armour managingthealarmmanager gladstonepower
TRANSCRIPT
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Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
Managing Alarms at
Gladstone Power Station
A Case HistoryISA Safety Symposium Houston May 23-24 2006
Presented by Alan Armour
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OVERVIEW OF GLADSTONE POWER STATION
6 X 280MW COALFIREDBOILER/TURBINES
1st UNIT ON LINE IN 1976
RAPID LOAD CHANGE
SEAWATER COOLED CONDENSERS
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3
Insert picture of old controlpanel and text from page7
CHRONICLE OF ALARM MANAGEMENT AT GPS1976-1994
ALARMS PROVIDED BY SEPARATE DATAACQUISITION SYSTEM
2216 ALARM POINTS PER UNIT
HARD COPY TO PRINTERS
ARCHIVED AS PRINTOUTS
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4
OTHER FEATURES
MANUAL ALARM ANALYSIS
UNIT TRIPS PROVIDED HUNDREDS OF PAGES
HEAVY ALARM TRAFFIC
NO PRIORITY SYSTEM
STANDARD NOMENCLATURE MANAGEMENT
BASIC SUPPRESSION OF OUT OF SERVICE PLANT ELEMENTARY INHIBITED ALARM PROCEDURES
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CONTROLSYSTEMSOVERVIEW
FOXBORO I/A DCS (SINCE 1994)
8 CONTROL DESKS
OVER 30,000 I/O, 3600 ALARMS/UNIT
CENTRALISEDCONTROL ROOM
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1994 - PRESENT
ALARMS INTEGRATED WITH DCS
HISTORIAN
EXTENSIVE ALARM REVIEW
3600 ALARM POINTS PER UNIT
INTRODUCTION OF THREE ALARM PRIORITIES
SOME ALARMS SENT TO PAGERS
INITIAL TRAFFIC OVER 2500 ALARMS PER DAYPER UNIT
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ISSUES WITH ALARMS SINCE UPGRADE
MASSIVE ALARM FLOODS
IMPORTANT ALARMS MISSED
MISMANAGED INHIBITED ALARMS
UNNECESSARY DAMAGE TO PLANT
FRUSTRATEDOPERATION STAFF
AUDIBLEALARM SYSTEM VANDALISED
LOW OPERATOR PRODUCTIVITY
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ALARM DESTINATION REVIEW
BEGINNING OF ALARM TRAFFIC MANAGEMENT
BENCH MARKS ESTABLISHED
ADDRESSED TRAFFIC ISSUES USING THESQUEAKING WHEEL PRIORITY METHOD
SET UP SPECIAL PLANT MODIFICATION DOCUMENTFOR ALARMS
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0
200
400
600
800
1000
1200
01/08/2001
13/08/2001
25/08/2001
06/09/2001
18/09/2001
30/09/2001
12/10/2001
24/10/2001
06/11/2001
18/11/2001
30/11/2001
12/12/2001
24/12/2001
05/01/2002
17/01/2002
29/01/2002
10/02/2002
22/02/2002
06/03/2002
18/03/2002
30/03/2002
11/04/2002
23/04/2002
06/05/2002
18/05/2002
30/05/2002
11/06/2002
23/06/2002
05/07/2002
17/07/2002
29/07/2002
TOTAL P1 ALARMS
TOTAL P2 ALARMS
TOTAL P3 ALARMS
2001/2 ANALYSIS-DAILY COUNT
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8%
44%
48%TOTAL P1 ALARMS
TOTAL P2 ALARMS
TOTAL P3 ALARMS
2001/2 ANALYSIS - ALARMS BY PRIORTY
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PURCHASED ALARM MANAGEMENT SOFTWARE
TASK FORCE FORMED
INTRODUCTION OF INHIBITED ALARM MANAGEMENT
INTRODUCTION OF STANDING ALARM MANAGEMENT
INCORPORATED EEMUA GUIDELINES
RISK ANALYSIS
CONTINUING PRESSURE FROM PRODUCTIONMANAGEMENT TO FURTHER REDUCE TRAFFIC
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LOGMATE(TIPS)
ALARM
MANAGER
ANNUNCIATOR
LIGHTS,AUDIBLEHISTORIAN
PROCESSGUARD
(MATRIKON)
HISTORIAN
REPORTS
INHIBITEDALARMSREPORTS
STANDINGALARMS
> 2 DAYS
ALARMS BYTAG
(TOP 20)
ALARMS BY
PRIORITY-INTERVAL
I/A SYSTEM
REPORTS
ALARM MANAGEMENT TEAM
MANAGEMENTOPERATIONSENGINEERINGMAINTENANCE
DCS SYSTEMS
ENGINEER
DCS FOXBORO I/A
(1 CONTROL SYSTEMS TECHNICIAN, 2 OPERATORS, 1 PROCESS ENGINEER, ALL PART TIME)
ALARM MANAGEMENT STRUCTURE
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2003
OPERATION STAFF REDUCED BY 18 (3 OFFEACH SHIFT, AND 3 OFF DAY SHIFT)
ALARM MANAGEMENT NOW A KEY ELEMENTIN PLANT OPERATIONS
ALARMS SCREENS FOR UNITS NOWDUPLICATED AND MONITORED FROM 1CENTRAL CONTROL DESK
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STANDING ALARMS
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STANDING ALARMS
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SMART ALARM EXAMPLE
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Tag
Alarm
Count Tag Description
4_SH_TEMP:STM_OTMP_ALM 3 BLR STM OUT TEMP H2
4_A_PASS_FF:5RM_2_ALM 2 A5 ROT MANIFOLD SPEED TRIP
4_AIR_HTR:AH_GO_ALM 2 AIR HTR GAS OUT TEMP L1
4_CW_TW:BACKFLUSH_2 2 BACKFLUSH REQUIRED
4_RH_TEMP:RH_DEV_ALM1 2 RH STM TEMP DEV HI
4_AIR_AUX:AIRINJ_1_ALM 1 AIR INJECTION SUBLOOP OFF
4_AIR_FLOW :A_O2_ALM_H1 1 A FLUE GAS O2 H1
4_AIR_HTR:AH_DEV 1 A-B AIR HT AIR IN TC DEV HI
4_D_PULV:PA_DMP_ALM 1 D PULV PA DAMP AUTO OFF
4_D_PULV:PLV_STR_ALM 1 D PULV START SEQ FLT
4_D_PULV:SD_FLT_ALM 1 D PULV SLEEVE DAMP FLT4_E_PULV:PA_DMP_ALM 1 E PULV PA DAMP AUTO OFF
4_E_PULV:SD_FLT_ALM 1 E PULV SLEEVE DAMP FLT
4_F_PULV:PA_DMP_ALM 1 F PULV PA DAMP AUTO OFF
4_F_PULV:PLV_STR_ALM 1 F PULV START SEQ FLT
4_F_PULV:SD_FLT_ALM 1 F PULV SLEEVE DAMP FLT
4_FW_FLOW:DL_ALM_H1 1 DRUM LEVEL ALARM H1
4_RH_TEMP:PSS_MST_ALM1 1 REAR PASS DAMP MAST AUTO OFF
4_TURB_WSE:VTMIN_1_ALM 1 TURB STRESS MARGIN L1
Total: 25
Gladstone Power Station
Unit 4 Alarm Count By Tag
09/08/04
0
0.5
1
1.5
2
2.5
3
3.5
4_SH
_TEM
P:ST
M_OT
...
4_A_
PASS
_FF:5
RM_..
.
4_AIR
_HTR
:AH_GO_
ALM
4_CW
_TW
:BACK
FLUS
H_2
4_RH
_TEM
P:RH_
DEV.
..
4_AIR
_AUX
:AIR
INJ_
1_AL
M
4_AIR
_FLO
W:A_
O2_A
...
4_AIR
_HTR
:AH_DEV
4_D_
PULV
:PA_DMP
_ALM
4_D_
PULV
:PLV_
STR_
ALM
4_D_
PULV
:SD_FLT
_ALM
4_E_
PULV
:PA_
DMP_
ALM
4_E_
PULV
:SD_
FLT_
ALM
4_F_
PULV
:PA_DMP
_ALM
4_F_
PULV
:PLV_
STR_
ALM
4_F_
PULV
:SD_FLT
_ALM
4_FW
_FLO
W:D
L_AL
M_H1
4_RH
_TEM
P:PSS
_MS.
..
4_TU
RB_WSE
:VTMI
N_...
Tag Name
AlarmC
ount
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Condition Data
1 2 3 Total Count Total Percent
Timestamp Count Percent Count Percent Count Percent
8/9/04 1:00 1 100% 1 100%8/9/04 2:00 1 100% 1 100%
8/9/04 3:00 1 13% 4 50% 3 38% 8 100%
8/9/04 5:00 1 50% 1 50% 2 100%
8/9/04 6:00 1 100% 1 100%
8/9/04 7:00 1 33% 2 67% 3 100%
8/9/04 8:00 2 67% 1 33% 3 100%
8/9/04 15:00 1 100% 1 100%
8/9/04 16:00 1 100% 1 100%
8/9/04 18:00 1 100% 1 100%
8/9/04 20:00 2 100% 2 100%
8/9/04 23:00 1 100% 1 100%
Gladstone Power Station Unit 4
Alarm Distribution by Priority per Hour
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
8/9/04 1:00 8/9/04 2:00 8/9/04 3:00 8/9/04 5:00 8/9/04 6:00 8/9/04 7:00 8/9/04 8:00 8/9/04
15:00
8/9/04
16:00
8/9/04
18:00
8/9/04
20:00
8/9/04
23:00
Distribution
0
1
2
3
4
5
6
7
8
9
TotalCount
1 2 3 Total Count
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AlarmPerformance Metrics
Alarm Performance Metrics (EEMUA Guidelines)
(1) Average number of alarms per hourLevel of interruption
(2) Maximum number of alarms per hourWorst case loading
(3) % of hours when there were >30 alarms per hour% time system is upset
Alarm System Performance
Maximum # Alarms per Hr
Average#Ala
rmsperHr 1 -Overloaded
2 - Reactive
3 - Stable4 - Robust
5 - Predictive
600060060
600
60
6 X
ImpossibleImpossible
Benchmark &Assessment
+
MATRIKON
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OTHER BENEFITS OF ALARM MANAGEMENT
FASTER START UP AND SHUT DOWN TIMES. REDUCED SICK LEAVE FROM OPERATION STAFF. (BETTER
WORK SATISFACTION, LESS STRESS)
MAINTENANCE CAN BETTER PLAN WORK.
BETTER RECOVERY FROM ABNORMAL SITUATIONS(REDUCED TRIPS, LESS DAMAGE TO PLANT ETC).
REDUCED LOSSES.
OPERATORS ARE LESS ALARM DRIVEN IN THEIR WORK.
EASIER TO IDENTIFY AND RESOLVE PROCESS PROBLEMS
REQUESTS FROM OPERATIONS FOR MORE ALARMS!
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GLADSTONE POWER STATION
UNIT TRIPS 1996-2006
0
2
4
6
8
10
12
14
TIME
Series1
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FUTURE WORK
REDUCE ALARM FLOODS DURING ABNORMAL SITUATIONS
CHANGES TO AUDIBLE ALARM PHILOSOPHY
REDUCE CONSEQUENTIAL ALARM TRAFFIC
MORE WORK ON STANDING ALARMS
INCLUDE ALARM TRAFFIC DATA IN KPI CALCULATIONS
FURTHER DEVELOP PACKAGE TO REDUCE ADMINISTRATIONCOSTS
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ACKNOWLEDGEMENTS
NRG GLADSTONE POWER STATION MATRIKON
SIT
EEMUA
INVENSYS
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QUESTION TIME