Sustain - Ability.: Alarm Management Workshop
Sustain - Ability.: Alarm Management Workshop
Sustain.Ability.
2014 Honeywell Users Group EMEA
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Alarm & Operations Management - Intro
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What is an Abnormal Situation?
Definition
• Any unexpected event or situation that confronts the operator
during the course of his/her duties that causes the plant operation
to be upset or disturbed to the point of concern.
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What is an Abnormal Situation?
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Cost Impacts of an Abnormal Situation
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Cost Impacts of an Abnormal Situation
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Target of Abnormal Situation Management
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How Does ASM Work?
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Abnormal Situation Management Consortium
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Understanding Abnormal Situations
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Understanding Abnormal Situations
• Inadequate or no procedure
• Inadequate or incorrect action People
• Failure to follow procedure/instruction 40%
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People and Work Context
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The Paradox of Automation
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Effectiveness of Response
• Reduces errors
• Decreases time
to implement
response
• Manages side
effects
• Increases
awareness
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Good Alarm Design
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Good Alarm Design
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Alarm Design Guidance
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Alarm Design Guidance
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The Main Sources of Guidance
• EEMUA 191
– most widely-applied
• ANSI/ISA-18.2
– likely to be heavily-used in the USA, although it’s style (as a “standard”) is
less “user-friendly”
• IEC 62682
– Likely to have a better acceptance as an international “standard”
• ASM
– probably the easiest to use but not as widely known outside of the ASM
Consortium
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EEMUA Publication 191
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EEMUA Publication 191
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ANSI/ISA-18.2-2009
• Sections on
– Compliance
– Alarm Philosophy
– Alarm System requirements
– Identification
ANSI/ISA-18.2-2009
– Rationalization Management of Alarm Systems for
the Process Industries
– Advanced Methods
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IEC 62682
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ASM Consortium Guidelines
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Key Performance Indicators
Average standing
alarms <10 <5 per day <10 50 100 65
Peak alarms
per 10 minutes <10 ≤10 <10 220 180 350
Distribution %
(low/med/high) 80/15/5 80/15/5 80/15/5 25/40/35 25/40/35 25/40/35
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Key Performance Indicators
4+ KPI's 0 KPI's
33% 33%
3 KPI's 2 KPI's
17% 17%
1 KPI
0%
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ASM Guidelines Critical for Success
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Management Practices
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Management Practices
1.1 Have you established support for alarm management from your company management? Yes Yes 67% 17% 17%
1.2 Have you developed a plant-wide philosophy for alarm management? Yes Yes 50% 33% 17%
1.3 Have you established an owner for the alarm system and ensured adequate staffing? Yes Yes 17% 50% 17%
1.4 Do you use a Management of Change (MOC) process for alarm changes? Yes Maybe 33% 33% 33%
1.5 Do you capture and integrate alarm requests generated from plant reviews? Yes Yes 33% 50% 17%
1.6 Have you established an alarm system’s worst actors monitoring program? Yes Yes 33% 17% 50%
Do you ensure that plant personnel understand and comply with the alarm management
1.7 philosophy? Yes Yes 0% 83% 17%
1.8 Do you run frequent backups and inspections of electronic journals? No Yes 50% 17% 33%
1.9 Do you ensure that alarm management is a part of an integrated safety program? Yes Yes 0% 50% 50%
1.10 Have you established an alarm system performance monitoring program? Yes Yes 17% 50% 33%
1.11 Do you periodically validate/enforce alarm settings? Yes Yes 17% 33% 50%
1.12 Do you perform periodic alarm rationalization revalidations? Maybe Yes 17% 17% 67%
1.13 Do you perform periodic alarm impact assessments? No Maybe 0% 33% 67%
1.14 Do you ensure that incident reviews include alarm system impact? Maybe Yes 33% 17% 50%
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Alarm System Design & Implementation
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Alarm System Design & Implementation #1
2.1 Do you ensure instrument reliability and accuracy? Maybe Yes 50% 33% 17%
2.2 Have you developed design rules to accommodate all common alarm types? Yes Yes 17% 50% 33%
2.3 Do you use common alarms for groups of instruments that have common responses? Yes Maybe 17% 33% 50%
2.4 Do you provide access to the alarm rationalization information? Maybe Maybe 17% 17% 67%
2.5 Do you minimize chattering alarms? Yes Yes 17% 83% 17%
2.6 Do you integrate alarms into process graphics? Yes Yes 67% 17% 17%
2.7 Do you provide effective alarm annunciation? Yes Yes 17% 67% 17%
2.8 Do you ensure alternative support is available for alarm response? No Maybe 0% 0% 100%
2.10 Have you installed an alarm and event historian? Yes Yes 83% 17% 0%
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Alarm System Design & Implementation #2
2.11 Have you established an alarm improvement project plan? Yes Yes 0% 83% 17%
2.12 Do you perform a comprehensive alarm rationalization review? Yes Yes 17% 33% 50%
2.13 Do you provide an alarm configuration database? Yes Yes 33% 17% 50%
2.14 Have you established a new project execution protocol? Yes Yes 0% 17% 83%
2.15 Do you provide safety system design and safety-related alarm handling? Yes Yes 0% 17% 83%
2.16 Do you segregate diagnostic information and notifications from annunciated alarms? Yes Yes 0% 17% 83%
2.17 Have you implemented an alarm shelving/disabled application? Maybe Yes 33% 33% 33%
2.18 Do you provide online access to alarm rationalization information? No Yes 0% 17% 83%
2.19 Have you defined operating targets and limits appropriate to the mode of operation? Maybe Maybe 0% 33% 67%
2.21 Do you provide a system for user-initiated notifications? Maybe Maybe 0% 0% 100%
2.22 Do you provide advanced applications to support situation awareness? No Maybe 0% 0% 100%
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Training
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Training
Work In Not
No. Statement CTS (2011) CTS (2014) Complete Progress Started
3.1 Do you provide operators with information and training on alarm system changes? Yes Yes 17% 67% 17%
Do you ensure alarm rationalization team members understand the alarm management
3.2 philosophy? Yes Yes 0% 67% 33%
3.3 Have you established scenario reviews and what if training? Maybe Maybe 0% 33% 67%
3.4 Have you enhanced training programs to include situation support tools? Maybe Maybe 0% 0% 100%
Have you enhanced training programs to include process control operators’ routine alarm
3.5 management duties? Yes Yes 0% 0% 100%
3.6 Do you educate process design personnel in alarm management? Yes Yes 0% 50% 50%
3.7 Do you use dynamic simulators as alarm management training tool? No Maybe 0% 0% 100%
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ASM Guidelines Critical for Success
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Improving Alarm Design
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Get the Basics Right First!
• Engineering of signals:
– Make sure the installation practice for sensors does not propagate
disturbances into the DCS
• Filtering:
– Add or set filtering to ensure valid PV signal reception to DCS
• Etc...
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#1 ANSI/ISA-18.2 Alarm Management Lifecycle
• Audit
– Reviewing processes, etc in use.
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ANSI/ISA-18.2 Alarm Management Lifecycle
• Philosophy
– Alarm philosophy documents the
site approach to alarm
management PHILOSOPHY
– Includes the definitions and IDENTIFICATION
principles
– Details of the practices and RATIONALIZATION
MANAGEMENT
procedures for each of the OF CHANGE
remaining life cycle stages DETAILED DESIGN
AUDIT
– The philosophy provides a
lasting reference to sustain an IMPLEMENTATION
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ANSI/ISA-18.2 Alarm Management Lifecycle
• Identification
– Many methods utilized
– Process hazard analysis PHILOSOPHY
– Incident investigations
– Important step in the life cycle IDENTIFICATION
– Methods are not detailed in
SP18.2 RATIONALIZATION
MANAGEMENT
DETAILED DESIGN
alarms from routine AUDIT
monitoring
IMPLEMENTATION
– This stage in the life cycle is a
holding point for possible alarms
OPERATION
to be processed in the next MONITORING
stage MAINTENANCE
& ASSESSMENT
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ANSI/ISA-18.2 Alarm Management Lifecycle
• Rationalization
– Reconciling each individual
alarm against the principles and PHILOSOPHY
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The Rationalization Team
• Possible members
– Operator and/or Supervisor from the plant concerned
– Process or Mechanical Engineer
– Instrumentation and/or Control Engineer
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Steps in Alarm Rationalization
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Steps in Alarm Rationalization
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Attention Points!
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ANSI/ISA-18.2 Alarm Management Lifecycle
• Detailed Design
– Basic configuration of alarms
– Human machine interface (HMI) PHILOSOPHY
for alarms
– Advanced methods of alarm IDENTIFICATION
management
– Should be control system RATIONALIZATION
MANAGEMENT
specific DETAILED DESIGN OF CHANGE
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Detailed Design – advanced methods
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ANSI/ISA-18.2 Alarm Management Lifecycle
• Implementation
– Stage where the design is put
into service PHILOSOPHY
DETAILED DESIGN
AUDIT
IMPLEMENTATION
OPERATION
MONITORING
& ASSESSMENT
MAINTENANCE
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ANSI/ISA-18.2 Alarm Management Lifecycle
• Operation
– Alarm is in service
– Reporting abnormal conditions to PHILOSOPHY
the operator
IDENTIFICATION
RATIONALIZATION
MANAGEMENT
OF CHANGE
DETAILED DESIGN
AUDIT
IMPLEMENTATION
OPERATION
MONITORING
& ASSESSMENT
MAINTENANCE
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ANSI/ISA-18.2 Alarm Management Lifecycle
• Maintenance
– Process measurement
instrument may need PHILOSOPHY
maintenance
– Other components may need IDENTIFICATION
repair
– Repair frequency can be RATIONALIZATION
MANAGEMENT
scheduled or determined by OF CHANGE
monitoring DETAILED DESIGN
AUDIT
– Periodic testing is a maintenance
function IMPLEMENTATION
MAINTENANCE
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ANSI/ISA-18.2 Alarm Management Lifecycle
OPERATION
MONITORING
MAINTENANCE & ASSESSMENT
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ANSI/ISA-18.2 Alarm Management Lifecycle
• Management of Change
– Structured process of approval
and authorization PHILOSOPHY
system
– Change process should feed RATIONALIZATION
back to the identification stage to MANAGEMENT
maintain consistency with the DETAILED DESIGN OF CHANGE AUDIT
alarm philosophy
IMPLEMENTATION
OPERATION
MONITORING
& ASSESSMENT
MAINTENANCE
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ANSI/ISA-18.2 Alarm Management Lifecycle
• Audit
– Periodic audit of the alarm
system and the processes PHILOSOPHY
OPERATION
MONITORING
& ASSESSMENT
MAINTENANCE
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2012 Honeywell Users’ Group EMEA
Sustain.Ability.
2014 Honeywell Users Group EMEA
Thank you