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HMI SCADA-08 Best Practices for Alarm Management

Rob Kambach


HMI/Supervisory Market Spectrum Plant Site Enterprise

• Ease of Use • Process Visualization • Basic Alarming • Short Term History • Device Connectivity

Key

N

eeds

/Asp

ects

• Larger Tag/Graphic Counts

• Graphic Standards • Extensible Vis (Client

Controls) • Basic Reporting • Basic Alm

Management

• Server Consolidation • Standard Equipment

Model • Thin Client • Centralized Historian • Fault Tolerance • Situational Awareness • Advanced Alarm

Management

• Multi-Plant HMI/Common Control Room

• Large Engineering Teams

• Common Standards

• Monitoring • Operational Centers • PIMS (Information

Management)

Scale/Cumulative

Process Machine Pr

oduc

ts


Current state around alarming Configured alarms per operator


Economical impact Affecting several crucial areas of plant operations: - Reduces the operational effectiveness - Economical impact: Unnecessary plant shutdowns (in the USA alone this

costs $20 Billion a year on productivity)

- Poor alarm management also causes losses in product quality, danger to population and environment and/or image loss of a respective company

Source : ASM Consortium Abnormal Situation Management


Safety Impact

Piper Alpha North sea 1988

Texaco Pembroke 1994

Bunkfield Oil Depot


Why did the number of alarms increase?

• Automation evolution (including fieldbus) brought more accessible

information per sensor/actuator

• Alarms are easily configurable now (no more wired) -> no real cost

at engineering or operating time to add alarms

• People (SI/EPC) tend to believe more is better : nothing can happen

without notice if everything has an attached alarm


A set of standards and guidelines ● EEMUA 191, Alarm systems a guide to design ● Namur NA 102 Worksheet, Alarm Management ● NPD YA 711, Principles for alarm design (Norwegian petroleum doctorate

slowly adopted throughout Europe as the standard) ● VDI/VDE Guideline 3699 (process control using monitors) ● ISA S18.02, Management of alarm systems for the process industry ● IEC 62682 Alarm Management Standard

ANSI/ISA 18.2 Management

of Alarm Systems for the Process Industries

API RP-1167 Alarm

Management For Pipeline

Systems

http://www.api.org/


IEC 62682 Alarm Standard Worldwide ● Introduces vendor neutral terms

●Shelving, Initiated by Operator to temporarily suppress an Alarm ●Suppressed by Design, Mechanism implemented within that prevents the

transmission of the alarm indication to the operator based on Plant State ●Out of Service, is the state of a alarm indication that is suppressed, typical

manually, for reasons such as maintenance These map to our system as Shelving, Plant State and Inhibit or Disabled

●The standard requires that all alarms currently shelved, suppressed by design and out of service can be listed. Alarms must be under access control to be placed out of service. If an alarm is placed out of service it must be recorded.


Situational Awareness HMI and Alarms Combined

Alarm

Impact

Time

Alarm Grid

What Happened ? Critical

Process Trends

Operational Limits

Alarm Boundaries

Tool

Tool

Knowledge Operator

Knowledge Operator

Traditional HMI

What is Happening ? SA Graphics

- 40 %

Interpretation time


Advanced Graphics, EEMUA, ISO Identify what type of information and support people

need in order to be able to deal successfully with unanticipated events (Higher) Plant Operating Target

Plant Capacity Limit

(Fewer) Operational Constraints

(Fewer) Planning Constraints

Day

s pe

r Yea

r

95% 100% < 60%

Daily Production

Recovery of 3-8% of Capacity

APG Efforts


2014 System Platform Alarm Enhancements

Released January 2014

Before 2014…….you could build your own alarm App…but you needed the know how.

Setup the logger Define Queries Configure/Connect Databases Have SQL Server SA Passwords Wire the Runtime to History Repeat all the same for Visualization Setup the logger as service


2014 delivers this experience…


Applying the guidelines

Define response times for each category

1.Alarm Priorities 2.The system shall only represent four active alarm priorities:

Priority 1 Critical (only Safety and Emergency related) Priority 2 High Priority 3 Medium Priority 4 Low Priority 5 Events and logging only no Alarms.

1.The four priorities and the impact to the business and operation. 2.Ranking and economical scale:

Operational risk of the Alarms


Severity indication on alarm borders Severity 1 response time < 5min

Severity 2 response time < 30min



Wonderware Implementation

Specification


Global Priority to Severity mapping

One location to change and customizable image…

Default Alarm Border Icons


Global defined styles for alarm colors and borders

One place to change how graphics represent Alarms


Alarm Border Animation Global Icons

Global Styles

Auto Configuration for Field_Attributes or Objects

Runtime


Possible Alarm Border States on Graphics

In Alarm Acked Un-Acked Flashing

Was in Alarm Returned to Normal Un-Acked

Disabled or Inhibited (Engineering)

Shelved (Operator)

2014 R2

Silenced / Suppressed (Operator, PlantState)

Yes Yes No Yes Yes Transitions logged

Yes Yes No Yes, tab Shelved

No In Alarm Summary Display

Yes Yes Yes Yes Yes Indicated in

alarm border

Yes No No Yes Yes Aggregated/ Counted

Alarm Border Can represent multiple alarms Its show the Alarms in the following order of importance Using something we call “Most Urgent” Un_Acked Severity 1,2,3,4 Acked 1,2,3,4 Unacked RTN Normal 1,2,3,4 Shelved 1,2,3,4 Disabled, Inhibited 1,2,3,4 Silence 1,2,3,4


Alarm Aggregation Counted and totalized by Area or Object

Active count On any level In the model


2014 R2 Release System Platform

Releasing October 2014

If for 2014 we delivered this….


2014 R2 delivers this: Scalability Factor times 10 Clients with out of the box experience Shelving and plant state suppression built-in

Alarm App


Update Clients: Runtime • Tabbed filtering • Actual alarm indicators on Tabs • Ack buttons • And styles and themes setup as default


Updated Clients: Historical • Defined with the standard Themes and Styles colors • Fonts best Practices HMI Standards • Dynamic Filter tabs • Group By functionality

History Blocks Extra Columns


Severity Indication in Runtime and History mode within the Alarm Symbols


Widgets for Alarming

Area Indicator Object or Device Indicator Navigation Badges


Alarm Shelving Who Can Shelve?

What can be shelved?

Shelving from Alarm Client or Scripting Mandatory: a Reason and duration Audit trail logged to Historian Any configured alarm can be shelved Only enabled Alarms can be shelved Alarm Border integration


Alarms Plant State-Based Suppression

●Global definition of plant states

●Area object based suppression of alarms ● Individual state on the area object has an I/O Extension


Added Operational Permissions

●Who can Shelve ●Who can Inhibit / Disable ●Who can change Plant State ●Who can modify Alarm and Event configurations


Operational organization of alarms

PLC

Operator

Engineering Inhibit / Disabled Based on Maintenance

Shelving Based on temporary conditions

Plant State Based on production Conditions


Unified Attribute Editor Same UI on any object to manage alarms

Duplicate Function

Bulk Editing Smart Filter

Icons that show what Features are On or Off


New High Performance Storage and Retrieval ●Choice upon install logging to legacy DB A2ALMDB

● 100 messages per second

●History Blocks same as process data ● 2000 messages per second


Release of WW Alarm Analyst Q1 2015


Wonderware Alarming 2.0 ●Easy to Use ●Compliance to regulations and best practices around alarming ●Alarm rationalization In context with Situational Awareness…OUT OF

THE BOX!!!!! ●Scalable by 10X , 2000 messages per second sustained ●Redundancy built-in as an option ●Most Robust system in the industry using Store & Forward ●Highest throughput in the industry ●Completely re-invented and revamped Alarm system to deal with the demands, flexibility and safety requirements of today’s and tomorrow’s projects

Differentiators


Approach

Analysis of Current Situation Operator Input

Alarm Adviser

Alarm Philosophy

Review Alarms

Alarm Rationalization Active When

Alarm Design

Plant State

Plant State

Shelving

Why

Implementation Suppression Implement

Alarm Performance Assessment Determine Fleeting

Determine Standing

Determine Bad Actors

Determine Frequent Alarm Adviser

Determine Fleeting

Eliminate Noise

Standing Fleeting Frequent Bad Actors

Annual

Monthly

1

2

1

2

3

4

Operational Limits Document

Wonderware Software


Alarm Adviser - Overview ●Common UI/UX ●Up to 10 years of historic alarm data ●Multiple sites/plants/systems ●Connects to

● Vijeo Citect ● InTouch ● System Platform ● ClearSCADA ● Foxboro


Configuration – Priority & Severity


Dashboard

The dashboard is available to all users


Dashboard – User defined KPIs EEMUA 191 Standards


Alarm Activity – Severity Distribution


Frequent Alarms


Long Standing Alarms - Longest


This makes a strong case … to manage 95% of your alarms in System Platform

• Typical 80% is low, 15% is medium, 4% is High, 1% Critical • Meaning 95% of your alarms do not cause a shutdown • By moving these alarms out of the PLC, you create room and make management a lot easier Benefits:

Centralized Configuration One approach to Shelving and Plant State Redundancy Built-in Out-of-the box Styles and Alarm Borders Aggregation Built-in Counting Built-in Severities Built-in (used for rationalization)


Where does this give you the advantage?

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