Alarm Management For Process Control
ContentsAbout the t a HandbookAudienceUsefulnessContentsPart I: The Alarm Management ProblemPart II: The Alarm Management SolutionPart III: Implementing Alarm ManagementBook DeliverablesImportant xvixxxvixxxvixxxviixxxviixxxviiPart 1: The Alarm Management Problem1Chapter 1: Meet Alarm Management31.1 Key Concepts1.2 Alarm Performance ProblemsSymptomsEvidence1.3 Reasons for Alarm ImprovementHow Alarms Fit into Process Operating SituationAlarm dd ix7/31/09 1:07 PM
Contents Chapter 11.4 A Brief History of Alarm Management1.5 The “Management” in Alarm Management1.6 Alarm Design Roadmap1.7 Audience for this Book1.8 Importance of Alarm Management1.9 Fundamentals of Alarm ManagementBottom Line of Alarm ManagementFundamentalsOperator ActionImportance of the Fundamentals1.10 Design for Human Limitations1.11 Alarm Management and Six Sigma1.12 Controls PlatformsPLC versus DCSPLC Special Considerations1.13 Continuous versus Discrete and Batch1.14 Application Effect on Alarm Design1.15 Time and Dynamics1.16 Historical IncidentsThree Mile IslandMilford HavenTexas CityWhy Now?1.17 The New DesignNot by Subtraction AloneStarting Alarm ImprovementAlarm PhilosophyData Gathering and AnalysisAlarm Conventions and Redesign Guidelines1.18 Example Alarm Redesign (Rationalization) Results1.19 Completing the DesignAdvanced TechniquesSituation AwarenessOperator Screen DesignOperational Integrity ImprovementCondition fm.indd x7/31/09 1:07 PM
Contents Chapter 21.20 Alarm Improvement Projects1.21 Lessons for Successful Alarm Management1.22 Important Design and Safety Notice1.23 Conclusion1.24 Notes and Additional ReadingNotesRecommended Additional ReadingChapter 2: Abnormal Situations2.1 Key Concepts2.2 Introducing Abnormal SituationsTwo ScenariosThe Two Sides of Abnormal Situations2.3 Observing Abnormal Situations2.4 Understanding Abnormal Situations2.5 Understanding IncidentsGeneral Concepts LearnedYour Plant Data2.6 General Lessons from IncidentsExamination for CauseHazards Defined by the FAATwo Events2.7 Critical Contributors to IncidentsSubtle AbnormalitiesThe Human Nature of OperatorsStop in Time2.8 The Importance of TimeAn ExampleProcess Safety TimeSUDAAlarm Activation Point and Time2.9 Why Abnormal Situations Are Important2.10 Message of Abnormal SituationsState of Control LoopsThe Magic in a Control LoopAbnormal Situations in fm.indd xi7/31/09 1:07 PM
Contents Chapter 32.11 Notes and Additional ReadingNotesRecommended Additional Reading737373Chapter 3: Strategy for Alarm Improvement753.1 Key Concepts3.2 How We Got Ourselves into TroubleControls Technology EvolutionHow We ThinkThe Way Forward3.3 The Alarm Management ProblemSymptomsRoot CausesA Good AlarmSo Many Alarms, So Little TimeBenefits of Rationalization3.4 Alarm Activation Path3.5 The Geography of Alarm ManagementPlant Area ModelSmallest Area of Rationalization3.6 Alarm Improvement TeamsRepresentationLocal TeamsSite TeamLarge Corporate Team3.7 Alarm Improvement Projects3.8 Standards and Regulations OverviewBest Practices SummaryKey MessagesGuides, Standards, and Regulations3.9 Proposed RegulationsDepartment of Transportation (United States)3.10 Standards and GuidesEEMUA 191NAMUR (Germany)ISA 93949494959698xiiimo-rothenberg-00fm.indd xii7/31/09 1:07 PM
Contents Chapter 4OSHA (United States)HSE (UK)EPRI (United States)Remarks3.11 Conclusion3.12 Notes and Additional ReadingNotesRecommended Additional ReadingChapter 4: Alarm Performance4.1 Key Concepts4.2 Alarm Problems4.3 Alarm Performance Assessment4.4 Alarm Metrics and BenchmarksWhy Have Metrics?Plant Area of Focus—A Single-Operator AreaBasic Configuration MetricsBasic Activation Metrics4.5 Alarm Assessment ToolsWhy Use a Tool?Characteristics of Good ToolsTool ProvidersGetting the Data InConfiguration DataActivation Data4.6 Configuration Analysis4.7 Activation AnalysisActivation Analysis across Industrial SegmentsDeriving Implications from Activation AnalysesAcknowledgment RatioTime to AcknowledgeTime to ClearAlarm FloodChattering and RepeatingRelated and ConsequentialStanding and 122123123xiiiimo-rothenberg-00fm.indd xiii7/31/09 1:07 PM
Contents Chapter 4Nuisance Alarms (Bad Actors)4.8 Advanced Activation Analysis4.9. Alarm Correlation AnalysesSituationsGeneral Comments4.10 One Day in the Life of an Alarm System—ConfigurationNumber of Tags and Tags with AlarmsNumber of Alarms by Alarm TypePriority of Configured AlarmsDuplicate Alarms4.11 One Day in the Life of an Alarm System—ActivationThe Raw DataAmount of Data Produced in One DayAlarm ActivationsTime in AlarmTime to AcknowledgeOperator Actions4.12 Alarm System Performance Levels4.13 Conclusion4.14 Notes and Additional ReadingNotesRecommended Additional 35137137139140140140141Part 2: The Alarm Management Solution143Chapter 5: Permission to Operate1455.1 Key Concepts5.2 Management’s Role5.3 Operating SituationsOperating in UncertaintyUnique EventsExplosive EventsDefinitions5.4 How Permission to Operate Came to Be5.5 How Permission to Operate 00fm.indd xiv7/31/09 1:07 PM
Contents Chapter 55.6 Permission to Operate5.7 Alternative Methods for Granting PermissionDe Facto DecisionsOperating Modality Decisions5.8 Managing the Operator’s PermissionQualifying AbnormalNo Help at HandObserver EvaluationOperator EvaluationPutting It All Together5.9 Shut Down and Safe ParkOperator-Initiated ShutdownAutomated ShutdownSafe Park5.10 Special TechnologyDetection and Warning of Abnormal ConditionsConditions Related to the PlantConditions Related to the Operator5.11 Operator Redeployment5.12 Process ComplexityLinearly Related ComplexityIntegrated/Complex Related5.13 Training and SkillsIndustrial ManufacturingMilitary Training5.14 Other Key Principles of OperationAdditional Operating PrinciplesField PrinciplesSafety System PrinciplesDesign and Inspection PrinciplesManagement Principles5.15 What Is Being Done by OthersTechnology in Development5.16 Conclusion5.17 9169169170xvimo-rothenberg-00fm.indd xv7/31/09 1:07 PM
Contents Chapter 6Chapter 6: Alarm Philosophy6.1 Key Concepts6.2 CaveatsA Foundation Is at the BottomOwner versus DesignerReliance on PhilosophyCompleteness6.3 Getting StartedOperator SurveyAdvice to the Reader on Timing of This Topic6.4 Special Alarm IssuesTypes of Alarms and Their Recommended UseSmart Field DevicesLight BoxesSpecial Cases of Redundant AlarmsAbout AlertsClasses of Alarms6.5 Overview of Alarm PhilosophyPhilosophy 101Operator-Centric ItemsPlant-Centric ItemsAlarm System PurposePhilosophy IntentElements in the Philosophy6.6 Alarm PriorityPriority LevelsPriority NamesHumorous Illustration of PriorityConsequence and SeverityUrgencyPriority AssignmentAlarm Priority Assignment Setup Review6.7 Enterprise Philosophy FrameworkOverviewFramework Philosophy DocumentAt the Enterprise 2193194196196xviimo-rothenberg-00fm.indd xvi7/31/09 1:07 PM
Contents Chapter 6Factoring It All into the Philosophy6.8 Site-Level PhilosophySite PersonalityThe Rest of the “Bases”6.9 Alarm Design PrinciplesFundamental PrinciplesFunctional PrinciplesKey Performance IndicatorsCritical Success FactorsApproved Management of Change RequirementsProcedure for RationalizationAlarm Configuration: Specific IssuesAlarm Activation Point DeterminationPriority AssignmentAlarm PresentationOperator RolesInterplay with ProceduresTrainingEscalationMaintenance6.10 Example Procedure: To Silence or to Acknowledge6.11 Philosophy Hit List6.12 Alarm Philosophy WorkshopWorkshop DetailsFacilitationPreparation6.13 Enterprise Philosophy Framework6.14 Conclusion6.15 NotesChapter 7: Rationalization7.1 Key Concepts7.2 IntroductionBasic ApproachesCornerstone Concepts of Alarm Management7.3 About the Word indd xvii7/31/09 1:07 PM
Contents Chapter 77.4 Checklist7.5 Getting Ready to RationalizeHousekeepingBad ActorsFilters and DeadbandsThe DataAlarm Documentation and Rationalization ToolsRationalization Is Not Just About Numbers7.6 Alarm Response ManualHeader InformationConfiguration DataCausesConfirmatory ActionsConsequences of Not ActingAutomatic ActionsManual Corrective ActionsSafety-Related Testing RequirementsExample Online Alarm Response SheetAdditional Items7.7 Rationalization MethodsAlarms Are Not the Important PartRationalization Approaches“Starting from Where You Are” Rationalization“Starting from Zero” Rationalization7.8 Required Alarms and Common ElementsRequired AlarmsCommon Elements7.9 “Starting from Where You Are” RationalizationWork Process7.10 “Starting from Zero” RationalizationWork ProcessWrap-Up7.11 Only Four Alarms7.12 Identifying Subsystem BoundariesDecomposition7.13 “Starting from Zero” 7249249251251256xviiiimo-rothenberg-00fm.indd xviii7/31/09 1:07 PM
Contents Chapter 7FurnaceHeat Exchanger7.14 Working Through the DatabaseMethod of FlowsMethod of ElementsChoosing a Method7.15 The Alarm Activation PointAlarm Activation Point DeterminationA Digression in Setting Alarm Activation PointsThe Limit of Alarm LimitsGeneralizing Alarm Activation Point CalculationsToo Much Time; Just Enough TimeAlarm “Pick-Up” Order7.16 Determining Alarm PriorityAssigning PriorityCalibrating the Alarm Priority Assignment ProcessNonweighted Maximum Severity withUrgency Direct to Priority7.17 Alarm Priority Assignment ExamplesSum of All SeveritiesSum of All Severities Weighted by UrgencyMaximum SeverityUrgency OnlyMaximum Severity Weighted by UrgencySummary of Examples7.18 Rationalization Working SessionsTeamsParticipant PreparationWork AreasWork SessionsEvents Schedule7.19 Partial RationalizationsConcepts and ExperienceBad ActorsRationalize Only Important Parts of theOperator’s 294294xiximo-rothenberg-00fm.indd xix7/31/09 1:07 PM
Contents Chapter 8Rationalize Only Alarms that ActivateBottom Line7.20 Conclusion7.21 Notes and Additional ReadingNotesRecommended Additional ReadingChapter 8: Enhanced Alarm Methods8.1 Key Concepts8.2 Beginning8.3 The Situation8.4 Safety NoticeOperator AwarenessMonitoringUnsafe Operations8.5 Enhanced Alarm Functions8.6 Enhanced Alarm InfrastructureGeneral ConsiderationsAlarm ProcessorsBasic InfrastructureEnhanced InfrastructureAlarm Integrity Monitoring8.7 Operator ConsentImplement AutomaticallyImplement Unless CancelledSuggest with Positive Response RequiredSuggest Only8.8 Operator-Controlled Suppression Techniques8.9 Preconfigured, Simplified Suppression Techniques8.10 Informative AssistanceWhen Informative Assistance Is UsefulHow to Do ItExamplesMore Examples8.11 Knowledge-BasedPattern RecognitionNeural 5316318319320321xximo-rothenberg-00fm.indd xx7/31/09 1:07 PM
Contents Chapter 9Fuzzy LogicKnowledge-Based ReasoningModel-Based Reasoning8.12 Keeping Track of Plant StateExplicit Plant StatesImplicit Plant States8.13 Alarm Information without Alarm ActivationPlant Area ModelConditional Alarming Facilitators8.14 Alarm Activation PermissionsCategory I AlarmsCategory II AlarmsCategory III Alarms8.15 Conclusion8.16 Notes and Additional ReadingNotesRecommended Additional 33333333Part 3: Implementing Alarm Management335Chapter 9: Implementation3379.1 Key Concepts9.2 Beginning9.3 Implementation StepsApprovalsConfigurationEnhanced Alarm FeaturesProcess Graphics and Other ureOperability ReviewFinal Approval9.4 ImplementationSimulators and TrainingCutover and 43343xxiimo-rothenberg-00fm.indd xxi7/31/09 1:07 PM
Contents Chapter 10Moving On9.5 ConclusionChapter 10: Life Cycle Management10.1 Key Concepts10.2 Assess Alarm PerformanceInitial AssessmentPeriodic AssessmentTiming of AssessmentsCollection of DataEvery Alarm Activation Points to Opportunity10.3 Interpretation of Periodic AssessmentsEvaluateLook for Added BenefitsModify and RepairMonitor and EnforceNuisance AlarmsAlarm CreepAdding and Removing Alarms10.4 Advanced Interpretation of Periodic AssessmentsNomenclature and DesignValueCases10.5 Statistical Process Control and Alarm ManagementBackgroundRelevance to Alarm ManagementGuidance10.6 EnforcementEnforcement by ShiftPeriodic EnforcementAperiodic Enforcement10.7 NotesChapter 11: Project Development11.1 Key 9371372xxiiimo-rothenberg-00fm.indd xxii7/31/09 1:07 PM
Contents Chapter 1111.2 The Fit of Alarm Improvement11.3 The Business CasePercentage of Daily LossesDirect CalculationNegotiationBottom Line11.4 Project Design ApproachesAlarm Improvement by Starting from Where You AreAlarm Improvement by Starting from ZeroUsefulness of Stages11.5 Project Construction AlternativesSitewide, ComprehensiveSitewide, StagedSitewide, Unit-by-Unit, ComprehensiveReview11.6 Why Some Projects Fail11.7 “Low-Hanging” Fruit11.8 ConclusionChapter 12: Situation Awareness12.1 Key Concepts12.2 Operator Support NeedsThe HatThe Disaster ChainNeed for Situation AwarenessVisualizations12.3 The Deviation Diagram12.4 User-Centered Design—Human FactorsHuman Factors lityImplementabilityUnified 398399xxiiiimo-rothenberg-00fm.indd xxiii7/31/09 1:07 PM
Contents Chapter 1212.5 Our Biological Clock12.6 Other Operator Support IssuesIntent RecognitionOperator VigilanceTo Push or to Pull12.7 Operator DisplaysPhysical Display ArchitectureModern DisplaysHierarchical Display ArchitectureThe Overview LevelThe Secondary LevelThe Tertiary Level12.8 Navigation12.9 Notifications Instead of Alarms12.10 Perception Problems with Video DisplaysRelationships and SizeCoding ConflictsColorComments12.11 New Operator Display DesignCoding Schemes and IconsOverview LevelSecondary LevelTertiary LevelDo ASM-Style Displays Work?12.12 Wrap-Up12.13 Notes and Additional ReadingNotesRecommended Additional ix 1: Definitions of Terms,Abbreviations, and Acronyms439Appendix 2: Twenty-Four Hours of Alarms452Appendix 3: Operator Alarm Usefulness Questionnaire501A3.1 Operator Alarm Usefulness Questionnaire502xxivimo-rothenberg-00fm.indd xxiv7/31/09 1:07 PM
Contents AppendicesExplanationPurposeGeneral InstructionsConfidentialitySurveyorsAdditional Information If You Have QuestionsWhere Questionnaire Is to Be ReturnedOperator Alarm Usefulness QuestionnaireNormal Steady OperationPlant Faults and TripsGeneralA3.2 Quiet Period Alarm Usefulness QuestionnaireExplanationInstructionsColumn DefinitionsSurvey Data 7517517518519Appendix 4:Alarm Philosophy from Honeywell European Users521Appendix 5:Overview of Alarm Management for Process ControlA5.1 The ChaptersPart I: The Alarm Management ProblemPart II: The Alarm Management SolutionPart III: Implementing Alarm Management537538538541544Appendix 6: Alarm Response Sheet547Appendix 7: Metrics and Key Performance IndicatorsPart I: Recommended Requirements for Analysis ToolsA7.1 PurposeA7.2 BackgroundA7.3 Analysis TypesA7.4 QueriesA7.5 Alarm Remediation AnalysesA7.6 Tools and Key 00fm.indd xxv7/31/09 1:07 PM
Contents AppendicesPart II: MetricsA7.7 IntroductionA7.8 Static (Configuration) MetricsA7.9 Dynamic (Activation) MetricsAppendix 8: Alarm Management PioneersA8.1 Opening NotesFather of Modern Alarm ManagementA8.2 Alarm Management TaskforcePioneering MembersObjectives for WorkA8.3 Abnormal Situation Management ConsortiumKey PlayersObjectives for WorkA8.4 Additional CreditsStandards and Practice OrganizationsTrainers and ConsultantsServices ProvidersTechnology ProvidersIndustrial Controls ProvidersPersonalities at LargeA8.5 NoteAppendix 9: Qualitative Risk Method for Priority AssignmentAcknowledgmentA9.1 Qualitative RiskA9.2 Porter’s Discussion on the Rationales for theQualitative Risk Matrix for Alarm PrioritizationGoalScopeA9.3 Description of MatrixProbability AxisSeverity AxisA9.4 Definition of 578xxviimo-rothenberg-00fm.indd xxvi7/31/09 1:07 PM
Contents AppendicesAppendix 10:Manufacturing Modalities and Alarm ManagementA10.1 IntroductionA10.2 Characteristics of Manufacturing ModalitiesA10.3 Comparison MatrixAppendix 11: Notifications ManagementA11.1 IntroductionA11.2 Points to ConsiderA11.3 Questions and henberg-00fm.indd xxvii7/31/09 1:07 PM
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Forewordhe control room of a process plant is by turns either a boring or terrifying place,much like the cockpit of a fighter jet or a large passenger aircraft: “hours of boredom punctuated by moments of sheer terror,” as the old aphorism goes. Theboredom comes from processes running properly. The terror comes when they do not.And, as the litany of process plant disasters shows, after the terror sometimes comes picking through the ruins, looking for bodies.What we’ve learned in a generation of studying those horrifying days after plantdisasters is that more often than not, the final straw has been the plant operators consistently making wrong decisions based on the information they think they have aboutwhat is going on in the process. Many of these disasters have been blamed on cascadesof alarms that made it impossible for operators to figure out which alarms actually wereimportant and what they meant.Safety instrumented systems are designed to be emergency shutdown systems, andoften they work properly. There are specific standards worldwide that define how asafety-instrumented system should work. What does not exist is the same kind of standard for alarms and alarm management.Doug Rothenberg has been in the forefront of research and standards making foralarm management in the process industries for many years. He did the pioneering workin the development and deployment of distributed control system (DCS) alarm management technology from 1989 through the present. He also was a founding member ofthe Alarm Management Task Force and the ASM Consortium and is a voting memberof ISA 18, the Alarm Management Standards Committee.His book is a comprehensive treatment of the current best practices in industrialprocess control alarm management. Doug covers the entire alarm management process from how to recognize the level of performance of existing systems through themethodology and procedures for redesigning (or designing new) state-of-the-practicealarm systems. You do not need any special or detailed experience in the configurationor specification of process control equipment. The ability
How Alarms Fit into Process Operating Situation 6 Alarm Management 8 Benefi ts 8 imo-rothenberg-00fm.indd ix 7/31/09 1:07 PM. x Contents † Chapter 1 1.4 A Brief History of Alarm Management 10 1.5 The “Management” in Alarm Management 11 1.6 Alarm Design Roadmap 12 1.7 Audience for this Book 13 1.8 Importance of Alarm Management 13 1.9 Fundamentals of Alarm Management 15 Bottom Line of .
Alarm 1 is a ‘Sound Once’ alarm, and Alarm 2 is an ‘Everyday’ alarm. Alarm 1 Setting/Alarm 2 Setting Press the ‘Alarm 1’ button (Ref.4) or ‘Alarm 2’ button (Ref.5) to activate alarm settings. ‘OFF’ will begin lashing on the screen. Select Alarm 1 or 2 b
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Run Card Requirements Continued Structure Fire goes to 7th Alarm and all 7 Alarm and all 7 Alarms are required. Brush Fire goes to 7th Alarm and all 7 Alarm and all 7 alarms are required. All other incident types can go to 4th Alarm Alarm and minimum of 2nd alarm is required.alarm is required. When a Compan
2. Open the alarm test valve. Verify that the sprinkler alarm bell and/or the pressure alarm switch/ electric alarm properly actuate. Close the alarm test valve and verify that water has ceased to flow from the alarm line drain. 3. Clean the 20 NB (3/4”) strainer provided on the sprinkler alarm bell line. 4. Clean the strainer of restriction .
Setting the Alarm 1. Press knob to turn ON alarm 2. Alarm time will begin to flash, adjust by rotating knob, press knob to select. (Alarm will automatically set to last selected alarm time after 6 seconds) 3. Press knob to turn OFF alarm In Single Day Alarm On Mode: alarm time will reset to 6:
DETECTION ZONE 11 DETECTION ZONE 12 ALARM ZONE 1 ALARM ZONE 2 ALARM ZONE 3 ALARM ZONE 4 Alarm Zones An alarm zone is clearly defined within the standard but generally is an area of the building coinciding with the fire compartment boundaries. There must be a clear break between these alarm zones to ensure alert and evacuation messages are not .
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Scrum Development Team A self-organizing, self-managed cross-functional team responsible for delivering commitments from the Product Backlog. User Stories Describe what the end product and its components should accomplish at the end of development. A product will usually have multiple user stories. Product Backlog A list of features or technical tasks which the team maintains and which, at a .
