Transcript PPT Template

Slide 1
WW HMI SCADA-15
Advanced Alarm Management
Rob Kambach
Invensys
© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of
Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.
Current state around alarming
Configured alarms per operator
Number of Alarms an operator
can theoretically respond to
10 per minute per operator
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Alarm responses by an operator
Give the operators time to properly respond
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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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Typical observed behavior
Operator overload leading to:
• Over-acknowledgement to keep management
happy and control room quieter
• Inhibiting “noisy alarms”
• Missing important alarms
Texaco Pembroke 1994
• Not being able to mitigate in proper time
Piper Alpha North sea 1988
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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)
- 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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Alarm meaning and use
• An alarm is a notice to the operator of a
malfunction, process deviation or abnormal
condition requiring an operator response
• An alarm is not an element of a control loop
• An event is an information which needs to be
recorded for traceability/audit purpose (but
no necessity to do anything in RT)
• Alarms & events have different purposes
• A batch step shouldn’t be an alarm
• A pump stop is an alarm only if it is not supposed to
be stopped
Slide 8
Figures
• Alarm floods start with more than one alarm per minute
• Alarm systems in frequent floods provide limited protection
• Look for the top 10 bad players: 20% of alarms generate
typically (often more) 80% of announced events
• Only counting alarms is useless (like weighing yourself
without a regimen), you need an improvement program (like
the OEE approach)
• Easy to seriously reduce the amount of spurious
alarms by 60% with proper reporting
• Going further and sustain would require more effort
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KPIs
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Operators have too many alarms to
manage
What can we do?
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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
ANSI/ISA 18.2
Management
of Alarm
Systems for
the Process
Industries
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API RP-1167
Alarm
Management
For Pipeline
Systems
The ISA 18.2 Alarm Mgt 10 step Lifecycle
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Alarm Philosophy
• Purpose of alarm system
• Definitions
• Alarm management
process
• Alarm design principles
• Alarm presentation
standard
• Performance and metrics
• Rationalization
• Management of change
• …
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ISA-18.02
Why Alarm Management?
More complicated automation systems, tighter
process control, smaller operational windows  more alarms
More sensors, easy to configure control loops  more alarms
Increased safety and security measures and guidelines  more alarms
Intelligent sensors, smart networks  more alarms
Too many alarms  information overflow  stress  human errors
Human errors  Emergency Shutdown Systems intervention, wrong or
late response to process upsets  flaring, waste, energy inefficiencies
 costs money ($, €, £)
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Workload of an Operator
Operator response formulated
by EEMUA Publ 191, p. 3
 7 cognitive processes per
abnormal situation
W=R*T
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Workload W created by the
alarm system = average
number of alarms * the time to
respond to and act upon and
alarm (EEMUA Publ 191, p. 6)
Improve the Situation
Reduce average number of alarms presented by the alarm system to
an operator (quantitative approach)
Reduce the time to respond to an abnormal situation (qualitative
approach) = advanced alarming
 Assists in cognitive processes (understanding current conditions,
understand future effects, finding root cause, taking appropriate
measures)
 Provide more time to respond (predictive alarming)
 Provide operator guidance (apply appropriate procedures)
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DMAIC
Define an alarm improvement
program
Measure the current situation
Analyse the areas for
improvement
Improve the situation
Control and hold the gain with
metrics
ISA S18.2 offers a lifecycle model
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© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of
Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.
Alarm system improvement
Many drivers to start an alarm
improvement program
1: Define objectives
2: Measure current behaviour
3: Analyse behaviour and
develop measures
4: Implement measures
5: Control improvement
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WAM Reporting
Runs on top of Wonderware SCADA system
Easy to install and connects to Wonderware’s alarm and event database
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WAM Reporting
Product info
EEMUA Publication 191 compliant reporting
Thin client (web browser) access to reports and/or report templates
Up to 10 concurrent clients
User administration: two types of users:
1. Those who can only access existing (pre-configured) reports (e.g. Alarm Top
10 of past week)
2. Those who can access templates and can configure reports
Reporting: measure the past behavior of the alarm system and
improvements made over time
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WAM Reporting
Product info
Typically on a server in
the business network
Can connect up to n
SCADA systems
Performance depends
on the server
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WAM Reporting
20 Pre-configured Report types: EEMUA 191 Compliant Reports + advanced
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Event Totals and Distribution by Priority
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Bad Actor Alarms
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WAM Reporting
Built in KPI Setup and Reporting
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WAM Reporting – Built-in Analysis
Advanced Analysis
Consequential Analysis
With automated pattern
detection and recommendations
Bad Actor Analysis
With automated
recommendations
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WAM Reporting
Web based Adminstration
Easy to setup and configure, auto generates PPT or Word
Reports; distributes per e-mail
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Why do you need it?
When you have no view on what workload the alarm system imposes
on operators
When the tools you are using today (e.g. dump in Excel and create
Pareto diagrams from the dump) are a constant source of discussion
When the tools of today are difficult to maintain, not correct (e.g. do
not take into account all alarms and events) or are out of date
When you want to automate the workflow, e.g. have reports integrated
in PowerPoint slides or Word documents which are sent around on a
regular basis (weekly, biweekly, monthly)
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Typical WAM Reporting Rollout
Install
Configure
Set Company KPIs
Adjust Reports
Configure Delivery Schedule
Configure Users/Recipients
System Ready
Train Users
History Collection
Handover
Typical 1.5 days
Uses existing Wonderware Alarm Database (WWALMDB)
Requires dedicated server/workstation
Start Monitoring/Assessing & Improving
Alarm Performance Today
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Configuration - Services
Installation and configuration (1 day)
Training on using reports (2 days)
Training on application administration (1 day)
Service level agreement
Slide 32
For additional info
Contact Didier Collas and/or Rob Kambach
Visit www.ureason.com
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Thank you!
Open for Questions
Slide 34