Dear Sir,

Operation alarm system improvement – MAX DNA

 ALARM SYSTEM CHECKLIST AVALIBILITY BASED ON PRIORITY.

 PRIORITY 1 ALARM – BLINKING & ANNUNCIATION WILL NOT STOP TILL VALUE GETS BELOW NORMAL. eg
(DRUM LEVEL, TEMPERATURE – HI HI VALUE) THIS ROW ALARM WILL HAVE TO BE REPORTED
IMMDIATELY TO INCHARGE. AS CHANCES OF OCCCURANCES ARE VERY LOW THIS ROW WILL REMAIN
SILENT MOST OF THE TIME.
 PRORITY 2 ALARM – THIS WILL GET ACTIVATED AT HI VALUE AND BLINKING & ANNUNCIATION WILL
REPEAT AT A INTERVAL OF 30S TILL NORMAL. OPERATOR WILL TAKE IMMDEATE ACTION TO NORMALISE
THE SAME.
 PRIORITY 3 ALARM – WILL STOP ANNUNCIATION ON BEING ACKNOWLEDGED LIKE SOOTBLOWER ALARMS
BUT WILL OCCUR AGAIN AT 300 S IF PERSIST.

ADVANTAGES OF ABOVE POINTS –

 REDUNDANCY OF ALARM AS HI ALARM IN PRIORITY 2 & HI-HI IN PRIORITY 1
 RELIABILITY OF ALARM
 PRIORITISATION
AN EXAMPLE OF ABOVE ALARM SYSTEM - MAIN STEAM TEMPERATURE MAX DNA VALUE 545 WILL TRIGGER A
PRIORITY 2 ALARM. HOWEVER IF MAIN STEAM TEMPERATURE REACH 550 A PRIORITY 1 ALARM WILL BE
TRIGGERED.
ADDITIONAL POINT – INSTEAD OF CALLING MAIN STEAM TEMPERATURE HI THE DESCRIPTION COULD BE GIVEN AS
MAIN STEAM TEMPERATURE HI – 545 DEG

Operation alarm system improvement – SIEMENS

BOILER
SIEMENS TG
MAX DNA ALARM SIEMENS
SIEMENS 1 colour changing
value indication SIEMENS 2 SIEMENS 3 SIEMENS 4

SIEMENS
MAXDNA BLR MAXDNA TG SIEMENS TG
ALARM

AS PART OF STANDARD PACKAGE THIS WAS STANDARD CONFIGURATION OF DCS IN EVERY UNIT. THE FOURTH
SIEMENS SYSTEM LATER WAS REMOVED FROM SOME UNITS BUT STILL EXISTS IN SOME UNITS.
IN EXISTING SYSTEM FOLLOWING STANDARD CONFIGURATION THE FOURTH SYSTEM CAN BE USED AS AN ALARM
SYSTEM. USING THE FLEXIBILITY PROVIDED IN SIEMENS SYSTEM AN ANNUNCIATION PAGE CAN BE EASILY SET UP
FOR SIEMENS PRIORITY 1 & PRIORITY 2 ALARMS. (LIMITATION-ALL ALARMS WILL BE GIVEN IN ONE PAGE ONLY SO
LIMITED & CRITICAL ALARMS WILL ONLY BE GIVEN)

BAL- BOILER ALARM TAL- TURBINE ALARM

HT DRIVE ALARM

ACTIVE INACTIVE
ALARM ALARM

DRUM
MST>54
LEVEL HI
5

MST >550 DRUM

LEVEL HI
SECOND TYPE – (INCORPORATE ALL ALARMS IN ONE PAGE UNDER DIFFEREENT TABS)

BOILER ALARM TURBINE ALARM GENERATOR/ ELECT RICAL BOP

SH METAL PA HEADER LOW

TEMPERATURE HI

RH METAL MILL A OUTLET

TEMPERATURE HI HI

FURNACE PR. HI PA FAN BRG

TEMP HI

FURNACE PR HI
HI

WHAT IS THE MAIN ADVANTAGE OF THIS KIND OF ALARM SYSTEM? THE MAIN ADVANTAGE OF THIS
KIND OF SYSTEM IS THAT ALL ALARMS WHETEHER ACTIV OR INACTIV ARE VISIBLE AND AS THERE ARE
ONLY TWO COLOURS IT IS EASY TO DIFFERNETIATE BETWEEN ACTIV AND INACTIVE ALARMS.

IF AN ALARM COMES THE COLOUR OF THE TAB WILL CHANGE UNTIL RESET AND ANYBODY SITTING ON
DCS CAN OPEN THE PAGE TO SEE WHETHER THEIR IS ANY ALARM OR NOT. WHEN THERE IS NO ACTIVE
ALARM THE BOILER ALARM TAB WILL BE GREEN AND RED IF THERE IS ANY ACTIVE ALARM.

SUPPOSE THERE IS ANY ELECTRICAL ALARM THE GENERATOR ELECTRICAL TAB WILL BECOME RED AND
WHEN OPERATOR CLICKS ON IT WILL LEAD TO ELECTRICAL ALARM PAGE WHERE THE ALARM
DESCRIPTION CAN BE CHECKED.

WHERE IS SUCH SYSTEM USEFUL? WHEN THERE ARE A LARGE NUMBER OF CLASSIFIED ALARMS AND
THERE IS ONLY ONE DCS SCREEN. AT SHIFT CHANGE ONE LOOK AT ALARM TAB WILL TELL THAT THERE IS
NO EXISTING BOILER ALARM OR TURBINE ALARM.

SUMMARY – ABOVE MEASURES CAN BE IMPLEMENTED AT NO COST AND WITHIN SYSTEM CAPABILITY.
OTHER MEASURES MAY INCLUDE OEM RECOMMENDED HARDWIRED ALARM SYSTEM ALONG WITH LVS
FOR SOFT ALARM. A BHEL ALARM ANALYSIS SYSTEM IS ALSO AVAILABLE AS SHARED BY SNAPSHOT. AN
UPCOMING DCS UPGRADE MAY ALSO BE BENEFICIAL.