Post on 26-Dec-2021
© 2017 Vedanta Limited
Cairn Oil & Gas
CB/OS-2 & YNM-Ravva
ALARM MANAGEMENT
© 2017 Vedanta Limited 2
Content
What is the need for alarm management
Implementation Cycle @ Ravva site
Implementation Cycle @ Suvali site
Where do we stand
© 2017 Vedanta Limited 3
Introduction
What is an Alarm?
An audible and/or a visible means of indicating a problem such as equipment malfunction,
process deviation or abnormal process condition.
Why alarm management?
Since humans can only do one thing at a time and can pay attention to a limited number of
things at a time, there needs to be a way to ensure that alarms are presented at a rate
that can be assimilated by a human operator, particularly when the plant is upset or in an
unusual condition.
© 2017 Vedanta Limited 4
EMERGENCE OF INDUSTRY STANDARDS
Abnormal situation
Management (ASM)
Consortium formed
EEMUA 191
1st Edition
ASM Alarm
Management
Guidelines
1st Edition
2007
2009
1994
1999
2003
EEMUA 191
2nd Edition
Emergence of Standards
and Regulations
• ISA 18.02
Understanding the
consequence of
excessive alarms
• Major accidents
and losses
• Production
losses
• Operator burnout
factor
Establishment of
systems and
practices
• Emergence of
EEMUA and ISA
standards
• Implementation of
Alarm
Management
Lifecycle
Ineffective Alarm
Management
• Excessive number of
alarms
• Alarms not
meaningful to
operator
• Alarms are disabled
often
© 2017 Vedanta Limited 5
ALARM SYSTEM MANAGEMENT LIFE CYCLE
PHILOSOPHY
IDENTIFICATION
RATIONALIZATION
DETAILED DESIGN
IMPLEMENTATION
OPERATION
MAINTANENCE
MANAGEMENT
OF CHANGE
MONITORING
&
ASSESSMENT
AUDIT
PHILOSOPHY: Define processes for alarm management &
prepare specific alarm management philosophy document
IDENTIFICATION: Determination of potential alarms
RATIONALIZATION: Rationalization, Classification,
Prioritization and documentation – Master Alarm Database
DETAILED DESIGN: Alarm response procedures, Basic
alarm design, HMI principles & Advanced Alarming features
IMPLEMENTATION: Implement alarm, testing and training
OPERATION: Operator response to alarms
MAINTANENCE: Repairs and periodic testing
MONITORING: Performance monitoring and reporting
MANAGEMENT OF CHANGE: Process to authorize change
AUDITS: Periodic audits and recommendations
© 2017 Vedanta Limited 6
ALARM MANAGEMENT STRATEGIES
USED IN RAVVA
Below are the steps carried out in Ravva plant as part of operationalization of Alarm
Management:
• Alarm Philosophy Procedures and related documents preparation
• Imparted Training to all relevant personnel’s
• Identify and formed task force team for system implementation
• Carried out Alarm Rationalization process for the existing system
• Documented the outcome and implemented changes related to alarm attributes
• Monitored system performance and conducted review meetings – Bi-weekly and Monthly
• Carried out Audits, Periodic surveys - Operator Questionnaire Survey
& Alarm Effectiveness Survey
• Reviewed Alarm set points with accordance to the operating conditions of the plant
• Implementation of Highly Managed Alarms concept
• Implementation of FIRST-OUT ALARM SCHEMES coupled with LIVE C&E
Aim is to develop & impart alarm management system, assess & improve system
performance and target for continual improvement towards system performance excellence
and sustainability of achieved results
© 2017 Vedanta Limited 7
ALARM MANAGEMENT STRATEGIES
USED IN RAVVA
Implementation of Advanced Alarm Management Techniques to curb alarm rates such as:
• Alarm Latching concept
• Alarm DEADBAND settings
• Alarm ON/OFF DELAY settings
• COUNTER Technique
• DE-BOUNCE TIMER Technique
© 2017 Vedanta Limited 8
ALARM MANAGEMENT STRATEGIES
USED IN RAVVA
STATISTICAL DATA – NO. OF ALARMS PER DAY ON AVG FROM Jun-14 to JUL-16
42
40
34
50
30
80
24
80
30
80
28
40
32
80
24
40
18
80
16
40
21
30
18
60
22
40
14
40
12
20
12
40
18
80
12
80
11
90
10
60
10
50
10
90
11
20
11
50
11
30
11
80
J UN -14 J UL-14 AUG -14
SEP- 14 O CT -14 NO V-14
DEC - 14 J AN -15 F EB- 15 MAR -15
APR- 15 MAY-15
J UN -15 J UL-15 AUG -15
SEP- 15 O CT -15 NO V-15
DEC - 15 J AN -16 F EB - 16 MAR -16
APR- 16 MAY-16
J UN -16 J UL-16
TOTAL
© 2017 Vedanta Limited 9
ALARM MANAGEMENT STRATEGIES
USED IN RAVVA
Alarm Management System Key Performance Indicators (KPIs) are:
• Alarm Rate per day
• Peak Alarm Rate
• Number of Alarm floods
• Frequently Occurring Alarms – Top 10s
• Stale Alarms
• Annunciated Alarm Priority Distribution
• Number of Alarm occurrences for a particular group of systems
• Number of Chattering Alarms
• Number of Fleeting Alarms
• Audits, Periodic surveys - Operator Questionnaire Survey and Alarm Effectiveness Survey
© 2017 Vedanta Limited 10
ALARM MANAGEMENT STRATEGIES
USED IN RAVVA
Constraints:
• Add-on projects and integration of control system
• Limitations with the existing PLC/SCADA Software
Key Results achieved post operationalization of Alarm Management in Ravva are:
• Achieved better priority distribution of alarms as per the recommended standards
• Improved and precise Alarm Message Composition
• Establishment and Availability of Alarm response procedures
• Segregation of events from Alarm logs
• Better Animations were provided in HMI graphics to support alarm systems
• Better survey results were achieved
• Considerable reduction in High priority alarms – 60% as per data analysis
• 60% Reduction in Alarm Flood condition
• Average Alarm rate per day in Ravva is being reduced from 4200 to 1100 alarms per day
© 2017 Vedanta Limited 11
ALARM MANAGEMENT SYSTEM –CB/OS-2 SITE
Following information/reports can be generated for study & analysis at Suvali site-
Alarm count over time- To determine alarm rate.
Alarm distribution priority – For checking priority wise alarms
Most frequent alarms – Alarms occurring on a frequently basis
Chattering Alarms – Most repetitive alarms over a duration
Intervention count over time – Manual intervention over a duration
Most frequent intervention – Most manual intervention of control valves
Alarm distribution over time – Shift wise
Alarm enable & disable report- Duration the particular system remained bypassed
Plant status – Standing alarms
Alarm count per process unit -
© 2017 Vedanta Limited 12
:
Alarm Rate
© 2017 Vedanta Limited 13
% High Alarms per time Reduction to 4% from 30% in Urgent alarms, 5% from 41% from in High Alarms, 2% from 13% in Low from
© 2017 Vedanta Limited 14
:
Alarm by Unit Tags
281
224 215 211 205 200 164
144 124
108
317
139 107
133 109
213
526
211
403
210
129
353
277
394
444
0
100
200
300
400
500
600
3rd
Sta
ge
oil s
ide
leve
l tran
sm
itter
AL
FH
HC
Liq
uid
Tra
nsfe
r Pu
mp
C D
isch
arg
eP
ressu
re
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de
Tra
nsfe
r Pu
mp
C
Oil T
ran
sfe
r Pu
mp
B d
isch
arg
e
3rd
Sta
ge
inte
rface
leve
l tran
sm
itter
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de
Tra
nsfe
r Pu
mp
B
Slu
g C
atc
he
r Co
nd
en
sa
te L
eve
lT
ran
sm
itter
AL
HF
Ne
w 2
nd
sta
ge
se
pe
rato
r Inte
rface
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ve
l
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ran
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arg
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t Te
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teF
lare
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m
GL
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ng
ine
Sp
ee
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LC
HC
DP
BC
-B L
ub
e O
il Co
ole
r To
Du
ple
x O
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ilter
HC
DP
HC
DP
BC
-B B
oo
ste
r Co
mp
Su
ctio
n
LA
#9
we
ll FT
HP
pre
ssu
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nsm
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#6
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w M
ete
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Instru
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PG
BC
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eve
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nsm
itter
PG
BC
PG
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Su
ctio
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cru
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er V
-23
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PG
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em
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r V-7
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ate
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51
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ate
r Syste
ms
Alarms By Tag
© 2017 Vedanta Limited 15
:
Alarm distribution over the time – Shift wise comparison
0
100
200
300
400
500
600
01/Oct/16 02/Oct/16 03/Oct/16 04/Oct/16 05/Oct/16 06/Oct/16 07/Oct/16 08/Oct/16 09/Oct/16 10/Oct/16 11/Oct/16 12/Oct/16 13/Oct/16 14/Oct/16 15/Oct/16
16:00
8:00
0:00
© 2017 Vedanta Limited 16
:
Standing alarms – Day wise
3
4
2 2 2
1
2
1
4
1
1
3
2
1
0
1
2
3
4
5
6
7
PGBC-B LIQ HANDLING SLUG CATCHER TANKER LOADING PGC-B FLARE TEG-1 ALHF GTG-B
Online Equipment Standing Alarms
Urgent
Low
High
© 2017 Vedanta Limited 17
Alarm count for different units
1974
968 940
814
643 589 556 532
469 376 365 321 307
249 226 213 199 169 168 151 145 134 133 131 110 107
0
500
1000
1500
2000
2500
Alarm Count By Unit
© 2017 Vedanta Limited 18
Daily total no. of Alarms Total alarms stand at around 875 from 1900 = 46% reduction
© 2017 Vedanta Limited 19
© 2017 Vedanta Limited 20
INDUSTRY VS CAIRN STANDARD COMPARISION
Benchmark of alarm for oil and gas industry
The Engineering Equipment and Materials Users Association
Source: BookAlarm Management for Process Control:
by: Douglas H. Rothenberg
Cairn Suvali Site- 875 alarms/ day Cairn Ravva 1100 alarms/day
Before- 1900 alarms/day 4200 alarms/day
© 2017 Vedanta Limited 21