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Alarm Management FundamentalsIntroducing the building blocks of effective alarm management
Tyron Vardy (Honeywell)
June 2018
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
• Alarm Management Overview- Why Alarm Management is ‘Still’ Important
- Investment Drivers
- Typical Project Outcomes and Expectations
• From Printing Alarms to Preventing Alarms- Why Alarm Management goes beyond Alarm Reporting
• Alarm Management Improvement Programme- Step by Step Approach to Alarm Management
Infrastructure
Noise Reduction
Alarm Rationalization
Operator Guidance
Alarm Prevention
Alarm Management Fundamentals
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
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Tyron Vardy
• Honeywell’s Connected Plant Product Director for Alarm
and Operations Management. Responsible for
Honeywell’s DynAMo software portfolio.
• 25 years experience in designing and implemented
control room solutions around the globe in industries
from Oil and Gas, to Utilities, Paper, Power and Nuclear.
• Graduated in the UK with a degree in Information and
Communication Technologies.
• Quick wins. Importance of a plan and methodology
• Profile of successful alarm management looks like
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Alarm Management Overview
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
A problem 25 years in the making
4
1990
Industrial Printers
1995
Software Printers
2000
Alarm Reporting
2010
Advanced Alarm
Management
2005
Alarm Management
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
A problem 25 years in the making
5
1990
Industrial Printers
1995
Software Printers
2000
Alarm Reporting
2010
Advanced Alarm
Management
2005
Alarm Management
Addressing
the Effect
Addressing
the Cause
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
An Alarm Management Journey
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Need for Alarm Management
• Historical Need
• Focus on reacting to alarms
- The digital age of
- If it CAN alarm it SHOULD alarm
- More Data + More Alarms = More Value
For every 1 alarm removed,
another 3 were added
• A Monster was Created
- Process Safety; Down
- Operational Risk; Up
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• Future Need
• Alarms can be managed and reduced
• Welcome to the Paradox of Automation
- Automation increases to reduce operator
interaction and operator error
- When things go wrong now
Alarms are real
Risk of abnormal situations higher
Alarms need clarity
Consequences and Actions
need to be well understood
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
What’s the Solution?
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“No Silver Bullet...”A solution based methodology
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
What’s the Solution?
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Operational
Requirements
Standards
Best Practices
ASM
Software
Short Term
Noise ReductionLong Term
Vision
Software
Plant Limits
People Limits
Alarm
Rationalization
Dynamic Alarming
Alarm
Philosophy
Where to Start?
Alarm Improvement Programme
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Don’t Reinvent the Wheel
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
A Well Documented Path to Success
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
With Understood Goals and Objectives
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Average Alarm Rate < 1 per 10 minutes
Peak Alarm Rate < 10 per 10 minutes
% Time in Flood < 1%
High Priority Alarms < 5%
If only it were that easy
Alarm Philosophies
Alarm Causes, Consequences, Corrective Actions
Priority/Time to Respond Matrix’s
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Safety Contact
Simplified Methodology
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This.. Prevents This..
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Safety Contact
Easily Actionable
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This.. Enables This..
DynAMo® Alarm Suite
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Five Steps to Alarm Improvement
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Phase 1
Simplify the complex to achieve alarm system improvement first time
Alarm Improvement Model
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Phase 1: Build a Solid Foundation
Create an Alarm Improvement Plan and develop a site specific Alarm Philosophy.
Understand the ‘Drivers’ and ensure ‘buy-in’ at both Operational and Business layers.
A solid Alarm Philosophy is the key to sustainability.
The rule book for your Alarm Improvement Program
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Phase 2
Simplify the complex to achieve alarm system improvement first time
Alarm Improvement Model
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Phase 2: Identify and Eliminate Bad Actors
Focus on areas of biggest risk and areas of greatest return.
Generate EEMUA, ISA compliant KPI assessment reports with quantifiable
deliverables.
Eliminating the Alarm Noise //noise <unwanted sound>
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Phase 3
Simplify the complex to achieve alarm system improvement first time
Alarm Improvement Model
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Phase 3: Proactive Alarm Management
Mode/state based alarming. Reduction of consequential alarms.
Limit management. Operating outside of plant limits and capabilities cause
abnormal situations. Abnormal situations cause alarms.
Don’t wait for the alarms. Re-focus on the Cause not the effect
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Phase 4
Simplify the complex to achieve alarm system improvement first time
Alarm Improvement Model
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Phase 4: Alarm Rationalization
Implement Master Alarm Database to track engineered changes and settings.
Define Causes, Consequences and Corrective operator actions for each alarm left.
Integrated DCS Console Alarm Help
Documentation is no good sat on a shelf
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Phase 5
Simplify the complex to achieve alarm system improvement first time
Alarm Improvement Model
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Phase 5: Continuous Improvement
Continue to report, monitor, benchmark and audit.
Alarm Improvement is not a one shot program
Operations won’t usual report a couple of extra alarms per shift.
When a couple turn into a hundred, you’re back to where you started.
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Getting Practical
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
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The philosophy must be general enough to provide long-term viability
and at the same time lead to clear determinations
Purpose of the Alarm System Key Performance Indicators
Roles and Responsibilities Escalation Policy
Alarm Design Principles Management of Change
Alarm Management Techniques How People are Trained
Priority Assignment
Rationalization Methodology
How Alarms are Presented
How Operators Respond
Phase 1: Alarm Philosophy
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
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Phase 2: Eliminate the Noise
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Identify the Noise
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Drill-in and Eliminate the Bad Actors
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
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Phase 3: Proactive Alarm Management
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Operate within safe limits. Stop the Abnormal Situations Earlier.
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
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Phase 4: Alarm Rationalization
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Master Alarm Databases. Alarm Response Manuals.
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Directly Plug-in to Experion for Real-time Operator Assistance
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
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Phase 5: Continual Improvement
Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Benchmark, Track and Audit Alarm Performance
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
Summary
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
• Doing something is better than
doing nothing.
• Start now. Numerous
standards, best practices,
and methodologies available.
• Keep it simple and don’t
get ‘metric blind’
• Proven to work across
any industry
• Use DynAMo
Alarm Management Fundamentals
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Honeywell Confidential - © 2018 by Honeywell International Inc. All rights reserved.
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