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  • 1. Six Sigma Project Six Sigma Project Alarm Management Alarm Management Brent J. Thomas Brent J. Thomas 2005-2006 1
  • 2. Alarm Management Define Measure Analyze Improve Control Define Phase Define Phase 2
  • 3. Alarm Management Define Measure Analyze Improve Control Identification Green 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 3
  • 4. Alarm Management Define Measure Analyze Improve Control Process Description Target Operation = Normal Operation = Upset Condition = DCS Intervention Alarm Boundaries: Low = Medium = High = Operator Intervention Interlocks and emergency procedures 4
  • 5. Alarm Management Define Measure Analyze Improve Control Problem Description Too Many Alarms Alarms that dont 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 5
  • 6. Alarm Management Define Measure Analyze Improve Control Soda Springs Alarm Management Team: Human Resources Doug Beauregard Manufacturing, Team Lead Aimee Anani p4 production Brian Kemmerer Burden Prep Monsanto Alarm Management Team: Reggie Kuzet Maintenance Matt Rollinson Luling, Team Lead Brent Thomas Process Control Mark Gamel Luling Andrew Johnson Luling Soda Springs Alarm Rationalization Team: Edward McGinnis Luling Aimee Anani p4 Production, Team Lead Jack Ahlers Muscatine Troy Carver Furnace Operations Specialist Kurt Schlawin Muscatine Matt Kirby Furnace ESH Representative Andre Divino Sao Jose dos Campos Brock Sherman Furnace Process Engineer Luiz Dourado Camacari Kenny Rasmussen Furnace Control Operator Jose Neto Camacari Vaughn Mickleson Furnace Control Operator David Mourino Zarate Rick Hendricks Furnace Control Operator Johnny Ollivier Antwerp Aaron Tarbet Furnace Control Operator Brent Thomas Soda Springs Brent Thomas Process Control 6
  • 7. Alarm Management Define Measure Analyze Improve Control 7
  • 8. Alarm Management Define Measure Analyze Improve Control 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 Solution 1) 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 8
  • 9. Alarm Management Define Measure Analyze Improve Control Project Planning Steps in an Alarm Management Project 1) Develop an Alarm Management Philosophy 1) 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 9
  • 10. Alarm Management Define Measure Analyze Improve Control Project Planning Steps in an Alarm Management Project 2) Select Alarm Metrics Monsanto 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 10
  • 11. Alarm Management Define Measure Analyze Improve Control Project Planning 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. 11
  • 12. Alarm Management Define Measure Analyze Improve Control Measure Phase Measure Phase 12
  • 13. Alarm M