Importance of Alarm Management for Preventing …...Importance of Alarm Management for Preventing...
Transcript of Importance of Alarm Management for Preventing …...Importance of Alarm Management for Preventing...
Importance of Alarm Management
for Preventing Accidents
which Lead to Environmental Pollution
Idemitsu Kosan Co., Ltd.
Technical & Engineering Center
Hiroaki Mimura
6th February, 2013
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1. Introduction
Accidents has a very serious impact on the Environment.
“Safety” is the most important aspect in plant operation!!
September 2003 in HOKKAIDO
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Caused by
BIG Earthquake
Cause of serious accidents
1. Introduction
Many accidents caused by human error
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I can’t watch toomany alarms!!
DCS appeared
2. Alarm management at IDEMITSU
Number of alarms is increasing
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STEP-3:Perform “Bad actor” alarm resolution
STEP-2:Collect data and benchmark your systems
STEP-1:Develop, adopt, and maintain an Alarm Philosophy
STEP-7:Control and maintain your improved system
STEP-6:Implement real time alarm management
STEP-5:Implement alarm audit and enforcement technology
STEP-4:Perform alarm documentation and rationalization
“7 steps to a highly effective Alarm System”
Always-needed steps:
Steps to implement based on alarm system performance
2. Alarm management at IDEMITSU
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We have been doing alarm reduction as
“Non-touch Operation Activity”
Focus on 10 highest frequency alarms
◆Frequent alarms →Reviewing alarm setting
→Reviewing PID parameter
◆Routine alarms →Automating routine operation.
◆Redundant alarms →Removing alarms
STEP-3:Perform “Bad actor” alarm resolution
STEP-2:Collect data and benchmark your systems
STEP-1:Develop, adopt, and maintain an Alarm Philosophy
2. Alarm management at IDEMITSU
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① Create a database of the alarms
② Separation of critical alarms display
③ Unnecessary alarm suppression
2. Alarm management at IDEMITSU
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STEP-7:Control and maintain your improved system
STEP-6:Implement real time alarm management
STEP-5:Implement alarm audit and enforcement technology
STEP-4:Perform alarm documentation and rationalization
Alarm management software “CAMS”
Go to
next STEP
SafetyGr-Ⅲ(critical)
Gr-Ⅱ Gr-Ⅰ
EnvironmentGr-Ⅲ(critical)
Gr-Ⅱ Gr-Ⅰ
Damage to theequipment(ESD)
Gr-Ⅲ(critical)
Gr-Ⅱ Gr-Ⅰ
Damage to theequipment (Design)
Gr-Ⅲ(critical)
Gr-Ⅱ
Damage to theequipment(Trip)
Gr-Ⅲ(critical)
Gr-Ⅱ Gr-Ⅰ
Quality Gr-Ⅲ Gr-Ⅱ
Operation change Gr-Ⅲ Gr-Ⅱ
Decreasein production
XHQ Gr-Ⅲ
Others XHQ ANA
Less than8hour
Less than2hour
Less than30min
Less than5min
Less than1min
Urgent
① Create a database of the alarms
Pu
rpo
se
3. Method
Urgency
GrⅠ: Control limit(ESD)
GrⅡ: Operation limit
GrⅢ: Operation value
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We classified all tags
② Separation of critical alarms display
3. Method
It is difficult to check critical alarms
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All process alarms
Critical alarms
It is easy to check critical alarms
Ex) FIC9014 (PID block) : Superheated steam to Refinery
③ Unnecessary alarm suppression
3. Method
Steam
FIC9014
ESDSIGNAL!!
VALVE SHUT!!
Refinery
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③ Unnecessary alarm suppression
3. Method
Time →
Flo
w R
ate
→
Lowlimit
Highlimit
ESD
Targetvalue
Velocity
Deviation
MV HL
1 F9014.HI
2 F9014.LO
3 F9014.DV+
4 F9014.DV-
5 F9014.VEL+
6 F9014.VEL-
7 F9014.MHI
8 F9014.MLO
9 F9014.IOP+
10 F9014.IOP-
11 F9014.OOPAlarm flooding by massive alarms
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Operator feels relief to control
plants by alarm suppression!!
Peak alarm rate / 10 min
・Should be manageable <10
・Hard to cope 20‐100
・Definitely excessive >100
EEMUA benchmarks
4. Alarm suppression performance
◆ A section of X plant the result of suppression in ESD
No suppression: 68
After suppression: 5
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No suppression : 1754
After suppression : 191
Operator can monitor
easily in ESD operation
4. Alarm suppression performance
◆ All section of X plant the result of suppression in ESD
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Reduction rate:
90%
◆ Good Mark
・You can decrease operator’s labor and improvethe plant safety.
・You can introduce alarm management systemwithout equipment costs.
◆ Bad Mark
・You must make a great effort to create alarmdatabase.
With the introduction of alarm management…
5. Conclusion
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Alarm
management
Life cycle
◆ Attention
・Only introducing software is meaningless!!
・It is very important to carry out regular reviewsof the alarm management!!
OperationRationalization
AssessmentMaintenance
5. Conclusion
I must classify all
alarm tags!
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Thank you for your attention.
Feel Easy!!
5. Conclusion
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