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Alarm Management Reflections - ISA...• ISA-TR18.2.6-2012 Alarm Systems for Batch and Discrete...
Transcript of Alarm Management Reflections - ISA...• ISA-TR18.2.6-2012 Alarm Systems for Batch and Discrete...
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Alarm Management
Reflections
Nicholas P Sands, CAP, PE
Manufacturing Technology Fellow, DuPont
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About the Presenter
Nicholas Sands, CAP, PE
• ISA Fellow
• Control engineer at DuPont
• 25 years of experience in chemical plants
• Co-chair of ISA18 standard committee
• Secretary of IEC 62682 standard committee
• Recreational musher
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Outline
• Safety Moment
• Challenges of Alarm Management
• Goals of Alarm Management
• The Lifecycle
• The Program
• Reflections
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Safety Moment – Overflow Incidents
In many overflow incidents, alarms were designed to
protect against the consequence, but:
• Instrument may not measure
• Alarm may not activate
• Operator may not see alarm
• Operator may not believe
alarm requires action
• Operator may not take action
in response to the alarm
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Common Challenges of Alarm Management
• Alarm management is recognized as a common issue in
the process industries
• Alarm-related issues have an estimated cost of more
than $20 billion per year to U.S. industry
• Poorly performing alarm systems are often a
contributing factor in industrial incidents
• Common issues include:
– Stale alarms
– Chattering alarms
– Alarms that do not require a response
– Other nuisance alarms
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Goals of Alarm Management
• Alarms should give the operator an indication of the
right time to take the right action to avoid undesired
consequences
• Operators should be trained on the right actions
• Alarm system should be monitored to keep
performance within limits and not overwhelm the
operator
• Nuisance alarms should be
identified and corrected to keep
the alarm system working
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Definition of Alarm
…An audible and/or visible means of indicating to
the operator
…An equipment malfunction, process deviation, or
abnormal condition requiring a timely response
- from IEC 62682 and ANSI/ISA-18.2-2015
- modified from ANSI/ISA-18.2-2009
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Alarm Management Lifecycle
• ANSI/ISA-18.2 lifecycle model represents the overall process of alarm system management for both new and existing systems
• The same lifecycle is in the IEC62682 standard
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DuPont Alarm Management Plan
1. Leadership
2. Monitoring
3. Benchmark
4. Quick Hits
5. Training
6. Philosophy
7. Rationalize
8. Improvement
9. Audit
9 7
6 5
4
3
2 8
1
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Results
• The 2012 program was
completed in December
• Over 250 control systems
worldwide are now monitored
• This is a culture change for
alarms and alarm systems
• There has been a dramatic
reduction in nuisance alarms
• There is progress in overall
alarm system performance
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Next Steps
• Dynamic Suppression
– Beyond designed suppression
• Providing Guidance
– Visualization of rationalization
information at the operator console
– Without this, difficult to get a return on
investment in rationalization
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Reflections
• Monitoring • Surprising (to some) data on the average alarm rate
• Key to continuous improvement
• Benchmark (initial audit) • Surprising (to some) number of alarms configured
• Rationalization • Excellent knowledge capture from experienced personnel
• Excellent training information
• Discovery process for how things actually work
• Different thinking needed vs PHA
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Reflections
• Alarm systems should be recognized as a key
indicator of operational excellence
• Well planned and executed alarm management
improves: – Safety
– Reliability
– Quality
– Efficiency
• Structured, sustainable, standards-based lifecycle
approach to alarm management should provide
significant operational and cost benefits
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Reflections
• A top-down approach is needed
• Suppression methods are key to continuous
improvement
• Integrity verification and rationalization information
availability are key functionalities
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More Information
• ISA-TR18.2.6-2012 Alarm Systems for Batch and
Discrete Processes
– Covers the application of ISA-18.2 lifecycle to batch processes
– Generally the same with more focus on:
– Rationalization for different operations and phases
– Design of alarms with more common designed suppression
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International Electrotechnical
Commission
Standards on Alarm Management
EEMUA 191 - Alarm Systems - A Guide
to Design, Management and
Procurement
Guideline, not a standard, updated in
2013
• ANSI/ISA 18.2 Management of Alarm
Systems in the Process Industries
Updated in 2015
• IEC 62682 Management of Alarm
Systems in the Process Industries
Based on ANSI/ISA 18.2
Published Oct 2014
Engineering Equipment and
Material Users’ Association
International Society of
Automation
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Questions?
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