Transcript
Page 1: Six Sigma Project Six Sigma Project

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Six Sigma ProjectSix Sigma Project

Alarm ManagementAlarm Management

2005-2006

Brent J. ThomasBrent J. Thomas

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Define PhaseDefine Phase

Alarm Management Measure Analyze Improve ControlDefine

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IdentificationGreen Belt: Brent J. Thomas

Black Belt Advisors: Aimee S. Anani, Mark L. Olson

Plant / Location: Soda Springs, Idaho

Project Title: DCS Alarm Management

Champion / Management Sponsor: Paul H. Kraus

Plant Manager: Bruce E. Pallante

Accounting Contact: Helen K. Smith

Start Date: 11-01-04

Completion date: August 31, 2006

Measure Analyze Improve ControlDefineAlarm Management

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Alarm Management

Operator Intervention

DCS Intervention

Interlocks and emergency procedures

Normal Operation =Upset Condition =

Target Operation =

High =

Low =Alarm Boundaries:

Medium =

Process Description

Measure Analyze Improve ControlDefine

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Alarm Management Measure Analyze Improve ControlDefine

•Too Many Alarms•Alarms that don’t mean anything desensitize operators to real ones

•Too Many Alarms At Once•Alarm floods allow no reaction time

•Too Many Alarms Have No Defined Response•Operators sometimes have no way of reacting to an alarm

•Poor Alarming Practices Blamed For Several Incidents•Three Mile Island and Chernobyl are examples

Problem Description

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Monsanto Alarm Management Team: Matt Rollinson Luling, Team Lead

Mark Gamel Luling

Andrew Johnson Luling

Edward McGinnis Luling

Jack Ahlers Muscatine

Kurt Schlawin Muscatine

Andre Divino Sao Jose dos Campos

Luiz Dourado Camacari

Jose Neto Camacari

David Mourino Zarate

Johnny Ollivier Antwerp

Brent Thomas Soda Springs

Measure Analyze Improve ControlDefine

Human ResourcesSoda Springs Alarm Management Team:

Doug Beauregard Manufacturing, Team Lead

Aimee Anani p4 production

Brian Kemmerer Burden Prep

Reggie Kuzet Maintenance

Brent Thomas Process Control

Soda Springs Alarm Rationalization Team: Aimee Anani p4 Production, Team Lead

Troy Carver Furnace Operations Specialist

Matt Kirby Furnace ESH Representative

Brock Sherman Furnace Process Engineer

Kenny Rasmussen Furnace Control Operator

Vaughn Mickleson Furnace Control Operator

Rick Hendricks Furnace Control Operator

Aaron Tarbet Furnace Control Operator

Brent Thomas Process Control

Alarm Management

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Measure Analyze Improve ControlDefineAlarm Management

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Solution1) Develop an Alarm Management Philosophy

2) Select alarm metrics

3) Assess present alarm system (Measure - Analyze phases of this project)

4) Reduce nuisance alarms (Analyze - Improve phases)

5) Rationalize alarms by need and priority (Improve phase)

6) Develop alarm configuration database (Improve – Control phases)

7) Implement knowledge-based alarming where appropriate

Alarm Management Measure Analyze Improve ControlDefine

Conclusions of Cause and Effect Analysis• We do a good job of selecting and maintaining instrumentation.

• Our methods were the root cause of the alarm system state – we had no philosophy or guidelines for configuring alarms

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Steps in an Alarm Management Project

1) Develop an Alarm Management Philosophy1) Every alarm will be rationalized by need and priority

2) Every audible alarm will have a defined response

3) Each response will have an appropriate response time

4) Alarm system metrics will be defined, measured, and reported

5) A continuous improvement process will monitor alarm system performance, identify meaningful opportunities for improvement and implement them

Alarm Management Measure Analyze Improve ControlDefine

Project Planning

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2) Select Alarm MetricsMonsanto established a corporate wide initiative to improve alarm system

performance at all locations after an incident occurred that was partly due to a

poor alarm system design. A corporate alarm team was chartered which agreed on

a set of metrics. The Average Alarm Rate is used most in this project.

Average Alarm Rate: Average number of alarms per hour per day.

Operator Loading: Number of 10 minute periods per day with 10 or more alarms.

Also reporting:Standing Alarms – alarms that exceed 24 hours in duration.

Alarms per console point count

Alarms per plant process area

Steps in an Alarm Management Project

Alarm Management Measure Analyze Improve ControlDefine

Project Planning

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Project Scope: The scope of this project will be limited to alarms generated by the electronic Distributed Control Systems at Soda Springs. It will not include hardwire panel alarms although those are addressed by the Alarm Team. It will be limited to the #9 furnace area of the Soda Springs process. #9 furnace was chosen because it is scheduled for conversion from PRoVOX to DeltaV control in early 2006. DeltaV has a number of alarm management tools that would facilitate the redesigned alarm management process.

Customers: Internal: Paul Kraus, P4 Production process owner, furnace operations, and furnace maintenance.

Customer CTQ: Alarms that are meaningful and help operators avoid upsets that impact safety, quality, and production.

Alarm Management Measure Analyze Improve ControlDefine

Project Planning

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Measure PhaseMeasure Phase

Define Measure Analyze Improve ControlAlarm Management

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3) Assess present alarm system

Steps in an Alarm Management Project

Alarm Management

Assessment

First the present alarm management system needed to be upgraded. LogMate, from TiPS, Inc., had been in use since 1992 but was little more than an event historian. It was not compatible with DeltaV or the new DVOP (DeltaV Operate for PRoVOX) consoles that were in development.

A new network-based version compatible with PRoVOX, DVOP, and DeltaV was available. The new version also posessed considerable analysis capability and the ability to document and manage the alarm configuration in the control system.

Resources from TiPS, Inc., the company that produces LogMate were used often during the project. Training was conducted for the Alarm Management Steering Team in March of 2005 and March of 2006. The product was upgraded three times during the project to enable it to provide tools for the analysis, improvement, and control phases. Some tools were added to LogMate by TiPS, Inc. at Monsanto’s request.

Define Measure Analyze Improve Control

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DVOP Console*.csv files

Event_Journal (Access database)

ASCII Capture port

LogMATE Capture

NetView – SOE (sequence of

events)

TRAC - Data Historian

Integration

TRAC – Key Performance

indicators

Alarm Rationalization

ACE – Bad Actors (80/20 Rule)

OPC Capture port

Alarm Generated in PRoVOX

Alarm Generated in DeltaV

PRoVOX and DeltaV

configuration databases

Alarm Knowledge

Base

Automated Alarm Activity Reports –

Email Notice

Measurement System

Alarm Management Define Measure Analyze Improve Control

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Define Measure Analyze Improve ControlAlarm Management

Measurement System

Define Measure Analyze Improve Control

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Process Characterization

Define Measure Analyze Improve ControlAlarm Management

Furnace roof pressure

5 of the 10 most common events are network

integrity errors

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Define Measure Analyze Improve ControlAlarm Management

Measurement System

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Process Characterization

Define Measure Analyze Improve ControlAlarm Management

Furnace roof pressure

Duplicate point

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Count 108 65 58 1551888 355 313 153 152 146 140 112Percent 3.0 1.8 1.6 4.351.8 9.7 8.6 4.2 4.2 4.0 3.8 3.1Cum % 92.4 94.2 95.7 100.051.8 61.5 70.1 74.3 78.5 82.5 86.3 89.4

Coun

t

Perc

ent

TagsOthe

r

TI93

5-3

LI949

-1

PI956

-3

ZS93

7-6

ES97

2-1

PC96

0-1

EI935

M-5

EI935

-5

PI956

6-4

TI96

00-7

PC93

6-1

4000

3000

2000

1000

0

100

80

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40

20

0

Pareto Chart of Furnace 9 Alarms

Define Measure Analyze Improve ControlAlarm Management

More than half are furnace roof pressure

Duplicate point

Process Characterization

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Define Measure Analyze Improve ControlAlarm Management

pressure deviation activated 83 times

of those 83, the high alarm activated 61 times within 10

seconds

furnace pressure A alarm (deviation)

Process Characterizationfurnace pressure C

alarm (high)

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Define Measure Analyze Improve ControlAlarm Management

furnace pressure A alarm (deviation)

furnace pressure C alarm (high)

Process Characterization

duplicate point

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Count 112 108 65 58 1551083 795 355 313 153 152 146 140Percent 3 3 2 2 430 22 10 9 4 4 4 4Cum % 89 92 94 96 10030 52 61 70 74 78 82 86

Coun

t

Perc

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TagsOthe

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TI93

5-3

LI949

-1

PI956

-3

ZS93

7-6

ES97

2-1

PC96

0-1

EI935

M-5

EI935

-5

PI956

6-4

TI9600

-7

PC93

6-1.h

igh

PC93

6-1.de

v

4000

3000

2000

1000

0

100

80

60

40

20

0

Pareto Chart of Furnace 9 Alarms

Define Measure Analyze Improve ControlAlarm Management

roof pressure high and deviation alarms

separated

Process Characterization

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Define Measure Analyze Improve ControlAlarm Management

roof pressure alarms removed

from data

Count 58 54 51 50355 313 152 146 140 112 108 65Percent 3.6 3.4 3.2 3.122.1 19.5 9.5 9.1 8.7 7.0 6.7 4.1Cum % 90.3 93.7 96.9 100.022.1 41.6 51.1 60.2 69.0 75.9 82.7 86.7

Coun

t

Perc

ent

TagsOthe

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II959

A-1

LI944

-1

TI93

5-3

LI949

-1

PI956

-3

ZS93

7-6

ES97

2-1

PC96

0-1

EI935

M-5

PI956

6-4

TI9600

-7

1800

1600

1400

1200

1000

800

600

400

200

0

100

80

60

40

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Pareto Chart of Furnace 9 Alarms

Process Characterization

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Analyze PhaseAnalyze Phase

Alarm Management Define Analyze Improve ControlMeasure

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DVOP Console*.csv files

Event_Journal (Access database)

ASCII Capture port

LogMATE Capture

NetView – SOE (sequence of

events)

TRAC - Data Historian

Integration

TRAC – Key Performance

indicators

Alarm Rationalization

ACE – Bad Actors (80/20 Rule)

OPC Capture port

Alarm Generated in PRoVOX

Alarm Generated in DeltaV

PRoVOX and DeltaV

configuration databases

Alarm Knowledge

Base

Automated Alarm Activity Reports –

Email Notice

Analysis System

Alarm Management Define Analyze Improve ControlMeasure

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Define Analyze Improve ControlMeasureAlarm Management

Process Capability

907560453015

Median

Mean

6462605856

1st Q uartile 49.306Median 59.0283rd Q uartile 74.306Maximum 100.000

58.944 63.600

56.944 61.806

18.732 22.036

A -Squared 2.04P-V alue < 0.005

Mean 61.272StDev 20.249V ariance 410.024Skewness 0.049607Kurtosis -0.235195N 293

Minimum 13.194

A nderson-Darling Normality Test

95% C onfidence Interv al for Mean

95% C onfidence Interv al for Median

95% C onfidence Interv al for StDev95% Confidence Intervals

Summary for Furnace 9 Alarms

Project: Alarm-management-04.MPJ; Worksheet: Worksheet 1; 6/5/2006

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Define Analyze Improve ControlMeasureAlarm Management

Lag

Aut

ocor

rela

tion

18161412108642

1.0

0.8

0.6

0.4

0.2

0.0

-0.2

-0.4

-0.6

-0.8

-1.0

Autocorrelation Function for Furnace 9 Alarms(with 5% significance limits for the autocorrelations)

Process Capability

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Define Analyze Improve ControlMeasureAlarm Management

Index

%pe

riod

s

2902612322031741451168758291

100

90

80

70

60

50

40

30

20

10

Project: Untitled; Worksheet: Worksheet 1; 6/5/2006

Time Series Plot of Furnace 9 Alarms

Process Capability

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Define Analyze Improve ControlMeasureAlarm Management

Observation

Indi

vidu

al V

alue

2912622332041751461178859301

90

60

30

_X=61.27

UCL=84.28

LCL=38.26

Observation

Mov

ing

Ran

ge

2912622332041751461178859301

45

30

15

0

__MR=8.65

UCL=28.27

LCL=0

1

1

11

1

1

111

111

111

1

11

111

1111

111

111111

11111111

111

11

111

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1111

11111

111

1

11111

11111111

1

1

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111

1

11

1

1

11

1

Project: Alarm-management-04.MPJ; Worksheet: Worksheet 1; 6/5/2006

I-MR Chart of Frunace 9 Alarms

Process Capability

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Define Analyze Improve ControlMeasureAlarm Management

105907560453015

USL

LSL 0Target *USL 71Sample Mean 61.2723Sample N 293StDev (Within) 7.67023StDev (O v erall) 20.2664

Process Data

C p 1.54C PL 2.66C PU 0.42C pk 0.42

Pp 0.58PPL 1.01PPU 0.16Ppk 0.16C pm *

O v erall C apability

Potential (Within) C apability

% < LSL 0.00% > USL 27.99% Total 27.99

O bserv ed Performance% < LSL 0.00% > USL 10.24% Total 10.24

Exp. Within Performance% < LSL 0.12% > USL 31.56% Total 31.69

Exp. O v erall Performance

WithinOverall

Process Capability of Furnace 9 Alarms

Process Capability

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Improve PhaseImprove Phase

Alarm Management Definition Analysis Improve ControlMeasure

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DVOP Console*.csv files

Event_Journal (Access database)

ASCII Capture port

LogMATE Capture

NetView – SOE (sequence of

events)

TRAC - Data Historian

Integration

TRAC – Key Performance

indicators

Alarm Rationalization

ACE – Bad Actors (80/20 Rule)

OPC Capture port

Alarm Generated in PRoVOX

Alarm Generated in DeltaV

PRoVOX and DeltaV

configuration databases

Alarm Knowledge

Base

Automated Alarm Activity Reports –

Email Notice

Improvement System

Alarm Management Definition Analysis Improve ControlMeasure

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Rationalization Step 1

Alarm Management Definition Analysis Improve ControlMeasure

Soda Springs Alarm Rationalization Team:Aimee Anani Furnace Process Engineer, Team Lead

Troy Carver Furnace Operations Specialist

Matt Kirby South Area Compliance Representative

Brock Sherman Furnace Process Engineer

Kenny Rasmussen Furnace Control Operator

Ray Shurtz Furnace Control Operator

Rick Hendricks Furnace Control Operator

Aaron Tarbet Furnace Control Operator

Brent Thomas Process Control Engineer, MT

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Definition Analysis Improve ControlMeasure

Rationalization Process

Alarm Management

Identify top ten worst

alarms

Review with Rationalization Team

Submit MOC for changes

MOC approved

?

Implement changes in control system, alarm database, and alarm catalog

Y

N

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0

2000

4000

6000

8000

10000

12000

Integrity Errors Audible Alarms

March-06August-06

Alarm Management

Improvements

86% reduction in integrity errors

61% reduction in audible alarms

Definition Analysis Improve ControlMeasure

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Definition Analysis Improve ControlMeasureAlarm Management

Improvements

6004803602401200

USL

LSL *Target 52USL 240Sample Mean 124.78Sample N 82StDev (Within) 92.1329StDev (O v erall) 210.64

Process Data

C p *C PL *C PU 0.42C pk 0.42

Pp *PPL *PPU 0.18Ppk 0.18C pm 0.28

O v erall C apability

Potential (Within) C apability

% < LSL *% > USL 18.29% Total 18.29

O bserv ed Performance% < LSL *% > USL 10.55% Total 10.55

Exp. Within Performance% < LSL *% > USL 29.22% Total 29.22

Exp. O v erall Performance

WithinOverall

Process Capability of March Integrity Errors

6004803602401200

USL

LSL *Target 52USL 240Sample Mean 16.4146Sample N 82StDev (Within) 5.63655StDev (O v erall) 8.47927

Process Data

C p *C PL *C PU 13.22C pk 13.22

Pp *PPL *PPU 8.79Ppk 8.79C pm 1.70

O v erall C apability

Potential (Within) C apability

% < LSL *% > USL 0.00% Total 0.00

O bserv ed Performance% < LSL *% > USL 0.00% Total 0.00

Exp. Within Performance% < LSL *% > USL 0.00% Total 0.00

Exp. O v erall Performance

WithinOverall

Process Capability of August Integrity Errors

Scaled to 1/10

Data from March, 2006 compared to data from August, 2006

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Definition Analysis Improve ControlMeasureAlarm Management

100806040200

USL

LSL *Target *USL 45Sample Mean 28.122Sample N 82StDev (Within) 13.3635StDev (O v erall) 17.2955

Process Data

C p *C PL *C PU 0.42C pk 0.42

Pp *PPL *PPU 0.33Ppk 0.33C pm *

O v erall C apability

Potential (Within) C apability

% < LSL *% > USL 14.63% Total 14.63

O bserv ed Performance% < LSL *% > USL 10.33% Total 10.33

Exp. Within Performance% < LSL *% > USL 16.46% Total 16.46

Exp. O v erall Performance

WithinOverall

Process Capability of March Alarms

100806040200

USL

LSL *Target *USL 45Sample Mean 10.8293Sample N 82StDev (Within) 7.33298StDev (O v erall) 9.5159

Process Data

C p *C PL *C PU 1.55C pk 1.55

Pp *PPL *PPU 1.20Ppk 1.20C pm *

O v erall C apability

Potential (Within) C apability

% < LSL *% > USL 0.00% Total 0.00

O bserv ed Performance% < LSL *% > USL 0.00% Total 0.00

Exp. Within Performance% < LSL *% > USL 0.02% Total 0.02

Exp. O v erall Performance

WithinOverall

Process Capability of August Alarms

ImprovementsAlarm activations in March, 2006 compared to August, 2006

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Alarm Management

Confidence of Improvement

No question that the network integrity errors

were reduced

No question that audible alarms are

fewer

Definition Analysis Improve ControlMeasure

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Alarm Management

Integrity Errors

Audible Alarms

Definition Analysis Improve ControlMeasure

Confidence of Improvement

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Control PhaseControl Phase

Definition Analysis Improve ControlMeasure

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Control System

Definition Analysis Improve ControlMeasureAlarm Management

DVOP Console*.csv files

Event_Journal (Access database)

ASCII Capture port

LogMATE Capture

NetView – SOE (sequence of

events)

TRAC - Data Historian

Integration

TRAC – Key Performance

indicators

Alarm Rationalization

ACE – Bad Actors (80/20 Rule)

OPC Capture port

Alarm Generated in PRoVOX

Alarm Generated in DeltaV

PRoVOX and DeltaV

configuration databases

Alarm Knowledge

Base

Automated Alarm Activity Reports –

Email Notice

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Control Plan

•Long term control will be achieved by the following:•Comprehensive alarm philosophy (completed by AMST)

•Established alarm knowledge base

•Configuration for DCS alarms and locations and access of hardwired alarms (done)

•Automatic nightly update from DeltaV (done)

•MOC approval system (done)

•Defined action for each audible alarm (AMST work in progress)

•Assigned responsibility for action required:•The CIM Group will be responsible for maintaining the tools

•Engineering and manufacturing will ensure adherence to policies and philosophy

Definition Analysis Improve ControlMeasureAlarm Management

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Alarm Management Definition Analysis Improve ControlMeasure

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Alarm Management Definition Analysis Improve ControlMeasure

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Alarm Management Definition Analysis Improve ControlMeasure

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Questions?

Alarm Management Measure Analyze Improve ControlDefine

Project Title: DCS Alarm ManagementPlant / Location: Soda Springs, Idaho

Presently implementing the same improvements for 7 and 8 furnaces and working on additional improvements for all three.

Project to be completed August 31, 2007

Burden prep will be addressed when furnaces are complete


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