Cairn Oil & Gas - OISD

© 2017 Vedanta Limited

Cairn Oil & Gas

CB/OS-2 & YNM-Ravva

ALARM MANAGEMENT

© 2017 Vedanta Limited 2

Content

What is the need for alarm management

Implementation Cycle @ Ravva site

Implementation Cycle @ Suvali site

Where do we stand


Introduction

What is an Alarm?

An audible and/or a visible means of indicating a problem such as equipment malfunction,

process deviation or abnormal process condition.

Why alarm management?

Since humans can only do one thing at a time and can pay attention to a limited number of

things at a time, there needs to be a way to ensure that alarms are presented at a rate

that can be assimilated by a human operator, particularly when the plant is upset or in an

unusual condition.


EMERGENCE OF INDUSTRY STANDARDS

Abnormal situation

Management (ASM)

Consortium formed

EEMUA 191

1st Edition

ASM Alarm

Management

Guidelines

1st Edition

2007

2009

1994

1999

2003

EEMUA 191

2nd Edition

Emergence of Standards

and Regulations

• ISA 18.02

Understanding the

consequence of

excessive alarms

• Major accidents

and losses

• Production

losses

• Operator burnout

factor

Establishment of

systems and

practices

• Emergence of

EEMUA and ISA

standards

• Implementation of

Alarm

Management

Lifecycle

Ineffective Alarm

Management

• Excessive number of

alarms

• Alarms not

meaningful to

operator

• Alarms are disabled

often


ALARM SYSTEM MANAGEMENT LIFE CYCLE

PHILOSOPHY

IDENTIFICATION

RATIONALIZATION

DETAILED DESIGN

IMPLEMENTATION

OPERATION

MAINTANENCE

MANAGEMENT

OF CHANGE

MONITORING

&

ASSESSMENT

AUDIT

PHILOSOPHY: Define processes for alarm management &

prepare specific alarm management philosophy document

IDENTIFICATION: Determination of potential alarms

RATIONALIZATION: Rationalization, Classification,

Prioritization and documentation – Master Alarm Database

DETAILED DESIGN: Alarm response procedures, Basic

alarm design, HMI principles & Advanced Alarming features

IMPLEMENTATION: Implement alarm, testing and training

OPERATION: Operator response to alarms

MAINTANENCE: Repairs and periodic testing

MONITORING: Performance monitoring and reporting

MANAGEMENT OF CHANGE: Process to authorize change

AUDITS: Periodic audits and recommendations


ALARM MANAGEMENT STRATEGIES

USED IN RAVVA

Below are the steps carried out in Ravva plant as part of operationalization of Alarm

Management:

• Alarm Philosophy Procedures and related documents preparation

• Imparted Training to all relevant personnel’s

• Identify and formed task force team for system implementation

• Carried out Alarm Rationalization process for the existing system

• Documented the outcome and implemented changes related to alarm attributes

• Monitored system performance and conducted review meetings – Bi-weekly and Monthly

• Carried out Audits, Periodic surveys - Operator Questionnaire Survey

& Alarm Effectiveness Survey

• Reviewed Alarm set points with accordance to the operating conditions of the plant

• Implementation of Highly Managed Alarms concept

• Implementation of FIRST-OUT ALARM SCHEMES coupled with LIVE C&E

Aim is to develop & impart alarm management system, assess & improve system

performance and target for continual improvement towards system performance excellence

and sustainability of achieved results



USED IN RAVVA

Implementation of Advanced Alarm Management Techniques to curb alarm rates such as:

• Alarm Latching concept

• Alarm DEADBAND settings

• Alarm ON/OFF DELAY settings

• COUNTER Technique

• DE-BOUNCE TIMER Technique



USED IN RAVVA

STATISTICAL DATA – NO. OF ALARMS PER DAY ON AVG FROM Jun-14 to JUL-16

42

40

34

50

30

80

24

80

30

80

28

40

32

80

24

40

18

80

16

40

21

30

18

60

22

40

14

40

12

20

12

40

18

80

12

80

11

90

10

60

10

50

10

90

11

20

11

50

11

30

11

80

J UN -14 J UL-14 AUG -14

SEP- 14 O CT -14 NO V-14

DEC - 14 J AN -15 F EB- 15 MAR -15

APR- 15 MAY-15

J UN -15 J UL-15 AUG -15

SEP- 15 O CT -15 NO V-15

DEC - 15 J AN -16 F EB - 16 MAR -16

APR- 16 MAY-16

J UN -16 J UL-16

TOTAL



USED IN RAVVA

Alarm Management System Key Performance Indicators (KPIs) are:

• Alarm Rate per day

• Peak Alarm Rate

• Number of Alarm floods

• Frequently Occurring Alarms – Top 10s

• Stale Alarms

• Annunciated Alarm Priority Distribution

• Number of Alarm occurrences for a particular group of systems

• Number of Chattering Alarms

• Number of Fleeting Alarms

• Audits, Periodic surveys - Operator Questionnaire Survey and Alarm Effectiveness Survey



USED IN RAVVA

Constraints:

• Add-on projects and integration of control system

• Limitations with the existing PLC/SCADA Software

Key Results achieved post operationalization of Alarm Management in Ravva are:

• Achieved better priority distribution of alarms as per the recommended standards

• Improved and precise Alarm Message Composition

• Establishment and Availability of Alarm response procedures

• Segregation of events from Alarm logs

• Better Animations were provided in HMI graphics to support alarm systems

• Better survey results were achieved

• Considerable reduction in High priority alarms – 60% as per data analysis

• 60% Reduction in Alarm Flood condition

• Average Alarm rate per day in Ravva is being reduced from 4200 to 1100 alarms per day


ALARM MANAGEMENT SYSTEM –CB/OS-2 SITE

Following information/reports can be generated for study & analysis at Suvali site-

Alarm count over time- To determine alarm rate.

Alarm distribution priority – For checking priority wise alarms

Most frequent alarms – Alarms occurring on a frequently basis

Chattering Alarms – Most repetitive alarms over a duration

Intervention count over time – Manual intervention over a duration

Most frequent intervention – Most manual intervention of control valves

Alarm distribution over time – Shift wise

Alarm enable & disable report- Duration the particular system remained bypassed

Plant status – Standing alarms

Alarm count per process unit -


:

Alarm Rate


% High Alarms per time Reduction to 4% from 30% in Urgent alarms, 5% from 41% from in High Alarms, 2% from 13% in Low from


:

Alarm by Unit Tags

281

224 215 211 205 200 164

144 124

108

317

139 107

133 109

213

526

211

403

210

129

353

277

394

444

0

100

200

300

400

500

600

3rd

Sta

ge

oil s

ide

leve

l tran

sm

itter

AL

FH

HC

Liq

uid

Tra

nsfe

r Pu

mp

C D

isch

arg

eP

ressu

re

Cru

de

Tra

nsfe

r Pu

mp

C

Oil T

ran

sfe

r Pu

mp

B d

isch

arg

e

3rd

Sta

ge

inte

rface

leve

l tran

sm

itter

Cru

de

Tra

nsfe

r Pu

mp

B

Slu

g C

atc

he

r Co

nd

en

sa

te L

eve

lT

ran

sm

itter

AL

HF

Ne

w 2

nd

sta

ge

se

pe

rato

r Inte

rface

Le

ve

l

Oil T

ran

sfe

r Pu

mp

A d

isch

arg

e

HC

liqu

id H

ea

ter s

he

ll sid

e o

utle

t Te

mp

.

Fire

Wa

ter P

um

pF

ire S

yste

m

HP

Pu

rge

Ra

teF

lare

Syste

m

GL

C E

ng

ine

Sp

ee

dG

LC

HC

DP

BC

-B L

ub

e O

il Co

ole

r To

Du

ple

x O

ilF

ilter

HC

DP

HC

DP

BC

-B B

oo

ste

r Co

mp

Su

ctio

n

LA

#9

we

ll FT

HP

pre

ssu

re tra

nsm

itter

LA

LB

#6

Flo

w M

ete

rL

B

LB

Instru

me

nt g

as d

rum

Le

ve

l tran

sm

itter

PG

BC

-B L

eve

l Tra

nsm

itter

PG

BC

PG

C-B

Su

ctio

n S

cru

bb

er V

-23

10

PG

C

PG

C-B

Afte

rco

ller D

isch

arg

e T

em

p.

De

ga

sse

r V-7

81

0P

WD

De

ga

sse

r V-7

81

0 L

eve

l Sh

utd

ow

n

Syste

mS

yste

m

Ra

w W

ate

r Su

mp

D-7

51

0W

ate

r Syste

ms

Alarms By Tag


:

Alarm distribution over the time – Shift wise comparison

0

100

200

300

400

500

600

01/Oct/16 02/Oct/16 03/Oct/16 04/Oct/16 05/Oct/16 06/Oct/16 07/Oct/16 08/Oct/16 09/Oct/16 10/Oct/16 11/Oct/16 12/Oct/16 13/Oct/16 14/Oct/16 15/Oct/16

16:00

8:00

0:00


:

Standing alarms – Day wise

3

4

2 2 2

1

2

1

4

1

1

3

2

1

0

1

2

3

4

5

6

7

PGBC-B LIQ HANDLING SLUG CATCHER TANKER LOADING PGC-B FLARE TEG-1 ALHF GTG-B

Online Equipment Standing Alarms

Urgent

Low

High


Alarm count for different units

1974

968 940

814

643 589 556 532

469 376 365 321 307

249 226 213 199 169 168 151 145 134 133 131 110 107

0

500

1000

1500

2000

2500

Alarm Count By Unit


Daily total no. of Alarms Total alarms stand at around 875 from 1900 = 46% reduction



INDUSTRY VS CAIRN STANDARD COMPARISION

Benchmark of alarm for oil and gas industry

The Engineering Equipment and Materials Users Association

Source: BookAlarm Management for Process Control:

by: Douglas H. Rothenberg

Cairn Suvali Site- 875 alarms/ day Cairn Ravva 1100 alarms/day

Before- 1900 alarms/day 4200 alarms/day


Documents

Cairn Oil & Gas - OISD