Too Many Alarms: Where Do I Begin?

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1 Too Many Alarms: Where Do I Begin? Standards Certification Education & Training Publishing Conferences & Exhibits Speakers: Kevin Patel, PE, MBA Signature Automation, LLC 2013 ISA Water / Wastewater and Automatic Controls Symposium August 6-8, 2013 Orlando, Florida, USA

2 Presenter 10 years of experience in integrating and programming instrumentation and control (I&C) systems, SCADA systems including PLCs, RTUs, HMIs and networking primarily for water and wastewater treatment facilities. Bachelor of Science in Computer Engineering from Texas A&M University Master in Business Administration from University of Texas at Dallas Current member of the ISA101, ISA105, ISA106 and ISA18 2

3 Presentation Outline Introduction Alarming Problems Alarm Management Benchmarking Case Study Statistics Alarm Design Methods Getting Started Summary

4 Introduction Alarm Systems Far More Powerful Today No Guidance is Given During Development Not Enough Information for Alarm Response Reliance on Unmanaged Alarm Systems Causing Safety Problems Development of ISA18.2, Technical Reports

5 Alarming Problems Nuisance Alarms Most common problem Alarms that generate in excess Acknowledged without consideration of validity mind-trix.com

6 Alarming Problems Stale Alarms Remain in alarm for long periods of time Acknowledged, then ignored No action taken during maintenance

7 Alarming Problems Flood Alarms Surge of many alarms at once Prevents appropriate response Delays reaction time

8 Alarming Problems Unclear Alarms Generate with unclear information for action Delays response time Eventually may become stale meuniversitylive.com

9 Alarm Management Benchmarking Alarm Performance Metrics Average annunciated rate per operator Peak annunciated per operator Alarm floods Frequently occurring alarms Chattering/fleeting alarms Stale Alarms Priority Distribution

10 Case Study Statistics Month 1 Initial Analysis of Site 4 days of data 193 Tags 209,083 Alarms ~363 Alarms Every 10 minutes

11 Case Study Statistics Month 1 Rank Top 20 Alarms Alarm Instances % of Total Day 1 Day 2 Day 3 Day 4 1 D110_002_220PLC02YA % D110_037_960PLC37YA % H110_002_220VRTEX04FIUR % V110_002_220VRTEX01FIMDI % H110_002_220VRTEX01FIUR % H110_002_220INFPS02FIUR % V110_002_220VRTEX03FIMDI % H110_002_220VRTEX03FIUR % H110_002_220PSHSF01AIUR % A % V110_038_JT MDI % FIT310_001_05_FI_UR % H110_002_220PSLDG02FIUR % VLV240_2_63_ZI_OR % VLV240_2_63_ZI_BAD % D_110_010964BIOSB06YA % PLC952_073_201_MOD_FAIL % V110_048_461TMZN3A2AIMDI % MS10_0M_COMMFAIL % PLC01-1SLOT7-FAULT % Total %

12 Case Study Statistics Month 1

13 Alarm Management Lifecycle Detailed Design Stage Basic Alarm Design HMI Design Philosophy Design of Advanced Alarming Techniques Identification Rationalization Detailed Design Management of Change Audit Implementation Operation Monitoring & Assessment Maintenance

14 Alarm Management Detailed Design Basic Alarm Design Alarm setpoints Alarm deadbands Alarm on/off delays HMI Design Where are alarm changes made HMI display requirements Alarm visual and audible indications Alarm logging Advanced Alarm Design Designed suppression Alarm redirection

15 Alarm Management Basic Alarm Design Signal Type Deadband (Percent of Operating Range) Delay Time (On or Off) Flow Rate ~5% ~15 Seconds Level ~5% ~60 seconds Pressure ~2% ~15 seconds Temperature ~1% ~60 seconds

16 Case Study Statistics Month 1 Top 2 points were PLC heartbeats (Disabled) 6 points were under-range alarms chattering (On Delay Timer was Added) 4 points were duplicate alarms (Disabled) Others were left as they seemed to be anomalies. Will re-check on next analysis to see if they continue to be a problem. 12 of the top 20 alarms were addressed.

17 Case Study Statistics Month 2 Rank Top 20 Alarms Alarm Instances % of Total Day 1 Day 2 Day 3 Day 4 Day 5 1 M AL % M AL % M AL % M AL % M AL % M AL % FIT310_001_05_FI_UR % VLV240_2_63_ZI_BAD % VLV240_2_63_ZI_OR % MS10_0M_COMMFAIL % PMP7334_256_01_MM % PMP7334_256_02_MM % V110_048_461TMZN3A2AIMDI % LSLL % PLC12-IPF % MS11-7E_COMM_ % PLC952_073_201_MOD_FAIL % M AL % H110_002_220PSHSF01AIUR % FP % Total %

18 Case Study Statistics Month 2

19 Case Study Conclusions Find the problem alarms and tackle them individually immediately. Small amount of changes can make a HUGE difference. Most systems have built-in capabilities to provide alarm suppression and alarm time delay. Take advantage of these features. Provide continuous monitoring and assessment to fine tune your alarm system.

20 Getting Started Time to get started is NOW! Execute alarm management on new or existing alarm systems For existing systems, it is best to start with a benchmark More than a one day venture

21 Thank You! Contact: Kevin Patel, P.E

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