13-15 November, 2013

CIGRE Tutorial & Colloquium on SMART GRID Mysore, Karnataka, India on 13-15 November, 2013

Under CIGRE Study Committee D2INFORMATION SYSTEMS AND TELECOMMUNICATION

“D2-01_30” “Alarms rationalization in Mexico

power units”

Octavio Gomez and Eric ZabreInstituto de Investigaciones Electricas

Cuernavaca, Morelos, Mexico

D2-01_30

13-15 November, 2013 D2-01_30

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.

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INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS:

With each change in the mode of operation of the power unit, the system generates more useless alarms to the operator.

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)

Operator’s exclamation…I need a better alarms management!!

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0

100

200

300

400

500

600

HORA

14/1

2/20

12 1

1:00

14/1

2/20

12 2

3:00

15/1

2/20

12 1

1:00

15/1

2/20

12 2

3:00

16/1

2/20

12 1

1:00

16/1

2/20

12 2

3:00

17/1

2/20

12 1

1:00

17/1

2/20

12 2

3:00

18/1

2/20

12 1

1:00

18/1

2/20

12 2

3:00

19/1

2/20

12 1

2:00

20/1

2/20

12 0

0:00

20/1

2/20

12 1

2:00

ALARMAS

Generation of alarms during the operation of the power unit as demand

change.

OVERLOADED

STABLE

INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS :

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INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS :

PHILOSOPHY

AUDIT

RATIONALIZATION

IDENTIFCATION

DESIGN

IMPLEMENTATION

MAINTENANCE

OPERATION

MANANGEMENT OF CHANGE

MONITORING & ASSESSMENT

A

We adopted the Alarm Management Cycle from ANSI/ISA 18.2

J

I

H

G

E

F

D

C

B

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INTRODUCTION TO ALARM MANAGEMENT IN CONTROL ROOMS :

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?

EEMUA 191 "Alarm Systems: A Guide to Design, Management and Procurement“ edition 2, - 2007.

AndANSI/ISA-18.2-2009. “Management of Alarm Systems for the Process Industries”.

International Society of Automation. USA 2009.

The methodology to alarms management is based on:

The answer always is the same: low utility.

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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”

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PERFORMANCE LEVELSEEMUA 191 PREDICTIVE

ROBUST

PREDICTIVESALARMS

STABLE

ADVANCED SOLUTIONS

REACTIVE

ALARM RATIONALIZATION

OVERLOADED

SEPARATE ALARMS OF

EVENTS

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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 andP&ID’sSetting for each alarm:

TAG, message, set-point,priority,operator action,possible causes and consequences

Separate alarms and events

Master of events

Master of alarms

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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

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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.

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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?

PREDICTIVE

ROBUST

PREDICTIVE ALARMS

STABLE AVANCED SOLUTIONS

REACTIVE

ALARM RATIONALIZ

ATION

OVERLADED

SEPARATE ALARMS OF

EVENTS

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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, andAlarm type.

From the P&ID´s we can know the process and instrumentation.

20-04-11 02:23:58:189 U4_AETI1676 MET COJ 4 BAA C FALLA Error en el canal20-04-11 02:23:58:179 U4_AETI1670 ENT LUB A ENF BAA C FALLA Error en el canal20-04-11 02:23:33:478 U4_AETI1671 SAL LUB DE ENF BAA C FALLA Error en el canal20-04-11 02:23:32:471 U4_AETI1677 MET COJ 3 BAA C FALLA Error en el canal20-04-11 02:23:30:441 U4_AETI1672 COJ 6 MET AL BAA C FALLA Error en el canal20-04-11 02:23:18:323 U4_AETI1671 SAL LUB DE ENF BAA C FALLA Error en el canal20-04-11 02:23:18:323 U4_AETI1670 ENT LUB A ENF BAA C FALLA Error en el canal20-04-11 02:23:18:323 U4_AETI1672 COJ 6 MET AL BAA C FALLA Error en el canal20-04-11 02:23:18:323 U4_AETI1674 COJ 6 EMPUJE BAA C FALLA Error en el canal20-04-11 02:23:18:323 U4_AETI1675 COJ 5 ACEITE BAA C FALLA Error en el canal

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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)

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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: Based on available time to attend the alarm and the severity of the consequences.

ALARM PRIORITY

CRITICAL ALARM HIGH

PRE-CRITICAL WARNING MEDIUM

PLANT TOLERANCE LOW

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ALARM RATIONALIZATION FOR PLANT OPERATION:

With master of alarms:

Operator actions

Write the operator actions on the process:

To open valve LV 1305To turned off pump P 1305And check indicators.And check equipment.And other actions such as

calling plant engineers.

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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…

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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.

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IMPLEMENTATION OF RATIONALIZED ALARMS:

With new database of alarmS rationalized:

Configuring DCSCreating new displays in

the DCSTraining operators

Testing alarms

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RESULTS OF APPLY THE ALARM MANAGEMENT IN THE CONTROL ROOMS:

DCS GT'u IC'u CC'pack STEAM'u HYDRO'uAlarms Before

Rationalization/UAlarms After

Rationalization/UMARK V/SIEMENS 4 880 190ABB/METSO 2 3,400 610OVATION/SIEMENS/METSO

10 3,450 650

DELTA V/ SIEMENS/OVATION/ABB 800XA

25 4,540 1,170

SIEMENS 77 4,750 490

TOTAL 4 2 10 25 77 17,020 3,110

GENERATION POWER UNITS WITH ALARM SYSTEMS RATIONALIZED

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RESULTS OF APPLY THE ALARM MANAGEMENT IN THE CONTROL ROOMS:

DCS GT'u IC'u CC'pack STEAM'u HYDRO'uSIEMENS 1

ABB/METSO 2OVATION/SIEMENS 4

DELTA V/ SIEMENS/ABB 800XA

14

SIEMENS 69

TOTAL 1 2 4 14 69

IMPLANTED UNITS RATIONALIZED ALARMS

PERFORMANCE LEVEL BEFORE THE RATIONALIZATION:

“OVERLOADED”

PERFORMANCE LEVEL AFTER THE

RATIONALIZATION: “STABLE”

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Operator alarm display before

alarm rationalization

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Operator alarm display before alarm rationalization

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Operator alarm display after alarm rationalization

0

50

100

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200

250

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

196

174185

206

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RESULTS OF APPLY THE ALARM MANAGEMENT IN THE CONTROL ROOMS:

BOMBAS DE ALTA TEMP

BOMBAS DE BAJA TEMP

AEREOENFRIADOR

ES

BOMBAS CONDENSADOS

COMPRESORES INSTRUMENTOS

COMPRESORES SERVICIOS

COMPRESORES ARRANQUE

NIVELES ANORMAL TQ´S

COMBUSTIBLES

TEMP ANORMAL TQ´S COMBUSTIBLES

NIVELES ANORMAL TQ´S ACEITES

LODOS

DISPARO DISPARO DISPARO DISPARO BAJA PRESION BAJA PRESION BAJA PRESIONN. DERRAME / BAJO

NIVELBAJA / ALTA

N. DERRAME / BAJO NIVEL

GENERADOR PRINCIPAL

AGUA DE ENFRIAMIENTO DE

MOTORMETAL CAMISA

FUEGO CAMARA DE BARRIDO

BOMBAS ALFA LUBRICADOR

CIRCUITO AIRE GASES MOTOR

CIRCUITO ACEITE DE MOTOR

BOMBAS PPAL ACEITE CIR

BOMBAS MODULO COMB

MODULO COMBUSTIBLE

RED. CARGAREQUIERE

AUMENTO ACEITERED. CARGA DISPARO RED. CARGA RED. CARGA DISPARO DISPARO BAJA PRESION

VENTILADORES CASA MAQUINAS

VENTILADORES AUXILIARES

TURBO CARGADOR

DETECTORES NIEBLA MODULO ALFA

LUBRICADOR

PROTECCIONES DEL MOTOR PPAL

CALDERA AUXILIAR

CALDERA DE RECUPERACION

BOMBAS CALDERA RECUPERACION

NIVELES CALDERIN / DESGASIFICADOR

DISPARO DISPARO DISPARO DISPARO DISPARO CIERRE VANOS DISPARON. DERRAME / BAJO

NIVEL

BOTON PARO EMERGENCIA

OPERADO TURBINA VAPOR

SISTEMA VACIO TURBINA

AEREOCONDENSADORES

FRECUENCIA DEL SISTEMA

OPERACIÓN DE PROTECCIONES TR

PPAL

OPERACIÓN DE PROTECCIONES TR

´S AUX.

OPERACIÓN DE PROTECCIONES

GENERADOR

INTERRUTORES ACOMETIDAS BOM1

AER1

INTERRUTORES ACOMETIDAS BOM2

AER2

DISPARO DISPARO BAJO VACIO DISPARO ALTA / BAJA ABIERTO 92020 ABIERTO ACOM ABIERTO 52G ABIERTO ABIRTO

INTERRUTOR ACOMETIDA CCM

SE Y SA

GENERADOR DIESEL CARGADORES DE

BATERIASINVERSOR

OPERACIÓN AUXILIARES 86

ULTIMA ALARMA  

REVISION  

ABIERTO INDISPONIBLE ACCIONES  

HIST EVENTOS TAG DESCRIPCION ALARMA REVISION ACCION

New operator alarm display.

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Operator alarm display after alarm

rationalization.Critical alarms

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Operator alarm display after to the

rationalization.Pre-critical alarms

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The “alarm book” as an

aid to the operator.

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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.

CONCLUSIONS:

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Thank you very much for your atenttion!!