Importance of Alarm Management for Preventing Accidents which Lead to Environmental Pollution

Transcription

1 Importance of Alarm Management for Preventing Accidents which Lead to Environmental Pollution 6 th February, 2013 Hiroaki Mimura Idemitsu Kosan Co., Ltd. Technical & Engineering Center 1

2 1. Introduction Accidents has a very serious impact on the Environment. Safety is the most important aspect in plant operation!! Caused by BIG Earthquake September 2003 in HOKKAIDO 2

3 1. Introduction Cause of serious accidents Many accidents caused by human error 3

4 2. Alarm management at IDEMITSU I can t watch too many alarms!! DCS appeared Number of alarms is increasing 4

5 2. Alarm management at IDEMITSU 7 steps to a highly effective Alarm System Steps to implement based on alarm system performance STEP-7:Control and maintain your improved system STEP-6:Implement real time alarm management STEP-5:Implement alarm audit and enforcement technology STEP-4:Perform alarm documentation and rationalization Always-needed steps: STEP-3:Perform Bad actor alarm resolution STEP-2:Collect data and benchmark your systems STEP-1:Develop, adopt, and maintain an Alarm Philosophy 5

6 2. Alarm management at IDEMITSU We have been doing alarm reduction as Non-touch Operation Activity Focus on 10 highest frequency alarms Frequent alarms Reviewing alarm setting Reviewing PID parameter Routine alarms Automating routine operation. Redundant alarms Removing alarms STEP-3:Perform Bad actor alarm resolution STEP-2:Collect data and benchmark your systems STEP-1:Develop, adopt, and maintain an Alarm Philosophy 6

7 2. Alarm management at IDEMITSU Go to next STEP Alarm management software CAMS STEP-7:Control and maintain your improved system STEP-6:Implement real time alarm management STEP-5:Implement alarm audit and enforcement technology STEP-4:Perform alarm documentation and rationalization 1 Create a database of the alarms 2 Separation of critical alarms display 3 Unnecessary alarm suppression 7

8 3. Method 1 Purpose Create a database of the alarms Safety Environment Damage to the equipment(es D) Damage to the equipment (Design) Damage to the equipment(tr ip) Gr-Ⅲ (critical) Gr-Ⅲ (critical) Gr-Ⅲ (critical) Gr-Ⅲ (critical) Gr-Ⅲ (critical) Quality Gr-Ⅲ Gr-Ⅱ Operation change Gr-Ⅲ Gr-Ⅱ Decrease in production XHQ Gr-Ⅲ Others XHQ ANA Gr-Ⅱ Gr-Ⅱ Gr-Ⅱ Gr-Ⅱ Gr-Ⅱ We classified all tags Gr-Ⅰ Gr-Ⅰ Gr-Ⅰ Gr-Ⅰ GrⅠ: Control limit(esd) GrⅡ: Operation limit GrⅢ: Operation value Less than 8hour Less than 2hour Less than 30min Less than 5min Less than 1min Urgent Urgency 8

9 3. Method ② Separation of critical alarms display Critical alarms All process alarms easy to It Itisisdifficult tocheck checkcritical criticalalarms alarms 9

10 3. Method ③ Unnecessary alarm suppression Ex) FIC9014 (PID block) : Superheated steam to Refinery ESD SIGNAL!! Refinery Steam VALVE SHUT!! FIC

11 3. Method ③ Unnecessary alarm suppression ESD Velocity High limit Flow Rate Target value Deviation Low limit MV HL Alarm flooding by massive alarms F9014.HI F9014.LO F9014.DV+ F9014.DVF9014.VEL+ F9014.VELF9014.MHI F9014.MLO F9014.IOP+ F9014.IOPF9014.OOP Time 11

12 4. Alarm suppression performance A section of X plant the result of suppression in ESD EEMUA benchmarks Peak alarm rate / 10 min No suppression 68 After suppression 5 Should be manageable <10 Hard to cope Definitely excessive >100 Operator feels relief to control plants by alarm suppression!! 12

13 4. Alarm suppression performance All section of X plant the result of suppression in ESD No suppression : 1754 After suppression : 191 Reduction rate: 90 Operator can monitor easily in ESD operation 13

14 5. Conclusion With the introduction of alarm management Good Mark You can decrease operator s labor and improve the plant safety. You can introduce alarm management system without equipment costs. Bad Mark You must make a great effort to create alarm database. 14

15 5. Conclusion Attention Only introducing software is meaningless!! It is very important to carry out regular reviews of the alarm management!! I must classify all alarm tags! Rationalization Operation Alarm management Life cycle Maintenance Assessment 15

16 5. Conclusion Feel Easy!! % % % Thank you for your attention. 16