Post on 06-Aug-2015
Australian Vinyls
Alarm Management and Rationalisation
AV – External Alarm Management and Rationalisation
AV – External Alarm Management and Rationalisation
AV – Alarm Management and Rationalisation
• Australian Vinyls – what we are • 2008 Planned Replacement of Plant Control
system • Increase in alarms generated • Alarm and message reduction program
AV Bio Control System Replacement Alarms Solutions
Australian Vinyls
• Manufacture PVC and Wood Plastic Composites
• PVC about 130kt per annum • Major Hazard Facility
AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation
Australian Vinyls
• PVC Process Overview AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation
Australian Vinyls
• Control System Replacement 2008 – New ABB system
• Alarm count dramatically increased – Device alarms (CCF) > 900 / shift – Sequence alarms (TCL) > 2700 / shift – >5 per minute – Floods in the multiple 000’s
AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation
Australian Vinyls AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation
Australian Vinyls AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation
Australian Vinyls AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation
Australian Vinyls
• Consequences of excessive alarms – Operators miss events / ignore key alarms – Incidents / unintentional equipment damage etc. – Short term mitigation
• Extra Control room operators • Engineering resources diverted to alarm management
AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation
Australian Vinyls
• Why did alarms levels increase – Older systems alarms expensive – New software alarms
• Easy to implement • Each device could have multiple alarms • People err on the side of caution • New additions tend to add in every bell and whistle
– New control system no specific effort put into this aspect before switch-over
AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation
Australian Vinyls
n Key steps – Establish a process Appoint a Champion
Data Collection - Daily analysis of A & M history Recording and reporting results / Daily / Monthly / Yearly Identify ‘nuisance’ alarms and messages – Daily / Monthly Recommend opportunities to eliminate Implement changes Measure progress – set Key Performance Indicators (KPI’s_)
AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation
Australian Vinyls
n Key steps – Analyse and Act Identify the main opportunities Repetitive TCL message frequencies (1 msg / 2 sec) Convert non essential TCL messages to INFO (non alarm) Widen deadband for analog signal “chatter” Fix device faults in fault Alarm masking (alarm when relevant)-consequential alarms Dynamic changing/enable/disable of alarm settings
• Focus on stripping column operation as >50% CCF alarms
AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation
Australian Vinyls
n Key steps – Set Targets n Initially CCF 150 / 12 hr shift
Initially TCL 250 / 12 hr shift n Key Steps – Set Priorities
n Also introduced a system to ensure any changes made to the alarm system were consistent and would not cause other issues – Formal management of change
AV Bio Control System Replacement Alarms Solutions
Priority Occurrence Emergency (Panel/ESD) Very infrequently High < 5/shift Medium < 2/hour Low < 10/hour
AV – External Alarm Management and Rationalisation
Australian Vinyls AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation
Australian Vinyls AV Bio Control System Replacement Alarms Solutions
AV – External Alarm Management and Rationalisation