the reformer
shutdown. “
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Thank you!
For more information please visit:
www.PiglerAutomation.com
Or call : (866) 871-1456
Email: [email protected]
Thank You!