© 2017 Vedanta Limited

Cairn Oil & Gas

ALARM MANAGEMENT
CB/OS-2 & YNM-Ravva
© 2017 Vedanta Limited 2

Content

What is the need for alarm management

Implementation Cycle @ Ravva site

Implementation Cycle @ Suvali site

Where do we stand
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Introduction
What is an Alarm?
 An audible and/or a visible means of indicating a problem such as equipment malfunction,
process deviation or abnormal process condition.
Why alarm management?
 Since humans can only do one thing at a time and can pay attention to a limited number of
things at a time, there needs to be a way to ensure that alarms are presented at a rate
that can be assimilated by a human operator, particularly when the plant is upset or in an
unusual condition.
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EMERGENCE OF INDUSTRY STANDARDS

Emergence of Standards
and Regulations
ASM Alarm EEMUA 191 • ISA 18.02
Management 2nd Edition
Guidelines
1st Edition
EEMUA 191 2009
Abnormal situation 1st Edition 2007
2003
Management (ASM) Establishment of
1999
Consortium formed Understanding the systems and
Ineffective Alarm consequence of practices
Management excessive alarms • Emergence of
1994
• Excessive number of • Major accidents EEMUA and ISA
alarms and losses standards
• Alarms not • Production • Implementation of
meaningful to losses Alarm
operator • Operator burnout Management
• Alarms are disabled factor Lifecycle
often
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ALARM SYSTEM MANAGEMENT LIFE CYCLE

PHILOSOPHY: Define processes for alarm management &
PHILOSOPHY
prepare specific alarm management philosophy document

IDENTIFICATION: Determination of potential alarms

IDENTIFICATION
RATIONALIZATION: Rationalization, Classification,
Prioritization and documentation – Master Alarm Database
RATIONALIZATION
MANAGEMENT DETAILED DESIGN: Alarm response procedures, Basic
OF CHANGE alarm design, HMI principles & Advanced Alarming features
DETAILED DESIGN AUDIT
IMPLEMENTATION: Implement alarm, testing and training

OPERATION: Operator response to alarms

IMPLEMENTATION
MAINTANENCE: Repairs and periodic testing

OPERATION MONITORING MONITORING: Performance monitoring and reporting

&
ASSESSMENT MANAGEMENT OF CHANGE: Process to authorize change
MAINTANENCE
AUDITS: Periodic audits and recommendations
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ALARM MANAGEMENT STRATEGIES

USED IN RAVVA
Aim is to develop & impart alarm management system, assess & improve system
performance and target for continual improvement towards system performance excellence
and sustainability of achieved results
 Below are the steps carried out in Ravva plant as part of operationalization of Alarm
Management:
• Alarm Philosophy Procedures and related documents preparation
• Imparted Training to all relevant personnel’s
• Identify and formed task force team for system implementation
• Carried out Alarm Rationalization process for the existing system
• Documented the outcome and implemented changes related to alarm attributes
• Monitored system performance and conducted review meetings – Bi-weekly and Monthly
• Carried out Audits, Periodic surveys - Operator Questionnaire Survey
& Alarm Effectiveness Survey
• Reviewed Alarm set points with accordance to the operating conditions of the plant
• Implementation of Highly Managed Alarms concept
• Implementation of FIRST-OUT ALARM SCHEMES coupled with LIVE C&E
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ALARM MANAGEMENT STRATEGIES

USED IN RAVVA
 Implementation of Advanced Alarm Management Techniques to curb alarm rates such as:

• Alarm Latching concept

• Alarm DEADBAND settings
• Alarm ON/OFF DELAY settings
• COUNTER Technique
• DE-BOUNCE TIMER Technique
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ALARM MANAGEMENT STRATEGIES

USED IN RAVVA
STATISTICAL DATA – NO. OF ALARMS PER DAY ON AVG FROM Jun-14 to JUL-16
TOTAL
4240

3450

3280
3080

3080

2840
2480

2440

2240
2130
1880

1880
1860
1640

1440

1280
1240
1220

1190

1180
1150

1130
1120
1090
1060

1050
JUN-14 JUL-14 AUG- SEP-14 OCT-14 NOV- DEC-14 JAN-15 FEB-15 MAR- APR-15 MAY- JUN-15 JUL-15 AUG- SEP-15 OCT-15 NOV- DEC-15 JAN-16 FEB-16 MAR- APR-16 MAY- JUN-16 JUL-16
14 14 15 15 15 15 16 16
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ALARM MANAGEMENT STRATEGIES

USED IN RAVVA
 Alarm Management System Key Performance Indicators (KPIs) are:
• Alarm Rate per day
• Peak Alarm Rate
• Number of Alarm floods
• Frequently Occurring Alarms – Top 10s
• Stale Alarms
• Annunciated Alarm Priority Distribution
• Number of Alarm occurrences for a particular group of systems
• Number of Chattering Alarms
• Number of Fleeting Alarms
• Audits, Periodic surveys - Operator Questionnaire Survey and Alarm Effectiveness Survey
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ALARM MANAGEMENT STRATEGIES

USED IN RAVVA
 Constraints:
• Add-on projects and integration of control system
• Limitations with the existing PLC/SCADA Software

 Key Results achieved post operationalization of Alarm Management in Ravva are:

• Achieved better priority distribution of alarms as per the recommended standards
• Improved and precise Alarm Message Composition
• Establishment and Availability of Alarm response procedures
• Segregation of events from Alarm logs
• Better Animations were provided in HMI graphics to support alarm systems
• Better survey results were achieved
• Considerable reduction in High priority alarms – 60% as per data analysis
• 60% Reduction in Alarm Flood condition
• Average Alarm rate per day in Ravva is being reduced from 4200 to 1100 alarms per day
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ALARM MANAGEMENT SYSTEM –CB/OS-2 SITE

Following information/reports can be generated for study & analysis at Suvali site-

 Alarm count over time- To determine alarm rate.

 Alarm distribution priority – For checking priority wise alarms
 Most frequent alarms – Alarms occurring on a frequently basis
 Chattering Alarms – Most repetitive alarms over a duration
 Intervention count over time – Manual intervention over a duration
 Most frequent intervention – Most manual intervention of control valves
 Alarm distribution over time – Shift wise
 Alarm enable & disable report- Duration the particular system remained bypassed
 Plant status – Standing alarms
 Alarm count per process unit -
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Alarm Rate
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% High Alarms per time

Reduction to 4% from 30% in Urgent alarms, 5% from 41% from in High Alarms, 2% from 13% in Low from
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Raw Water Sump D-7510

444

Water Systems
System
394

System
277

Degasser V-7810 Level Shutdown

Degasser V-7810
353

PWD
129

PGC-B Aftercoller Discharge Temp.

PGC-B Suction Scrubber V-2310
210

PGC
PGBC-B Level Transmitter
403

PGBC
211

LB Instrument gas drum Level transmitter

LB#6 Flow Meter
526

LB
LA#9 well FTHP pressure transmitter
213

LA
109

HCDP BC-B Booster Comp Suction

HCDP BC-B Lube Oil Cooler To Duplex Oil
Alarms By Tag

133

Filter
HCDP
GLC Engine Speed
107

GLC
HP Purge Rate
139

Flare System
Fire Water Pump
317

Fire System
108

HC liquid Heater shell side outlet Temp.

124

Oil Transfer Pump A discharge

ALHF New 2nd stage seperator Interface
144

Level
Slug Catcher Condensate Level
164
Transmitter
200
205 Crude Transfer Pump B
3rd Stage interface level transmitter

211
Oil Transfer Pump B discharge
Alarm by Unit Tags

215
Crude Transfer Pump C
HC Liquid Transfer Pump C Discharge

224
Pressure
3rd Stage oil side level transmitter

281
ALFH
© 2017 Vedanta Limited

600

500

400

300

200

100

0
:
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Alarm distribution over the time – Shift wise comparison

600

500

400

16:00
300
8:00
0:00

200

100

0
01/Oct/16 02/Oct/16 03/Oct/16 04/Oct/16 05/Oct/16 06/Oct/16 07/Oct/16 08/Oct/16 09/Oct/16 10/Oct/16 11/Oct/16 12/Oct/16 13/Oct/16 14/Oct/16 15/Oct/16
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Standing alarms – Day wise

Online Equipment Standing Alarms

7

6
3

5
1

4
4 2 4 Urgent
Low
3 High
3 1

2
2 2 2 1 2

1
1 1

0
PGBC-B LIQ HANDLING SLUG CATCHER TANKER LOADING PGC-B FLARE TEG-1 ALHF GTG-B
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Alarm count for different units

2500
Alarm Count By Unit
1974
2000

1500

968 940
1000
814
643
589 556 532
469
500 376 365 321 307
249 226 213 199 169 168 151 145 134 133 131 110 107

0
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Daily total no. of Alarms

Total alarms stand at around 875 from 1900 = 46% reduction
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INDUSTRY VS CAIRN STANDARD COMPARISION

 Benchmark of alarm for oil and gas industry
 The Engineering Equipment and Materials Users Association

Source: BookAlarm Management for Process Control:

by: Douglas H. Rothenberg

Cairn Suvali Site- 875 alarms/ day Cairn Ravva 1100 alarms/day
 Before- 1900 alarms/day 4200 alarms/day
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