ALARM MANAGEMENT

2

Outline

Purpose of Alarm Management Process of Alarm Management Implementation

for Projects

Purpose of Alarm Management Reduce factors that causes incidents and escalations Reduce risk to personal safety, financial loss and Environment impact Set focused attention on issues of process and equipment control &

defects Improve operators abilities to prioritize based on alarms priority,

filtering and shelving Improve efficiency and effectiveness of intervention Improve interface with HMI and thus less human error Improve lifecycle performance as alarm analyzed and resolution action

applied

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Facilities should have NO alarms or VERY LOW alarms if they are;Well DesignedWell ImplementedWell OperatedWell Maintained

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Key Objectives of Alarm Management

Milford Haven Explosion, July 1994, UKMilford Haven Explosion, July 1994, UK

Langford Gas Plant Incident,1998, AustraliaLangford Gas Plant Incident,1998, Australia

Burchfield Incident, 2005, UKBurchfield Incident, 2005, UK

Texas City BP Amoco explosion, March 2005, USATexas City BP Amoco explosion, March 2005, USA

Excessive number of alarms in emergency situation reduced the effectiveness of operator response

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Alarm Management Standards

PDO is following developments around the world in the area of Alarm Management and capturing lessons learnt.

AuditAudit

PhilosophyPhilosophy

ImplementationImplementation

(MO

C)M

anagement of Change

(MO

C)M

anagement of Change

IdentificationIdentification

RationalizationRationalization

DesignDesign

OperationOperation

MaintenanceMaintenance

Monitoring &

Assessm

entM

onitoring &

Assessment

PhilosophyDefine processes for Alarm Management and Alarm System Requirement Specification (ASRS) as per Objective and StandardsIdentificationDefine potential Alarms. (Process Hazard Analysis PHA, P&ID, Plant Operating Manual, Cause & Effect and Alarm & Trip setting drawings) RationalizationRationalization, Classification, Prioritization and documentationDesignBasic alarm design, HMI design and advanced alarm designImplementationInstall alarms, initial testing and trainingOperationOperator responds to alarms , refresher and trainingMaintenanceMaintenance repair and replacement, periodic testingMonitoring & AssessmentMonitoring Alarm data and report performanceManagement of Change Processes to authorize additions, modifications and deletion of alarmsAuditPeriodic audit alarm management process

PhilosophyDefine processes for Alarm Management and Alarm System Requirement Specification (ASRS) as per Objective and StandardsIdentificationDefine potential Alarms. (Process Hazard Analysis PHA, P&ID, Plant Operating Manual, Cause & Effect and Alarm & Trip setting drawings) RationalizationRationalization, Classification, Prioritization and documentationDesignBasic alarm design, HMI design and advanced alarm designImplementationInstall alarms, initial testing and trainingOperationOperator responds to alarms , refresher and trainingMaintenanceMaintenance repair and replacement, periodic testingMonitoring & AssessmentMonitoring Alarm data and report performanceManagement of Change Processes to authorize additions, modifications and deletion of alarmsAuditPeriodic audit alarm management process

Alarm Management LifecycleAlarm Management Lifecycle

EEMUA 191

ISA 18.2

DEP 32.80.10.14

GU 513

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Step 3:Step 3:Step 3:Step 3:• Perform Bad Actor Alarm Resolution

Step 4:Step 4:Step 4:Step 4:• Implement Real-time Alarm Management

Step 5:Step 5:Step 5:Step 5:• Perform Alarm Documentation and Rationalization (D&R) [Critical:5%, High:15%, Low:80%]

Step 6:Step 6:Step 6:Step 6:• Implement Alarm Audit & Enfonce Techniques (A&E)

Step 7:Step 7:Step 7:Step 7:• Control & Maintain the Improved Systems

Step 2:Step 2:Step 2:Step 2:• Collect Data & Benchmark system

Step 1:Step 1:Step 1:Step 1:• Develop, Adopt & Maintain an Alarm Philosophy

Process of Alarm Management

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Alarm Rationalization Alarm Rationalization Workshop

Applicable for Green Field/Brownfield/FCP/Expansion Projects Complete Variable Table (VT) Utilize PDO Approved Facilitators for Rationalization. Rationalization Workshop Requirements

o Documentation: POM, Alarm & Trip Setting, PEFSo Workshop Participants: PDO Approved Facilitator, Operations, Maintenance,

Process Engineering, C&A, Rotating/Static/Other Constraint Owners Only the following Priorities in the System

o CRITICALo HIGHo LOWo JOURNAL

Issue Workshop Closeout Report Forward Variable table to ONO63/Function (UEOA31/33)

PDO Approved Facilitators Saif Al Berwani Dalmar Jama Mohsin Alharthy Biplap Mazumdar Kannan, Palaniappan UEOA28 Contact function (UEOA31/33) for latest list

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Rationalization Implementation Implementation

Ensure Implementation of Rationalization Workshop Outcome in the system OEMs made aware of implementation Requirement NO ALARMS TO BE CONFIGURED IN THE SYSTEM UNLESS IT IS IN VARIABLE

TABLE System Requirements

PDO uses Alarm Management Software called PAS. Currently 55 facilities connected to PAS system.

PAS License required for each new facility (if not currently connected) are;o Data Connection Licenseo Audit & Enforce License

DCS Licenses required (if not currently available) are:o OPC A&Eo Alarm Suppressiono Alarm Shelving

Contact Function (UEOA31/33) for License requirements.

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Alarm Management KPIs & Reporting Alarm Management KPIs

1. Average Alarm Rate / Hour (per operator console): OI: : 12 Alarms / Hour DEP/GU : 06 Alarms / Hour Project : <3 Alarms / Hour (Blade 24 Top Quartile)

2. Standing Alarms (Future - 2015)3. Peak Alarms (Future - 2015)

Project Acceptance Criteria Acceptable KPIs for 3 months period before acceptance

Commissioning Alarms Alarms during commissioning (prior to handover) should NOT go to the

operator. Commissioning alarms should go to dedicated “commissioning” workstations. Vendors made aware of commissioning alarms management as above

Reporting Monthly Reporting Commissioning alarm to be excluded from reporting (only if going to

commissioning workstation) Manual exclusion using Web Based AM dashboard at this time. Project to

support ONO63/AM focal points.

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Bad Actor Fix Progress Monitoring

Overall Bad Actor Fix %age w.r.t. Baseline (Asset A) = 73%Overall Bad Actor Fix %age w.r.t. Baseline (Asset B) = 49%Overall Bad Actor Fix %age w.r.t. Baseline (Asset C) = 66%

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Alarm Management Roadmap

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Alarm QualificationIt shall require a defined Operator Response

It shall not

duplicate other

alarms

It sh

ould

indi

cate

wha

t

Pri

ority

Ope

rato

r

shou

ld a

ssig

n to

it

NOT too early that no operator response is required

NOR too late that no time left to respond

It shall have an appropriate

message that is easily

understood

It sh

all h

ave

signi

fican

t

oper

ation

al v

alue

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Alarm Management JourneyJourney Begins – Long Term Trend 2009-2013

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Alarm Management Roadmap

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Conclusion High alarm rate signifies shortfall of one or more of the following:

Design. Implementation of design intent. Operation effectiveness. Maintenance effectiveness

Alarm Management performance improvement needs: Motivated concerted team effort Sustainability of achievement Reiteration and goal post changing Culture embedding at all level Documentation for consistency Analysis tool i.e. data/dashboard

Targets achievable when focus is maintained by: Daily monitoring at facility level Weekly review by Integrity Engineering Monthly review and reporting at Asset Leadership level Quarterly corporate level review

Leadership support is required to successfully achieve and sustain Alarm Management