Transcript D2-01_30

“D2-01_30”
“Alarms rationalization in Mexico
power units”
Octavio Gomez and Eric Zabre
Instituto de Investigaciones Electricas
Cuernavaca, Morelos, Mexico
CIGRE Tutorial & Colloquium on SMART GRID
Mysore, Karnataka, India on 13-15 November, 2013
Under CIGRE Study Committee D2
INFORMATION SYSTEMS AND TELECOMMUNICATION
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CONTENTS:
 INTRODUCTION TO ALARM
MANAGEMENT IN CONTROL
ROOMS.
 ALARM RATIONALIZATION FOR
PLANT OPERATION.
 IMPLEMENTATION OF
RATIONALIZED ALARMS.
 RESULTS OF APPLY THE ALARM
MANAGEMENT IN THE CONTROL
ROOMS.
 CONCLUSIONS.
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INTRODUCTION TO ALARM MANAGEMENT IN
CONTROL ROOMS:
At some power unit in Mexico at 11:00 pm…
From control center…
-Peak hour is over, please low charge…..
The unit is generating 300 mw, and then… low until 180
mw…
The monitor of operator receives to alarms flood (300 to
400 alarms/minute).
at 11:30 pm…
From control center…
-Please up charge because the power central next is shut-down…..!!!
The unit is generating 180 mw, and then… up until 300 mw…
The monitor of operator receives to alarms flood (300 to 400 alarms/minute)
With each change in the mode of operation of the power unit, the system
generates more useless alarms to the operator.
Operator’s exclamation…
I need a better alarms management!!
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HORA
INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS :
ALARMAS
600
500
400
OVERLOADED
300
200
100
STABLE
Generation of alarms during the
operation of the power unit as demand
change.
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INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS :
We adopted the Alarm Management Cycle from ANSI/ISA 18.2
A
B
PHILOSOPHY
IDENTIFCATION
J
I
CRATIONALIZATION
D
MANANGEMENT OF
CHANGE
AUDIT
DESIGN
E IMPLEMENTATION
F
G
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OPERATION
H
MONITORING &
ASSESSMENT
MAINTENANCE
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INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS :
The methodology to alarms management is based on:
EEMUA 191 "Alarm Systems: A Guide to Design, Management and Procurement“
edition 2, - 2007.
And
ANSI/ISA-18.2-2009. “Management of Alarm Systems for the Process Industries”.
International Society of Automation. USA 2009.
Diagnosis and determination of “performance level” of
alarms systems:
Survey to power unit operator
Utility of alarms during normal operation?
Utility of alarms during upset?
Utility of alarms during shut-down?
The answer always is the same: low utility.
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INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS :
Others issues for diagnosis and determination of
“performance level” of alarms systems:
number of alarms in database?
rate of alarms during a shift?
rate of alarms during an upset?
rate of alarms during a shut-down?
Diagnosis: all systems were “OVERLOADED”
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PERFORMANCE LEVELS
EEMUA 191
PREDICTIVE
ROBUST
STABLE
REACTIVE
OVERLOADED
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PREDICTIVES
ALARMS
ADVANCED
SOLUTIONS
ALARM
RATIONALIZATION
SEPARATE
ALARMS OF
EVENTS
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ALARM RATIONALIZATION FOR PLANT OPERATION:
Formation of the
group responsible for
alarms management
Setting for each alarm:
 TAG,
 message,
 set-point,
 priority,
 operator action,
 possible causes
and consequences
Develop alarm
philosophy.
Set targets of the
rationalization
Gathering data:
Historical record,
Database and
P&ID’s
Master of
alarms
Separate alarms
and events
Master of events
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ALARM RATIONALIZATION FOR PLANT OPERATION:
Formation of the group responsible for alarms management
 The Superintendent of Central
becomes aware current status of
alarm system
 The Superintendent of Central
designates staff to alarm
management.
 Chief operating
 Chief C&I
 Chief Electrical
 Facilitator
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ALARM RATIONALIZATION FOR PLANT OPERATION :
Develop alarm philosophy.
 To define responsibilities and functions of each of the
participants.
 To define basis for design of alarms.
 To define alarms priority classes.
 To define criteria for the display alarms in the
operator’s screen.
 To define the method for monitoring the performance
of alarm system.
 To define the method of alarm system maintenance.
 To define tests to alarms.
 To define structure of alarm system documentation.
 To define guidelines for implementation of
rationalized alarms.
 Operator training for new philosofy alarms.
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ALARM RATIONALIZATION FOR PLANT OPERATION:
Set targets of the rationalization.
To define the target level of
alarm system performance.
“STABLE” is the target level.
PREDICTIVE
What kind type of alarms will be
rationalized?
Only process alarms?
System diagnostic alarms?
Maintenance alarms?
ROBUST
STABLE
REACTIVE
PREDICTIVE
ALARMS
AVANCED
SOLUTIONS
ALARM
RATIONALIZ
ATION
SEPARATE
ALARMS OF
EVENTS
How many alarms are
rationalized by day?
OVERLADED
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ALARM RATIONALIZATION FOR PLANT OPERATION:
Gathering data: Historical record, Database and P&ID’s
With historical records, we can identify:
 Useful alarms.
 Useless alarms.
 Nuisance alarms.
 Frequent alarms.
 Alarm rate in normal operation.
 Alarm rate prior to upset.
 Alarm rate in to upset.
 Alarm rate after upset.
From the database we can know:
Number of alarms configurated in
the DCS, and
Alarm type.
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02:23:30:441
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U4_AETI1676
MET COJ 4 BAA C
FALLA
Error en el canal
U4_AETI1670
ENT LUB A ENF BAA C
FALLA
Error en el canal
U4_AETI1671
SAL LUB DE ENF BAA C FALLA
Error en el canal
U4_AETI1677
MET COJ 3 BAA C
FALLA
Error en el canal
U4_AETI1672
COJ 6 MET AL BAA C
FALLA
Error en el canal
U4_AETI1671
SAL LUB DE ENF BAA C FALLA
Error en el canal
U4_AETI1670
ENT LUB A ENF BAA C
FALLA
Error en el canal
U4_AETI1672
COJ 6 MET AL BAA C
FALLA
Error en el canal
U4_AETI1674
COJ 6 EMPUJE BAA C
FALLA
Error en el canal
U4_AETI1675
COJ 5 ACEITE BAA C
FALLA
Error en el canal
From the P&ID´s we can know the process and instrumentation.
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ALARM RATIONALIZATION FOR PLANT OPERATION:
Separate alarms and events
(alarm identification)
Events and alarms are presented together in the same
display ( list form).
Events:
pump turned on,
Valve opened,
..and so on.
Alarm:
“an audible or visible means of indicating to the operator
an equipment or process malfunction or abnormal
condition”. (EEMUA 191)
“an audible and/or visible means of indicating to the
operator an equipment malfunction, process deviation, or
abnormal condition requiring a response”. (ANSI/ISA 18.2)
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ALARM RATIONALIZATION FOR PLANT OPERATION:
With master of alarms:
Write a new alarm message: easily understood by the operator.
Define setting alarm: based on the process dynamics.
“Chattering alarm require a careful study”
Define priority:
Based on available time to attend the alarm and the severity of the
consequences.
ALARM PRIORITY
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CRITICAL
ALARM
HIGH
PRE-CRITICAL
WARNING
MEDIUM
PLANT
TOLERANCE
LOW
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ALARM RATIONALIZATION FOR PLANT OPERATION:
With master of alarms:
Operator actions
Write the operator actions on the
process:
To open valve LV 1305
To turned off pump P 1305
And check indicators.
And check equipment.
And other actions such as
calling plant engineers.
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ALARM RATIONALIZATION FOR PLANT OPERATION:
With master of alarms and P&ID´s:
Identify possibles causes of the alarm:
What happened downstream of the alarm?
What happened upstream of the alarm?
What was the first change in the process?
What changed surroundings of the process?
Some valve stuck.
Some valve that is opened without the
ordered by the operator or from DCS.
Any pump that provided more flow.
A pump turned off without operator
intervention.
and so…
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ALARM RATIONALIZATION FOR PLANT OPERATION:
With master of alarms and P&ID´s:
Identify possibles consequences
of the alarm not resolved
opportunely:
Plant trip.
Unit trip.
Equipment damage.
Loss of process fluids.
Damage to the environment.
Injury to staff.
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IMPLEMENTATION OF RATIONALIZED ALARMS:
With new database of alarmS rationalized:
Configuring DCS
Creating new displays in
the DCS
Training operators
Testing alarms
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RESULTS OF APPLY THE ALARM MANAGEMENT IN THE CONTROL ROOMS:
GENERATION POWER UNITS WITH ALARM SYSTEMS RATIONALIZED
DCS
GT'u
MARK V/SIEMENS
ABB/METSO
OVATION/SIEMEN
S/METSO
DELTA V/
SIEMENS/OVATIO
N/ABB 800XA
SIEMENS
4
TOTAL
4
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Alarms Before
Rationalization/U
880
3,400
Alarms After
Rationalization/U
190
610
3,450
650
4,540
1,170
77
4,750
490
77
17,020
3,110
IC'u CC'pack STEAM'u HYDRO'u
2
10
25
2
10
25
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RESULTS OF APPLY THE ALARM MANAGEMENT IN THE CONTROL ROOMS:
IMPLANTED UNITS RATIONALIZED ALARMS
DCS
SIEMENS
ABB/METSO
OVATION/SIEMENS
DELTA V/ SIEMENS/ABB
800XA
SIEMENS
GT'u
1
TOTAL
1
PERFORMANCE
LEVEL BEFORE THE
RATIONALIZATION:
“OVERLOADED”
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IC'u
CC'pack
STEAM'u
HYDRO'u
2
4
14
69
2
4
14
69
PERFORMANCE LEVEL
AFTER THE
RATIONALIZATION:
“STABLE”
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Operator alarm
display before
alarm
rationalization
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Operator alarm display before alarm rationalization
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Operator alarm display after alarm rationalization
250
196
200
206
185
174
150
100
50
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
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RESULTS OF APPLY THE ALARM MANAGEMENT IN THE CONTROL ROOMS:
New operator alarm display.
BOMBAS DE ALTA
TEMP
BOMBAS DE BAJA
AEREOENFRIADOR
TEMP
ES
VENTILADORES
CASA MAQUINAS
COMPRESORES
INSTRUMENTOS
COMPRESORES
SERVICIOS
COMPRESORES
ARRANQUE
NIVELES ANORMAL
TQ´S
COMBUSTIBLES
TEMP ANORMAL
TQ´S
COMBUSTIBLES
NIVELES ANORMAL
TQ´S ACEITES
LODOS
DISPARO
DISPARO
DISPARO
BAJA PRESION
BAJA PRESION
BAJA PRESION
N. DERRAME / BAJO
NIVEL
BAJA / ALTA
N. DERRAME / BAJO
NIVEL
AGUA DE
ENFRIAMIENTO DE
MOTOR
METAL CAMISA
FUEGO CAMARA
DE BARRIDO
BOMBAS ALFA
LUBRICADOR
CIRCUITO AIRE
GASES MOTOR
CIRCUITO ACEITE
DE MOTOR
BOMBAS PPAL
ACEITE CIR
BOMBAS MODULO
COMB
MODULO
COMBUSTIBLE
RED. CARGA
REQUIERE
AUMENTO ACEITE
RED. CARGA
DISPARO
RED. CARGA
RED. CARGA
DISPARO
DISPARO
BAJA PRESION
PROTECCIONES
DEL MOTOR PPAL
CALDERA
AUXILIAR
CALDERA DE
RECUPERACION
DISPARO
DISPARO
CIERRE VANOS
DISPARO
GENERADOR
PRINCIPAL
BOMBAS
CONDENSADOS
VENTILADORES
AUXILIARES
DETECTORES
NIEBLA
TURBO CARGADOR
DISPARO
DISPARO
BOTON PARO
EMERGENCIA
OPERADO
TURBINA VAPOR
SISTEMA VACIO
TURBINA
DISPARO
DISPARO
BAJO VACIO
INTERRUTOR
ACOMETIDA CCM
SE Y SA
GENERADOR
DIESEL
ABIERTO
INDISPONIBLE
HIST EVENTOS
TAG
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MODULO ALFA
LUBRICADOR
DISPARO
OPERACIÓN DE
OPERACIÓN DE
AEREOCONDENSA FRECUENCIA DEL
PROTECCIONES TR PROTECCIONES
DORES
SISTEMA
PPAL
TR´S AUX.
DISPARO
ALTA / BAJA
INVERSOR
OPERACIÓN
AUXILIARES 86
ABIERTO 92020
ABIERTO ACOM
BOMBAS CALDERA NIVELES CALDERIN
RECUPERACION / DESGASIFICADOR
DISPARO
N. DERRAME / BAJO
NIVEL
OPERACIÓN DE
INTERRUTORES
INTERRUTORES
PROTECCIONES ACOMETIDAS BOM1 ACOMETIDAS BOM2
GENERADOR
AER1
AER2
ABIERTO 52G
ABIERTO
ABIRTO
ULTIMA ALARMA
CARGADORES DE
BATERIAS
REVISION
ACCIONES
DESCRIPCION ALARMA
REVISION
ACCION
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Operator alarm
display after alarm
rationalization.
Critical alarms
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Operator alarm
display after to the
rationalization.
Pre-critical alarms
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The “alarm
book” as an
aid to the
operator.
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CONCLUSIONS:
The performance level of alarm system in generating units
should be STABLE to avoid:
Plant trip.
Unit trip.
Equipment damage.
Loss of process fluids.
Damage to the environment.
Injury to staff
The operator display should be
changed to operator have more
process information.
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Thank you very much for your
atenttion!!
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