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13-15 November, 2013

“D2-01_30” “Alarms rationalization in Mexico power units”. Octavio Gomez and Eric Zabre Instituto de Investigaciones Electricas Cuernavaca, Morelos, Mexico. CIGRE Tutorial & Colloquium on SMART GRID Mysore, Karnataka, India on 13-15 November, 2013 Under CIGRE Study Committee D2

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13-15 November, 2013

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  1. “D2-01_30” “Alarms rationalization in Mexico power units” Octavio Gomez and Eric Zabre Instituto de Investigaciones Electricas Cuernavaca, Morelos, Mexico CIGRE Tutorial & Colloquium on SMART GRID Mysore, Karnataka, India on 13-15 November, 2013 Under CIGRE Study Committee D2 INFORMATION SYSTEMS AND TELECOMMUNICATION D2-01_30 13-15 November, 2013

  2. CONTENTS: • INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS. • ALARM RATIONALIZATION FOR PLANT OPERATION. • IMPLEMENTATION OF RATIONALIZED ALARMS. • RESULTS OF APPLY THE ALARM MANAGEMENT IN THE CONTROL ROOMS. • CONCLUSIONS. D2-01_30 13-15 November, 2013

  3. INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS: At some power unit in Mexico at 11:00 pm… From control center… -Peak hour is over, please low charge….. The unit is generating 300 mw, and then… low until 180 mw… The monitor of operator receives to alarms flood (300 to 400 alarms/minute). at 11:30 pm… From control center… -Please up charge because the power central next is shut-down…..!!! The unit is generating 180 mw, and then… up until 300 mw… The monitor of operator receives to alarms flood (300 to 400 alarms/minute) With each change in the mode of operation of the power unit, the system generates more useless alarms to the operator. Operator’s exclamation… I need a better alarms management!! D2-01_30 13-15 November, 2013

  4. INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS : OVERLOADED STABLE Generation of alarms during the operation of the power unit as demand change. D2-01_30 13-15 November, 2013

  5. AUDIT PHILOSOPHY A MANANGEMENT OF CHANGE IDENTIFCATION RATIONALIZATION DESIGN IMPLEMENTATION MONITORING & ASSESSMENT OPERATION MAINTENANCE INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS : We adopted the Alarm Management Cycle from ANSI/ISA 18.2 J I B C D E H F G D2-01_30 13-15 November, 2013

  6. INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS : The methodology to alarms management is based on: EEMUA 191 "Alarm Systems: A Guide to Design, Management and Procurement“ edition 2, - 2007. And ANSI/ISA-18.2-2009. “Management of Alarm Systems for the Process Industries”. International Society of Automation. USA 2009. Diagnosis and determination of “performance level” of alarms systems: Survey to power unit operator Utility of alarms during normal operation? Utility of alarms during upset? Utility of alarms during shut-down? The answer always is the same: low utility. D2-01_30 13-15 November, 2013

  7. INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS : Others issues for diagnosis and determination of “performance level” of alarms systems: number of alarms in database? rate of alarms during a shift? rate of alarms during an upset? rate of alarms during a shut-down? Diagnosis: all systems were “OVERLOADED” D2-01_30 13-15 November, 2013

  8. D2-01_30 13-15 November, 2013

  9. ALARM RATIONALIZATION FOR PLANT OPERATION: Formation of the group responsible for alarms management Develop alarm philosophy. Set targets of the rationalization Gathering data: Historical record, Database and P&ID’s • Setting for each alarm: • TAG, • message, • set-point, • priority, • operator action, • possible causes and consequences Master of alarms Separate alarms and events Master of events D2-01_30 13-15 November, 2013

  10. ALARM RATIONALIZATION FOR PLANT OPERATION: Formation of the group responsible for alarms management • The Superintendent of Central becomes aware current status of alarm system • The Superintendent of Central designates staff to alarm management. • Chief operating • Chief C&I • Chief Electrical • Facilitator D2-01_30 13-15 November, 2013

  11. ALARM RATIONALIZATION FOR PLANT OPERATION : Develop alarm philosophy. • To define responsibilities and functions of each of the participants. • To define basis for design of alarms. • To define alarms priority classes. • To define criteria for the display alarms in the operator’s screen. • To define the method for monitoring the performance of alarm system. • To define the method of alarm system maintenance. • To define tests to alarms. • To define structure of alarm system documentation. • To define guidelines for implementation of rationalized alarms. • Operator training for new philosofy alarms. D2-01_30 13-15 November, 2013

  12. ALARM RATIONALIZATION FOR PLANT OPERATION: Set targets of the rationalization. • To define the target level of alarm system performance. • “STABLE” is the target level. • What kind type of alarms will be rationalized? • Only process alarms? • System diagnostic alarms? • Maintenance alarms? • How many alarms are rationalized by day? D2-01_30 13-15 November, 2013

  13. ALARM RATIONALIZATION FOR PLANT OPERATION: Gathering data: Historical record, Database and P&ID’s • With historical records, we can identify: • Useful alarms. • Useless alarms. • Nuisance alarms. • Frequent alarms. • Alarm rate in normal operation. • Alarm rate prior to upset. • Alarm rate in to upset. • Alarm rate after upset. • From the database we can know: • Number of alarms configurated in the DCS, and • Alarm type. From the P&ID´s we can know the process and instrumentation. D2-01_30 13-15 November, 2013

  14. ALARM RATIONALIZATION FOR PLANT OPERATION: Separate alarms and events (alarm identification) • Events and alarms are presented together in the same display ( list form). • Events: • pump turned on, • Valve opened, • ..and so on. • Alarm: • “an audible or visible means of indicating to the operator an equipment or process malfunction or abnormal condition”. (EEMUA 191) • “an audible and/or visible means of indicating to the operator an equipment malfunction, process deviation, or abnormal condition requiring a response”. (ANSI/ISA 18.2) D2-01_30 13-15 November, 2013

  15. ALARM RATIONALIZATION FOR PLANT OPERATION: With master of alarms: Write a new alarm message: easily understood by the operator. Define setting alarm: based on the process dynamics. “Chattering alarm require a careful study” Define priority: Basedonavailable time toattendthealarm and theseverity of theconsequences. D2-01_30 13-15 November, 2013

  16. ALARM RATIONALIZATION FOR PLANT OPERATION: With master of alarms: • Operatoractions • Writetheoperatoractionsontheprocess: • To open valve LV 1305 • Toturned off pump P 1305 • And checkindicators. • And checkequipment. • And otheractionssuch as callingplantengineers. D2-01_30 13-15 November, 2013

  17. ALARM RATIONALIZATION FOR PLANT OPERATION: With master of alarms and P&ID´s: Identify possibles causes of the alarm: What happened downstream of the alarm? What happened upstream of the alarm? What was the first change in the process? What changed surroundings of the process?Some valve stuck.Some valve that is opened without the ordered by the operator or from DCS.Any pump that provided more flow.A pump turned off without operator intervention.and so… D2-01_30 13-15 November, 2013

  18. ALARM RATIONALIZATION FOR PLANT OPERATION: With master of alarms and P&ID´s: Identify possibles consequences of the alarm not resolved opportunely: Plant trip. Unit trip. Equipment damage. Loss of process fluids. Damage to the environment. Injury to staff. D2-01_30 13-15 November, 2013

  19. IMPLEMENTATION OF RATIONALIZED ALARMS: With new database of alarmS rationalized: Configuring DCS Creating new displays in the DCS Training operators Testing alarms D2-01_30 13-15 November, 2013

  20. RESULTS OF APPLY THE ALARM MANAGEMENT IN THE CONTROL ROOMS: GENERATION POWER UNITS WITH ALARM SYSTEMS RATIONALIZED D2-01_30 13-15 November, 2013

  21. RESULTS OF APPLY THE ALARM MANAGEMENT IN THE CONTROL ROOMS: IMPLANTED UNITS RATIONALIZED ALARMS PERFORMANCE LEVEL AFTER THE RATIONALIZATION: “STABLE” PERFORMANCE LEVEL BEFORE THE RATIONALIZATION: “OVERLOADED” D2-01_30 13-15 November, 2013

  22. Operator alarm display before alarm rationalization D2-01_30 13-15 November, 2013

  23. Operator alarm display before alarm rationalization D2-01_30 13-15 November, 2013

  24. Operator alarm display after alarm rationalization D2-01_30 13-15 November, 2013

  25. RESULTS OF APPLY THE ALARM MANAGEMENT IN THE CONTROL ROOMS: New operator alarm display. D2-01_30 13-15 November, 2013

  26. Operator alarm display after alarm rationalization. Critical alarms D2-01_30 13-15 November, 2013

  27. Operator alarm display after to the rationalization. Pre-critical alarms D2-01_30 13-15 November, 2013

  28. The “alarm book” as an aid to the operator. D2-01_30 13-15 November, 2013

  29. CONCLUSIONS: The performance level of alarm system in generating units should be STABLE to avoid: Plant trip. Unit trip. Equipment damage. Loss of process fluids. Damage to the environment. Injury to staff The operator display should be changed to operator have more process information. D2-01_30 13-15 November, 2013

  30. Thank you very much for your atenttion!! D2-01_30 13-15 November, 2013

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