Alarm Management Solutions - isawwsymposium.com€¦ · Standards Certification Education &...

22
Standards Certification Education & Training Publishing Conferences & Exhibits Alarm Management Solutions Enabling Operator Effectiveness by Improving Alarm Management Strategy 2014 ISA Water / Wastewater and Automatic Controls Symposium August 5-7, 2014 – Orlando, Florida, USA Speaker: Tom Maczuzak

Transcript of Alarm Management Solutions - isawwsymposium.com€¦ · Standards Certification Education &...

Standards

Certification

Education & Training

Publishing

Conferences & Exhibits

Alarm ManagementSolutions

Enabling Operator Effectiveness byImproving Alarm Management Strategy

2014 ISA Water / Wastewater and Automatic Controls SymposiumAugust 5-7, 2014 – Orlando, Florida, USA

Speaker: Tom Maczuzak

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA 2

Presenter: Tom Maczuzak

• Over 20 years of I&C experience.

• Various types of plants in municipal water,

electric generation and industrial sectors.

• Specializes in Advanced Alarm Management.

• MA, MBA, JD degrees.

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA 3

Presentation Outline

• How big is the problem?

• How the problem came to be

• ISA 18.2

• Alarm management solutions

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

• Do you recognize any of these behaviours?

– Operators acknowledge / silence alarms without lookingat or acting on them?

– Alarm horns turned off?

– Operators don't know what a particular alarm means?

– Alarms disabled / suppressed for long periods withoutreview?

• Do you measure?

– Number of alarms / hour?

– Number of alarms disabled / suppressed?

– Time to silence / acknowledge?

How is your Alarm System Performing

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

10) You always need to scroll your alarm list9) Your SOP only says “Acknowledge the alarm”8) Constantly pressing the “Silence” button7) Use the “Ack All” feature way too often6) A&E historian fills up every 3 months5) You have one value for H, HH and HHH limits4) All alarms are ‘High’ priority3) Nervous when the ‘usual alarms’ are missing2) Make bets on what the next alarm will be!1) Active alarm dated 8-Aug-2009 09:34:00

Top 10 signs you may have problem

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Example Alarm Issues Found at Sites

120 Alarms/hr385 standingalarms

>100 alarms inalarm summaryAlarm prioritiesare mixed (sortedon time)

No formal changecontrolWho canchange? Whocan approve?No formal

rationalizationprocess -Should it even bean alarm?

Manually writtenreports in logbookNo periodicreports

Missing orincomplete alarmresponseNo SOP

Alarm burstshappenfrequently

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Alarm Management - Then and Now

Then: number of alarmswas limited by the physicalspace in the control room

• Discrete panel boards

• More important alarms,closer to the operator

Now: DCS & SCADA –virtually no limit to the numberof alarms

“Alarms are presumed free”results in tidal waves ofalarms

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

What is alarm system management?

• Alarm management is not a product, feature set, or a onetime implementation activity

• Alarm management is part of a site strategy

– Established by company management

– Starts with an alarm philosophy

– Must include a clear owner, procedures, and the rolesand responsibilities of all involved

– Extends to the system configuration, maintenanceand resolution of issues

– Ensuring the strategy is followed - enforcement

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

ISA 18.2 Alarm Management Lifecycle

Establish terminologyand practices for alarmsystems to effectivelymaintain an alarmsystem over time

Key PerformanceIndicators (KPI) -measure the quality ofthe alarm system

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Alarm Philosophy Document (ISA 18.2)

The first step

Document thatdescribes howalarms shouldwork in a plant

Defines aconsistent alarmphilosophy for allsystems

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Alarm Philosophy Document (ISA 18.2)

Process ofconfiguring andreviewing alarmsagainst theprinciples of thealarm philosophy

Determining anddocumenting therationale anddesign

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Alarm Philosophy Document (ISA 18.2)

Continuousmonitoringmechanism needsto be implemented

Compares thecurrent with thedesired quality

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Alarm Philosophy Document (ISA 18.2)

Most-frequent alarms

Longest-standingalarms

Average time toacknowledge

Alarm prioritydistribution

Number of alarmsdisabled, inhibited,shelved andhidden…

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

ISA 18.2 Alarm Philosophy Requirements

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Tools to Identify Problem Areas

Alarm & Events Over time and Alarm & Event FrequencyReports identify problem area

Alarm rate as f(t)

Alarmsordered byfrequency

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Identify ‘Bad-Actor’ Alarms

Use an Alarm and/or Event Frequency tool to view the mostfrequent alarms - Simply specify a time period and run areport…

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Acceptable Alarm Rates KPI

Measure the quality of the alarm system - benchmarksAlarm Rates / Time

X

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Priority Distribution KPI

Measure the priority distribution against the prioritydistribution guidelines

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

• How many standing alarms do I have atany given time?

• What do I do in an alarm burst situation?• Do I have well defined SOPs for alarm

response?• Do I keep track of your alarm setpoint

changes?• What is the priority distribution of my

alarms?• Are my alarms rationalized?• What’s my average alarm rate?• How do my operators react when they see

a high priority alarm pop up?

Summary - Recognizing the Problem

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

• Understand the whole picture– Map goals to the ISA standard– Map your organization to processes– Map Goals DCS capabilities

• Maximize use of HMI tools and capabilities

• Follow a structured approach

Summary - Reaching a Solution

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Example alarm analysis tools

• Instantaneous reports

• Alarm / Event frequency

• Alarms over time

• Priority distribution

• Alarm duration

• Time to acknowledge

• Alarm performance

• Operator actions

• Standing alarms

• Co-occurences

Summary - Use Modern Tools

2014 ISA WWAC SymposiumAug 5-7, 2014 – Orlando, Florida, USA

Contact information

If you have further questions , please contact me at:

PRESENTER Tom Maczuzak

COMPANY ABB, Inc.

CONTACT PHONE (440) 585-6862

CONTACT E-MAIL [email protected]