CAMS For HIS Introduction - 261113 PDF

26/11/56
CAMS for HIS

(Consolidated Alarm
Management System)
ISD-MASP-S06015 Rev. 2 -1-

Copyright © Yokogawa Electric Corporation
July 2011
By Kittikarn Richucositsawat
Content
Day 1:
Alarm Management
Purpose of CAMS
CAMS for HIS Operation
– CAMS Structure and features
– Historical Viewer of CAMS for HIS
Day 2:
CAMS for HIS Engineering
– CAMS Alarm Engineering
– CAMS for HIS Builders
– Export/Import
– Function Check of CAMS for HIS
July 2011
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Time
9:00 – 10:30 Course Training

10:30 – 10: 45 Coffee Break
*********** Lunch Time **************

14:30 – 14:45 Coffee Break

July 2011
Alarm Management
What is Alarm Management?

Alarm management is the application of human factors
along with instrumentation engineering and systems thinking to
manage the design of an alarm system to increase its usability.
Most often the major usability problem is that there are too many
alarms annunciated in a plant upset, commonly referred to as alarm
flooding.
What is an alarm system?

July 2011
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Alarm Management
What is an alarm system?

Alarm systems are a very important way of automatically
monitoring the plant condition and attracting the attention of the
process plant operator to significant changes that require
assessment or action. They help the operator:
• To maintain the plant within a safe operating envelope.

• To recognize and act to avoid hazardous situations.
• To identify deviations from desired operating conditions that could lead
to financial loss such as off-quality product.
• To better understand complex process conditions. Alarms should be an
important diagnostic tool, and are one of several sources that an
operator uses during an upset.

July 2011
Philosophy of Alarm System

Proprietary info goes here… July 2011 Page １-6
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Purpose of Alarm
The purpose of an alarm system is to direct

operator’s attention towards plant
conditions requiring timely assessment or
action.
- EEMUA #191 Alarm System Design Guide -
A Guide to Design, Management and Procurement
(EEMUA: Engineering Equipment and Material
Users Association)
Well managed plant is boring

The operator is requested to make a change
only when an alarm system instructed it.
What is a good alarm?
Each alarm should alert, inform and guide

Each alarm should be useful and relevant
Each alarm should have a defined response
Adequate time should be allowed for the operator to carry
out a defined response
The alarm system should be explicitly designed to take
account of human limitations
CHARACTERISTICS OF A GOOD ALARM
Relevant: not spurious or of low operational value
Unique: not duplicating another alarm
Timely: not long before any response or not too late
Prioritized: indicating the priority the operator deal with
Understandable: having a clear & easy to understand message
Diagnostic: identifying the problem that has occurred
Advisory: indicative the action to be taken
Focusing: drawing attention to the most important issues
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Operational Priority
1st Priority: Safety (casualties from the hazard)

2nd Priority: Environmental (breach of
environmental limits)
3rd Priority: Financial (plant damage, loss of
operation) Upset Abnormal
Normal
4th Priority: Quality (off specification product)

Optimal
5th Priority: Efficiency (quality give-away, less

valuable products)
What’s alarm occur?
X1: too late

X2 X3
X2: adequate
X4 Control
Target X3: no need
X1 Normal System
X4: adequate
but only
Upset Operator effective in
Intervention stable
operation
Shutdown
ESD
Plant State Operator’s primary role Key alarm information
Normal Monitoring & Optimization Minor operating adjustments needed
Upset Situation management Operator intervention needed
Shutdown Ensure safe shutdown Safety actions needed
ISD-MASP-S06015 Rev. 2 - 10 -
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Operator’s Role at Plant Upset
Detect abnormal Monitor outcome Action to fix

process condition of correct actions underlying cause
Simple loop
Understand current Action to correct current

process condition process condition How to
increase
those
activitie
Ascertain future Action to prevent s
consequences effect from spreading
Investigate root
cause
Complex
loop
ISD-MASP-S06015 Rev. 2 - 11 -
Basis of Alarm System Design
ISD-MASP-S06015 Rev. 2 - 12 -
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Alarm System Design Activities
Risk assessment: identify alarms to protect

something and alarms to reduce risks, quantify the
severity of consequence for alarm prioritization
Ergonomics: interface with the operator
Design of individual alarms: risk assessment,
prioritization, operator response, alarm setting,
suppression, management control
Design integration: integrate individual alarm
design to meet the given KPI such as % high priority
Alarm system configuration: modify alarm
configuration of the alarm system to the revised one
(CAMS)
Testing and commissioning: testing and evaluation
of revised alarm system
ISD-MASP-S06015 Rev. 2 - 13 -
Performance Measurement
ISD-MASP-S06015 Rev. 2 - 14 -
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Alarm KPIs
Long term alarm rate in steady operation

– More than 1 / min: not acceptable
– 1 / 2 min: over demanding (industry av.)
– 1 / 5 min: manageable
– 1 / more than 10 min: acceptable
Number of alarms displayed in 10 minutes following a major plant
upset
– More than 100: excessive and of no use
– 100 – 20: hard to cope with
– Under 10: manageable if not complicated
Long standing alarms: should be fewer than 10 (fewer than 30
shelved)
% hours when there were more than 30 alarms
– More than 50%: not acceptable
– 50 – 25%: hard to cope with
– Under 5%: manageable
ISD-MASP-S06015 Rev. 2 - 15 -
Identification of present
condition and target
settings
ISD-MASP-S06015 Rev. 2 - 16 -
Proprietary info goes here… July 2011 Page 3-16
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Alarm System Performance
Identifying the as-is performance and targeting the

performance to be achieved
Parameters to be evaluated: operator’s acceptance,
alarm KPIs, operator interface, alarm system
functionality, ancillary processes
– Level 1 (Overloaded): alarm system does not work. Alarms
tend to be ignored or disabled.
– Level 2 (Reactive): alarm system works during normal
operation. Individual alarm is not integrated.
– Level 3 (Stable): alarm system is reliable during normal
operation. All alarms are meaningful and well defined.
– Level 4 (Robust): alarm system is reliable even in a plant
upset. Operators have a high confidence to the system
– Level 5 (Predictive): Operator can operate a plant without
plant upset or minimize the impact of plant upset
ISD-MASP-S06015 Rev. 2 - 17 -
Proprietary info goes here… July 2011 Page 3-17
Ref: EEEMUA #191

Performance Levels Alarm Systems Edition 2
Appendix 13 Performance Levels
Performance Typical Typical Focus for

Levels KPIs Further Improvement
1) Av. alarms/10min
2) Max alarms/10min
3) % hrs more than
30alarms
1 > 100 Establish a site-specific alarm philosophy document
Overloaded > 1000 Establish a well-defined change control process for alarms, linked to the agreed alarm philosophy
> 50% Analyze alarm journals to identify ‘bad actors’ and address these as a priority
Invest in software/hardware for electronic alarm journal archiving
Survey alarm tuning parameters (dead-band, etc.) and implement generic improvement
Establish minimum (e.g. paper-based) control mechanism for alarms disabled by the operator
Improve alarm representation on process schematics, particularly for critical alarms
2 100 > X > 10 Reinforce alarm management philosophy and ensure wide adoption
Reactive > 1000 Establish automated analysis and delivery of alarms system performance metrics (together with a ‘bad actors’ list)
50% > X > 25% Implement grouping of alarms with an identical operator action, and discrepancy alarming to associated actions
Carry out basic alarm rationalization to reduce the content of the alarm system to only what is meaningful (as
determined by the site alarm management philosophy) and identify the correct alarm setpoints
Implement software alarm shelving to support control of alarms displayed by the operator
3 10 > X > 1 Implement automatic dynamic alarm management for logical blocks of alarms
Stable 1000 > X > 100 Improve usability of manually-initiate alarm masking features
25% > X > 5% Implement adaptive alarm tuning, e.g. to automatically suppress bouncing alarms
Integrate the alarm response manual into the DCS alarm system interface
Implement model-based multivariable alarming to provide early warning and avoid multiple single variable alarms
4 10 > X > 1 Implement automatic event diagnosis, combining pattern matching with surveillance of analogue variables in
order to diagnose critical vents that give rise to multiple alarms
Robust 100 > X > 10
Implement advanced alarm filtering, to remove predictable secondary alarms
5% > X > 1%
Implement procedure monitors, to provide procedural support during critical operations, including identification of
‘the next most important alarm/action’ relevant to this task
Implement model-based intelligent operator support system both (a) for individual alarms and (b) to guide the
operator towards proactive intervention during normal operation rather than replying on reaction to alarms
towards the edge of the operating envelope
5 <1 Not Applicable – this represents the best level of performance for currently available operator/DCS technologies
Predictive < 10
< 1%
ISD-MASP-S06015 Rev. 2 - 18 -
Confidential
July 2011 Proprietary info goes here… Page 3-18
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Purpose of CAMS
ISD-MASP-S06015 Rev. 2 - 19 -
July 2011
Purpose of CAMS for HIS

A lot of accidents in various industrial plants
Overlook critical alarms and make wrong decisions
Increase in the Lack of Alarm

Number of Alarms Management
Alarm
Flooding
Expansion of the Lack of Functions

Monitoring Area in Alarm Systems
Great financial or safety losses from accidents

ISD-MASP-S06015 Rev. 2 - 20 -
July 2011
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Causes to Alarm Flooding

What’s happening ??
“Alarm flooding” is happening. It means that the window of alarm monitoring is filled with
a huge number of alarms by the following reasons.
Increase in the number of alarms Lack of knowledge to manage

The first appearance of DCS is alarms
in 1970s. People don't pay attention to
define an appropriate alarm, etc.
Diversification of alarms Lack of ability in the system to

There are a lot of alarms from control the alarms
DCS, SCADA, Safety system, Lack of function to reduce
MES, ERP, Field instruments, operator’s load, etc.
etc…
Expansion of monitoring scope

per an operator
Alarm
Laborsaving, etc… flooding
ISD-MASP-S06015 Rev. 2 - 21 -
Page.21 July 2011
EEMUA Publication No.191 Alarms Systems

Fundamental approach against alarm flooding
◆ Define only ◆ Deliver the defined
good alarms alarms only when needed
– Relevant – Suppress alarms from a
– Unique single process
– Timely (e.g. HI while indicating HH)
– Prioritized – Suppress alarms from out of
service plant units
– Understandable
– Suppress alarms based on
– Diagnostic
the operation mode
– Advisory
(e.g. startup operation)
– Focusing
– Suppress chattering alarms
Unnecessary alarms are not defined or appeared.

Takes a long time until projects are completed
ISD-MASP-S06015 Rev. 2
- 22 -
July 2011
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YOKOGAWA’S Approach
Practical approach against alarm flooding
◆Display only necessary alarms at the right time
(Unnecessary alarms are still remained)
EEMUA #191 fundamental Yokogawa’s practical

and long-term approach and immediate approach
Redress the root of Choose what one
alarm flooding ! would like to monitor !
Consolidated Alarm Management System (CAMS) for HIS

Practical engineering approach
- e.g.) Filtering, Shelving
ISD-MASP-S06015 Rev. 2 - 23 -
July 2011
EEMUA #191-based Alarm System Design
Opportunity Lifecycle
Identification Solution Implementation Services Effectiveness
Services Services
Comparative Fundamental EEMUA #191 Operational Regular

Effectiveness Nuisance -based State-based Effectiveness
Analysis Alarm Alarm System Alarm Analysis
Reduction Design Management
Alarm Rationalization
Free Plant Analysis Services
Control Room Design
Yokogawa
Management
Operator Training
Seminar
Best Practice Pilot
Master Planning
APC/Blend Property Control
Improvement
Leader APC/Multi-variable Control
Development
Program Regulatory Control Stabilization
Time
Plant Operation
ISD-MASP-S06015 Rev. 2 - 24 -
July 2011
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Changes in Ways of Thinking
This is suitable for current situations of the plants where the

integration of information is in progress
ExaPlog and AAA

CAMS for HIS
ISD-MASP-S06015 Rev. 2 - 25 -
July 2011
CAMS Basic Concepts

“C” for CAMS (Consolidated Alarm Management System) Stands
for “ Consolidated” and it represents three things. These three
consolidations form the center of the CAMS concept
1) Consolidated Acquisition of Alarm & Events, such as:
• Real-time alarms & events
• Sequence of Events (SOE) saved at shutdown
2) Consolidated Storage of Alarm & Events, such as:
• Real-time alarms & events generated by a new alarm management system
3) Consolidated Management of Various Applications that use
Alarm & Events, such as:
• Real-time alarm & event monitoring (online monitoring)
• Historical alarm & event viewer (offline viewer)
• Alarm configurator (alarm design function)
• Alarm KPI report (alarm system enhancement)
• Alarm & Event analysis (operation and shutdown analysis)
• Alarm set value change management (threshold changes and alarm
suppression by operators)
ISD-MASP-S06015 Rev. 2 - 26 -
July 2011
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Essence of CAMS for HIS
• The alarm dialog to

– Deliver only the necessary alarms
to be handled
• Only to the right person
• At the right timing
ISD-MASP-S06015 Rev. 2 - 27 -
July 2011
2
Outline of “CAMS for HIS”
CAMS for HIS concept
“To deliver the right information to the right people at

the right time.”
CAMS for HIS features
All necessary alarms & events are consolidated and displayed

on one window.
To append high-value information to each alarm & event

and display them are possible.
The ”CAMS for HIS” is used mainly for the real-time alarm monitoring
by operators.
The “CAMS for HIS conforms to the “EEMUA Publication No.191 Alarm
Systems”.
ISD-MASP-S06015 Rev. 2 - 28 -
Page.28 July 2011
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The Scope of CAMS for HIS

Operator/ System Process Other Users
Maintenance Engineer Engineer (Manager, DCS suppliers)
Engineer
Real-time Monitor System Configurator Historical Viewer Other Applications
Revision Management
Addition of Attributes
Change Management
A&E Analysis/Report
Dynamic KPI Monitor
Alarm Prioritization
3. Consolidation of
Static KPI Monitor

Shutdown Analysis
Load Shedding Eclipsing
Suppression Logic
Screen Definition
Roll-based
Eclipsing Shelving Tools
Test Function
Shelving Sorting
Sorting Filtering
Filtering
Removing of
Obvious 2. Consolidation of
Information Historical A&E on HDD
(Incl. SOE & CAMS events)
Addition of New Identifiers and More Value-added Information 1. Consolidation of

Real-time A&E on Memory
Acquisition and Normalization of all Alarms & Events
Vnet, Vnet/IP Vnet, Vnet/IP OPC A&E OPC A&E (SIOS) OPC A&E OPC A&E OPC A&E
DCS Safety Instrumented

Asset Network PIMS/MES/ERP Compressor Control Non-Yokogawa
(CENTUM CS 3000)
System Management System Control System Vibration Monitor DCS
(ProSafe-RS) (PRM) (STARDOM)
ISD-MASP-S06015 Rev. 2 - 29 -
Yokogawa Technology Fair –July 2011
Rayong, Thailand Page 29
CAMS for HIS features

Traditional Alarm list dialogs
•System Alarm
•Process Alarm
•Ope-Guide Message
•PRM’s Maintenance Alarm
all are shown in different dialogs
CAMS for HIS

• Process alarms, System alarms, alarms from
the ProSafe-RS safety system and from the
PRM Plant Asset Management system are
covered
• A single operation is required to call up the
related dialogs
• Functions to reduce the operators’ overload
to avoid overlook of important alarms
• Filtering, Eclipsing, Suppression, Shelving
ISD-MASP-S06015 Rev. 2 - 30 -
July 2011
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CAMS for HIS
Consolidated Defined Manage

- DCS - Define - Eclipsing
- SIS - Group - Sorting
- Sub-sys. (OPC) - Msg. Monitor - Shelving
- Shelving - Load Shedding
- Add Attribute - Suppression
- Filtering
DCS SIS OPC
CAMS for HIS Screen
PLC
HART FF HART
Devices Devices Devices
ISD-MASP-S06015 Rev. 2 - 31 -
July 2011
How does CAMS for HIS Works?
HIS ENG/SENG PRM
SIS A&E
DCS A&E
Customizable
Filtered
A&E
Vnet/IP (1Gbps)
DCS SIS SIOS Other A&E

(OPC A&E)
Asset A&E
PLC
HART FF HART
Devices Devices Devices
ISD-MASP-S06015 Rev. 2 - 32 -
July 2011 Page 32
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CAMS for HIS Dialog

Click blinking icons The latest three alarms
to open the CAMS View are always shown
Shelving Pane
– Non-urgent alarms
can be shelved in temporary
– Operators can concentrate
to the alarms which requires
urgent actions
Filter Pane
– Based on the priority, consequence, tag, etc
– Only the related alarm message for the operator can be
shown to reduce the workload. Alarm list is shown here
ISD-MASP-S06015 Rev. 2 - 33 -
July 2011
3
Support Quick Actions against the Alarms

• A single operation is required to call up the related dialogs
Context menu on the alarm message

– Right-click on a alarm message to show the
context menu
– It calls up that alarm related faceplate,
tuning view, trend graph or graphic
by a single mouse click
ISD-MASP-S06015 Rev. 2 - 34 -
July 2011
3
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Thank you very much

for your attention
ISD-MASP-S06015 Rev. 2 - 35 -
July 2011
18

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26/11/56

CAMS for HIS

ISD-MASP-S06015 Rev. 2 -1-

9:00 – 10:30 Course Training

*********** Lunch Time **************

13:00 – 14:30 Course Training

ISD-MASP-S06015 Rev. 2 -3-

What is Alarm Management?

ISD-MASP-S06015 Rev. 2 -4-

What is an alarm system?

• To maintain the plant within a safe operating envelope.

ISD-MASP-S06015 Rev. 2 -5-

Philosophy of Alarm System

ISD-MASP-S06015 Rev. 2 -6-

The purpose of an alarm system is to direct

Well managed plant is boring

What is a good alarm?

Each alarm should alert, inform and guide

1st Priority: Safety (casualties from the hazard)

4th Priority: Quality (off specification product)

5th Priority: Efficiency (quality give-away, less

What’s alarm occur?

X1: too late

Plant State Operator’s primary role Key alarm information

Normal Monitoring & Optimization Minor operating adjustments needed

Upset Situation management Operator intervention needed

Shutdown Ensure safe shutdown Safety actions needed

Operator’s Role at Plant Upset

Detect abnormal Monitor outcome Action to fix

Understand current Action to correct current

Basis of Alarm System Design

Alarm System Design Activities

Risk assessment: identify alarms to protect

Long term alarm rate in steady operation

Alarm System Performance

Identifying the as-is performance and targeting the

Ref: EEEMUA #191

Performance Typical Typical Focus for

Purpose of CAMS for HIS

Increase in the Lack of Alarm

Expansion of the Lack of Functions

Great financial or safety losses from accidents

Causes to Alarm Flooding

Increase in the number of alarms Lack of knowledge to manage

Diversification of alarms Lack of ability in the system to

Expansion of monitoring scope

Purpose of CAMS for HIS

EEMUA Publication No.191 Alarms Systems

Unnecessary alarms are not defined or appeared.

Purpose of CAMS for HIS

EEMUA #191 fundamental Yokogawa’s practical

Consolidated Alarm Management System (CAMS) for HIS

EEMUA #191-based Alarm System Design

Comparative Fundamental EEMUA #191 Operational Regular

Changes in Ways of Thinking

This is suitable for current situations of the plants where the

ExaPlog and AAA

CAMS Basic Concepts

Essence of CAMS for HIS

• The alarm dialog to

Outline of “CAMS for HIS”

CAMS for HIS concept

“To deliver the right information to the right people at

* Lunch Time ****