optimization systems - intech process automation & optimization net loss due to minor process...
TRANSCRIPT
Alarm
Management
Systems
Your Global Automation Partner
Optimization
Operations
Solutions for
Oil & Gas
Alarms are an essential part of modern systems and the primary means of alerting operators of abnormal situations in their facilities. Even the best designed systems can become ineffective in the absence of alarms, resulting in potential human and financial setbacks.
Research has shown that many process plants have improperly configured alarms that do not follow international guidelines and add to operators’ confusion. For an effective alarm system and smooth unobstructed plant operations, alarms need to be relevant, unique, timely, prioritized and understandable. Nearly all facilities with ineffective alarm systems show distinct symptoms of poor alarm system design.
A significant number of alarms are raised by minor issues
Alarms remain active for very long periods of time
There are no guidelines for alarm implementation
Operators are unsure of how to respond to some alarms
Processes run normally despite some alarms constantly going off
Some alarms do not require an operator’s response or attention
Numerous alarms go off during routine operation but have no purpose
Symptoms of Poor Alarm System Design:
A Need for Good Alarm Management
Alarm Management Overview
Poorly configured alarms risk the safety of:
Plant, Personnel, Equipment
Good alarms increase safety of all three by:
Reducing unnecessary alarms Prioritizing important alarms
Safety
Alarms not configured properly result in: Reduced production revenue Losses from damaged assets
Properly configured alarms increase profitability by: Increasing uptime Decreasing incidental losses
Profitability
Over 40% of incidents are caused by human factors
Poorly configured alarms add to these risks
Good alarms reduce errors from the human factor by facilitating operators
Human Factor
Alarms Management Lifecycle
Philosophy
Identification
Rationalization
Design
Implementation
Operation
Maintenance
Audit
Monitoring&
Assessment
Managementof
Change
A comprehensive document of work processes, sites and control systems along with best practices for alarm management.
A complete description of processes to update,
change or remove alarms in order to meet changing
requirements or optimize systems.
Data is monitored and benchmarked against
performance standards defined in the alarm
philosophy.
Data is collected for a baseline assessment of current alarm systems against standards, “Bad Actor” alarms are identified.
Areas of trouble in the alarm systems are identified and compared to the alarm philosophy document to evaluate a course of action.
Alarms are re-engineered according to the alarm principles defined in the philosophy document.
The re-engineered alarms are implemented and documented; relevant operators are trained how to respond to alarms.
The site is run with the new alarm systems. Operator- supporting tools are installed; further trainings are given.
Alarms are periodically calibrated and tested for accuracy, repairs and replacement activities are performed.
INTECH provides a unique customer-tailored Alarm Philosophy Document.
INTECH analyzes data for 6-8 weeks and helps customers understand the cause of bad actors
INTECH helps the site team understand, classify and prioritize alarms.
INTECH makes the Master Alarms Database (MADB) for the site.
INTECH installs the MADB and performance management tools; also trains operators.
INTECH trains operators how to handle alarms and provides alarm management tools.
INTECH follows standard maintenance procedures and performs fidelity tests.
arm
lps
sify
ase
nce
and
Part of the continuous
improvement effort, with
periodic alarm and system
audits
Alarm Management Lifecycle
Time
Normal Operating Region
Maximum Profitability Region
Break Even Point
Profitable Region
Pla
nt P
rofit
abili
ty
Substantial Net Loss Due to Unscheduled
Plant Shutdown
Optimum ProfitabilityAPC & Optimization
Net Loss Due toMinor
Process Upset
0
1500
3000
4500
6000
7500
9000
10500
12000
13500
15000
# of Daily Alarms
All AlarmsEnabled Alarms
Alarms OptimizationImplemented
Before Rationalization After Rationalization
Daily Alarm Count: > 16,000 Daily Alarm Count: < 5,000
Hourly Average for Week: 742 Hourly Average for Week: 390
High Priority Alarms Contribution: 65% High Priority Alarms Contribution: 43%
INTECH’s Alarm Management Solutions ensure that incidents occurring from bad alarm configuration are minimized. INTECH achieves this by classifying, prioritizing and optimizing alarms to generate useful information for operators. This ensures that operators are immediately alerted to issues that can potentially cause serious damage to the plant and environment, and offset a large portion of the plant’s past profitability.
Most modern alarm systems are implemented at the software level and require no physical hardware installation, this has led to a significant increase in the number of available alarms at any site - a growth fueled by international standards that require periodic monitoring for process assessment. The major drawback to all this however is an overwhelming amount of alarm notifications being constantly generated during operation in the absence of alarm management.
INTECH’s Alarm Management reduces the overall number of alarms going off to manageable numbers through continuous improvement. INTECH identifies “bad actor” alarms - alarms that cause nearly half of all alarms - and optimizes them. Additionally nuisance alarms - which don’t serve any real purpose - are identified and reconfigured to reduce overall alarms. This results in up to 90% reduction in average daily alarms.
Reduction in Overall Alarms:
INTECH’s Alarm Management Suite
Performance and Financial Benefits
INTECH provides a standardized Metrics and Reporting interface, allowing seamless collection and arrangement of alarms, events and all associated data remotely from any source. Additionally this data can be generated into standards-compliant reports that give a precise snapshot of system performance.
INTECH’s Master Alarm Database is a comprehensive database that contains all alarms and a management of change framework, allowing for quick documentation and monitoring of changes made to the alarm system. It retains rationalization settings realized in the alarm philosophy, and manages deviations.
INTECH provides tools to summarize alarms by taking measurements over specified periods and performing analytics to generate relevant alarm data. The summary data includes alarms per time period analysis, priority distribution, flood periods, chattering alarms, and operator changes.
Reporting and Metrics
Master Alarm Database
Alarm Summary
INTECH’s Advanced Solutions Deployment - Software Architecture
Hand Held Terminal
PDC-Windows CE
Manual Logging
Manual Logging /Hand Held Terminal Client
1. Data Acquisition
8. PDC/Historian Interface
2. Advanced Process Historian
Production Data
REPORTS
SAP PM
RAW DATA
RESULTS Process Historian
Historic Process Data
Manual Data
Historic Process Data
5. Reporting7. Processing Simulation
LEGEND:
Equipment Run Hours, Starts and KPIs Efficiencies
Process DATA
OPCDAI/F
MS-Excel Reports
Ontology Framework
Excel-Data Link
Thin Client WEB-APPS (Browser)
Process Engr. W/S
Data Analysis/ Extract
KPIs
Process Simulation
Server
3. AlarmManagement
4. Control LoopPerformanceManagement
Alarms & Events AE I/F
Loop Tuning
DAI/F
Alarms Analysis, Rationalization Module
Control Loop Performance Management Module
Visual Interfaces (GUI) - To be
deployed by INTECH
Sometimes Already Deployed or To Be Offered by INTECH
Already Deployed Systems within IT / CCR Landscape
6. Condition based Maint.
Advanced Process Historian to SAP PM Interface
ACE (Advanced Calculation Engine) Tank Mass/Vol KPI. Run Hours total
Starts, Efficiency Calculations
Alarm & Loop Analysis Client DCS
OPC Server
What Our Customers Say...“I commend you on your efforts in
customizing the business analysis
software for trial deployment for a Web
Based Alarm Management Dashboard. It meets our objectives and has produced the desired results.”
Control & Automation Leader
“[We] commend INTECH’s knowledge of alarm management, dedication, commitment and effort. Most importantly,
works have been completed safely and
INTECH has been able to work successfully
in our diverse environment”
Central Maintenance Coordinator
“INTECH’s team worked with
extraordinary zeal & efforts at the Adhi
Electronic Flow Metering Project which
included on-line trends and alarms of
sales gas parameters’ limits. The
competency level and performance of their deputed team is satisfactory and commendable. “
Deputy Chief Engineer
PPL
EPC OEM OEMEnd User EPC
SolutionsAker
Vendor Expertise
Standards & Certifications
* Notice: All registered logotypes, trademarks, brands, product and services marks used in this document are acknowledged as properties of their respective companies/owners and such companies/owners have not consented to their use by INTECH (Term INTECH is used for INTECH Process Automation Inc. and its affiliates). INTECH is not affiliated with these logotypes, trademarks, brands, product and
services marks and any use by INTECH should not be construed as an endorsement of INTECH or its services. The services described herein are provided solely by INTECH.© 2014. All rights reserved by INTECH Process Automation Inc.
CIS
Americas
Europe Office
World HQINTECH Process Automation Inc.4903 W. Sam Houston Parkway N. Suite A-100Houston, TX 77041, USATel: +1 713 849 1000 Fax: +1 713 856 0785
INTECH Process Automation SARL168 Avenue Charles de Gaulle 92 522 Neuilly-sur-seine Cedex, FranceTel: +33 1 7037 53 00
INTECH Process Automation LLP.Building 15A, Koktem-1, Bostandyk Region, Almaty, Kazakhstan Tel: +7 7273 56 16 20Fax: +7 7273 56 16 211a Temirhanova Str. Atyrau, KazakhstanTel: +7 7122 32 01 16Fax: +7 7122 32 00 52
Caracas – Venezuela. Av. Francisco de Miranda, Centro Comercial Lido. Torre D. Oficina 41-D.Tel: +58 212 9056385
Middle EastInternational HQINTECH Process Automation FZCOP.O. Box 61479, Office No. 16618 Lob 16,Jebel Ali, Dubai, United Arab EmiratesTel: +971 4 8808423Fax: +971 4 8876553
North Africa OperationsTel: +971 55 607 3230, +971 553768482
P.O. Box 61479, WT01FD06,Jebel Ali, Dubai United Arab EmiratesTel: +971 4 8810056Fax: +971 4 8810057
INTECH Process Automation Inc. Br.G-201 Al-Salah Tower, P.O. Box 4270, Al-Khobar - 31952 Kingdom Of Saudi ArabiaTel: +966 13 8966052, +966 13 8966053
INTECH Process Automation FZCO Br. 470, Italian City, Erbil, Iraq Tel: +964 780 131 2198, +964 750 309 3766Mnawi Basha, Basra, Iraq.Tel: +964 780 131 2198, +964 770 831 9073
South AsiaINTECH Process Automation (Pvt.) Ltd.2nd Floor, Club and Community Center,PCSIR Society Phase II,Lahore Pakistan 54782Tel: +92 42 111 468 324, 3531 2509/11Fax: +92 42 3531 4149
Asia Pacific
INTECH Process Automation (Shanghai) Co. Ltd.Room 1230, 12F, Building A No. 331North Caoxi Road, Shanghai, ChinaTel: +86 21 2426 1951Fax: +86 21 2426 1877
INTECH Process Automation Pte. Ltd.21 Merchant Road #04-01 Royal Merukh S.E.A BuildingSingapore 058267 Tel: +65 6828 9128Fax: +65 6828 9112
PT INTECH Process AutomationRukan Permata Senayan, Block D31Jl. Tentara Pelajar, Kebayoran Lama,Jakarta Selatan 12210, IndonesiaTel: +62 2157 940 835Fax: +62 2157 940 836
Africa
Sales Email: [email protected] E-mail: [email protected]
INTECH Process Automation Nigeria Ltd.Plot 64, Abacha Link Road, G.R.A., Phase III, BiobuPort Harcourt, NigeriaTel: +234 0 84462776
INTECH Process Automation Nigeria Ltd.Liaison Office Lagos, NigeriaTel: +234 805 9330560
INTECH Process Automation Inc.(Sucursal de Angola)86 - Rua Anibal De Melo Vila AliceLuanda, Republica de AngolaTel: +244 222 264052, +244 222 263145Fax: +244 222 265813
www.intechww.com
facebook.com/Intechprocessautomationlinkedin.com/company/49479 twitter.com/INTECHww