importance of alarm management for preventing …...importance of alarm management for preventing...
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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
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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
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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
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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
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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%
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◆ 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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