Post on 04-Jun-2018
transcript
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 1/50
Gregory Chng Boon Hwee
Yokogawa Engineering Asia
Process Operation Solution
Process Solution Centre, Yokogawa Engineering AsiaCopyright © by Yokogawa Engineer Asia5/13/2005 3:09:41 PM
Process Alarm Management
Friday, May 13, 2005
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 2/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 2
1. Advanced Operation Assistance (AOA) Solution
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 3/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 3
Advanced Operation Assistance (AOA) Solution
Upper solution of process operation done by operatorsTo assist daily work of production people to realize safer and more
cost-effective operation. For example, – In desk work • Support to prepare an operation report
• Support to turn up operation related problems• Support to standardize operation know-how
– In normal operation• Suppress unnecessary DCS alarms to notify only important DCS alarms
• Notify an early sign of abnormality faster than it is detected by DCS alarms• Prevent miss-operation
– In transition operation (e.g. startup/load change/reactor switchover)• Give an adequate instruction to the operator in a sequential order• Prevent miss-step/miss-procedure
Process
CONTROL domain OPERATION domain
MES, ERP
Process Control (DCS)
Advanced Process Control Advanced Operation Assistance
Process Operation (Operators)
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 4/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 4
Difference between APC and AOA
APC (Advanced Process Control)
– Position: Additional function of DCS – Purpose: Improvement of controllability – Configuration: Runs on additional PC – Main user: Engineering people – Approach: Based on mathematical process model
– Benefit: More cost-effective control
AOA (Advanced Operation Assistance) – Position: Additional function of DCS – Purpose: Improvement of operation work
– Configuration: Runs on operator’s console or additional PC – Main user: Production people (operator/process engineer) – Approach: Based on knowledge and experiences of skillful
operator/process engineer – Benefit: Safer and more cost-effective operation
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 5/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 5
System architecture
Run on HIS or Additional PC
Supports Windows2000/XPproServer/client configurationComponent software – Exaopc
(OPC interface package)
– Exaplog(Event reporting/analysis package)
– Exapilot(Operation efficiency improvement package)
• Exapilot Professional or Standard• Advanced alarm function• MS Excel link icon
Support all DCS via OPCinterface
HISENG
FCS
V net
AOA Client
Ethernet
PC
PC
FCS
HF bus
ABCBus
converter
Setting
AOA Server
Gathering
Setting
Gathering
CENTUM-XL, V
Micro XL
Event message
Gathering
(max. 4)
AOA Client
CENTUM CS 1000
CENTUM CS 3000
Exaopc is required
System architecture
(In case of additional PC)
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 6/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 6
2. Exaplog
Event reporting and analysis package
2.1 Operation event viewer/analyzer
2.2 Operation event reporter
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 7/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 7
Assist desk work of production Dept. – Reporting of operational event
– Monitoring of operational event
– Analysis of operational event
Utilize a DCS alarm and event message whichis less frequently used
Exaplog
Message Printer
Huge
Running Cost
Huge
Storage Space
Specialistic
Manual Work
Exaplog (Software Printer)
Minimum
Running Cost
Minimum
Storage Space
Semi-automatic
Work
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 8/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 8
2.1 Operation event viewer/analyzer
5 viewers
– Event balance trend (EBT) – Monthly/Weekly EBT
– Category sort
– Point ID (Tag) sort
– Message summary
(same as DCS printer)
5 filters – Scope in
– Exclude – Character
– Process unit
– User defined
Event balance trend (EBT) Category sort
Point ID sortMessage summary
Character/Process unit
User defined
Monthly/Weekly EBT
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 9/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 9
Event balance trend (EBT)
Process Requests
Operator’s Actions
X-axis : Time (24hours)
Y-axis : Number of events
Display the balance between – Process requests (+)
• System alarm• Process alarm
• Annunciator message• Operation guidance, etc.
– Operators actions (-)• Tag data entry
• Tag mode change, etc.
No. Pattern Type EBT Pattern Suspected Problem Countermeasure
Long term analysis about seasonal change
Long term analysis about erosion/corrosion
Unnecessary alarms/messages Retuning of alarm set values
Integration of redundant alarms/messages
Masking of low priolity alarms/messages
Low automation rate Automation using DCS
Manual operation according to know-how Automation using Exapilot
Complex operation sequence Simplify operation sequence
Lack of support function Navigation using Exapilot
Insufficient Operator capability Operator training
Human error Error detection using Exapilot
Unstable process Introduction of advanced process control
Excessive Operation
Operator Work Overflow
Inadequate Operation
I
II
III
IV
V
No urgent problem
Redundant alarms/messages
Balanced
Excessive Nortification
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 10/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 10
Category sort, Point ID sort
Category sort
– Type – Sub type
– Detail
– Batch ID
– Station
Point ID (Tag) sort – Tag
– Tag + Detail
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 11/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 11
2.2 Operation event reporting
Various reports can be exported to CSV file
– Tag list which notifies many alarms• Per detail (e.g. HH/HI/LO/LL/VEL/DEV/IOP)
• Per priority (e.g. High/Medium/Low)
• Per process unit (e.g. station#, process unit filter)
– Tag list which alarm set point have been changed – AOF (alarm off) tag list
– Manual control tag list, and more
Additional editing can be done using MS-Excel
User defined report can be registered
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 12/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 12
(4)
(1)Select “Sub Type” tub
(2)Select “Tag Alarm”
(3)Press “Scope in filter” button
(4)Select “Tool\Export Result”
to save a result of analysis as CSV file
(5)Edit a report file using MS-Excel function
(1)
(2)
(3)
(5)
e.g. Tag list which notifies many alarms
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 13/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 13
(1)Select “Detail” tub
(2)Select “MAN”
(3)Press “Scope in filter” button
(4)Select “Tool\Export Result”
to save a result of analysis as CSV file
(5)Edit a report file using MS-Excel function
(1)
(2)
(3)
(4)
(5)
e.g. Tag list which controlled manually
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 14/50
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 15/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 15
Pharmaceutical plant, USA
The background
– Large batch chemical plant – Legacy system was replaced to CS3000 – Over 10,000 I/O
The problem – 50,000 alarms per day
– Audible alarms were disabled• Operators where missing critical alarms• Alarms were disappearing from display in 10 minutes• Lost production• Increased safety hazards• Increased production cost
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 16/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 16
The approach – Use Six Sigma methodology
– Set overall goal of 10 alarms/day – Use Exaplog to measure and analyze alarms
The result – Cut the alarming rate by a 98%
• Field improvement – Improvement of field instrumentations (re-ranging)
• Alarm optimization and management – Elimination of nuisance Opeguide messages – Retuning of alarm threshold
– Two of the four operator stations back on-line – Operator mistakes have decreased – Productivity has increased by notification of adequate
alarms – Operating issues around several pieces of equipments
have been resolved by systematic alarm analysis
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 17/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 17
PTA, Southeast Asia
Benefits
– Eliminate unnecessary DCS alarm events and operation for40%
– Improve inefficient operation sequences
– Operator can concentrate on only necessary alarm events
– Lower miss-operation
Process Alarm
Daily
Average
(Before)
TI-xxxx, HH alarm 73 30
TI-xxxx, Hi alarm 145 Change to proper HI alarm setting 50
LC-xxxx, Auto mode 27 PID tuning 0
LC-xxxx, Man mode 26 PID tuning 0
Change to proper HH alarm setting
Countermeasure
Daily
Average
(After)
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 18/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 18
3. Exapilot
Operation efficiency improvement package
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 19/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 19
Exapilot
Additional DCS function for – Knowledge-based process control
– Knowledge-based process monitoring
Application can be programmed as flow chart or logic chart – Specialist programming skill is not needed
– High usability
– High understandability – High maintainability
Existing application in DCS is no need to modify
Various usages – Automation of transient operation
– Alarm management
– Operator training
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 20/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 20
Flow chart programming tool (Standard)
Visible icons
for flow chart program
Application example
Application example
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 21/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 21
Logic chart programming tool (Option)
Application example
Grammar of logic chart
Visible icons
for logic chart program
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 22/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 22
Ready-made templates
For flow chart
For logic chart
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 23/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 23
3.1 Alarm Management
(1) Masking of unnecessary DCS alarm
(2) Dynamic alarm setting(3) Addition of pre-alert
(4) Replacement to advanced alarm
(5) Prevention of miss-operation
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 24/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 24
What is required to the alarm system ?
For safer and more cost-effective operation of industrial systems – To help the operator to correct potentially dangerous situations
before the ESD is forced to intervene – To recognize and act to avoid hazardous situations
– To identify deviations from desired operating conditions that couldlead to financial loss
– To better understand complex process conditions
An effective alarm system
TargetNormalUpsetShut
Down
Key Alarm Information
X X
XX X X X X X
XX XXXXXXX X
X X X X X X X
X X
X X X X X X
X XPlant State
ESD
needed
Operator
intervention
needed
Minor operating
adjustment
needed
X = Alarm
EEMUA No.191
i f
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 25/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 25
20152 alarms/day
Refinery Phenol plant
5274 alarms/day
Unnecessary alarms notified despite safe or efficient operationNecessary alarms not notified despite unsafe or inefficient operation(it’s not general because alarm must be set narrowly for safety reasons)
However, in fact…
Demand to additional alarm management function
5471 alarms/day
PTA plant
An ineffective alarm system
TargetNormalUpsetShut
Down
Key Alarm Information
X X
XX X X
X
X
X
X
X XXX
X
X
X
X
X
X X
X X
X X
X
X
X X
X
X
X X
X
X X
Plant StateESD
needed
Operator
intervention
needed
Minor operating
adjustment
needed
X = Alarm
EEMUA No.191
(1) M ki f DCS l
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 26/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 26
(1) Masking of unnecessary DCS alarm
Masking of unnecessary HI/LO alarm – Because alarm threshold is unmatched
Masking of longstanding false HI/LO alarm – Because alarm hysteresis parameter is unmatched
Re-activation of longstanding true HI/LO alarm – Because still function of CENTUM is not used
Masking of oscillation HI/LO alarm – Because PID parameters are unmatched
Masking of repeating annunciator message – Because appropriate DCS sequence (delay timer) is not prepared
Masking of unnecessary IOP/IOP- alarm – Because tag range is unmatched (range over)
Fault diagnosis for necessary IOP/IOP- alarm – Because field transmitter is failed – Because wire is come down
1. Detect and suppress unnecessary DCS alarms automatically
2. Display the reason of occurrence as countermeasure
3. Report a suppressed alarms list
A) R ti HI/LO l ( ki l i )
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 27/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 27
A) Repeating HI/LO alarm (masking logic)
Monitoring
period
Note) Mean: PV moving average, Dev: PV standard deviation, SH: Scale HI, SL: Scale LO, A: parameter (default=2)
(1) IF New_PH= Mean - 3 x Dev >= Original_PL + 0.1 x (SH - SL) & |New_PH - Mean| >= |Original_PH - Mean|
THEN New_PH = Mean - 3 x Dev
(2) IF New_PH = Mean - 3 x Dev <= Original_PL + 0.1 x (SH - SL) & |New_PH - Mean| >= |Original_PH - Mean|
THEN New_PH = Mean - A x Dev
SL
SH
Original_PH
Original_PL
Start
monitoring
1 2 3
New_PH
Number of
occurrence
HI HI HI
Time
PV
Start
masking
PurposeThis logic can mask an unnecessary HI/LO alarm
which is slowly oscillating near PH/PL.
Logic
This logic consists of “monitoring” logic, “masking”
logic and “recovery” logic. Monitoring logic is started
when first HI/LO alarm is occurred, and then
monitors the number of occurrence while ordered
monitoring period. In case the number reaches anordered times, masking logic is run.
Masking logic
PH/PL is automatically changed so that new PH/PL
is not announced. The reason of suppression is
displayed as a countermeasure.
Reason of occurrence: Alarm threshold is unmatched
A) R ti HI/LO l ( l i )
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 28/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 28
A) Repeating HI/LO alarm (recovery logic)
Recovery logic
Condition 1:
IF Mean + 3 x Dev < Original_PH or Original_PH < Mean – 3 x Dev
THEN Return to Original_PH
Condition 2:
IF New_PH>= Mean
THEN Return to Original_PH
(In case the maximal value of oscillation is greater than Original_PH, HI alarm will be notified again)
Condition 3:
IF |Original_PH– Mean| >= |New_PH – HYS x (SH – SL) – Mean| (HYS=0.02)
THEN Return to Original_PH
(In case the maximal value of oscillation is greater than Original_PH, HI alarm will be notified again)
SL
SH
Original_PH
Original_PL
New_PH
Time
PV
Mean Mean Mean
|Original_PH - Mean|
|New_PH – Hys x (SH – SL) – Mean|
Hys x (SH-SL)
3 x Dev
3 x Dev
Condition 1 Condition 2 Condition 3
Mean
B) L t di f l l
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 29/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 29
B) Long standing false alarm
Monitoring period
S
L
SH
Original_PH
Start
monitoring
New_PH
HYS x (SH - SL)
HI NR
Time
PV
Start
masking
Purpose
This logic can mask unnecessary HI/LO alarmwhich is lower/higher than PH/PL but still in
the band of hysteresis.
Masking logic
In case PV is in the band of hysteresis formonitoring period, PH/PL will be changed tohigher/lower vale momently.
3 x Dev
Mean
HYS x (SH - SL)
3 x Dev
2sec
Reason of occurrence: Hysteresis parameter is unmatched
Note) Mean: PV moving average, Dev: PV standard deviation, SH: Scale HI, SL: Scale LO, HYS: parameter (default=0.02)
IF PH/PL is in activation AND
Mean + 3 x Dev < Original_PH & Mean + 3 x Dev > Original_PH– HYS x (PH – PL)
THEN New_PH = Original_PH + HYS x (PH – PL) for 2 seconds
THEN Return to Original_PH
THEN New_PH = Mean - 3 x Dev
Stop
masking
C) L t di t l
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 30/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 30
C) Long standing true alarm
Monitoring
period
IF HI/LO is activated for ordered period & Mean + 3 x Dev >= Original_PH
THEN New_PH/New_PL= SH/SL, 2 seconds later, Return to Original PH/PL
S
L
SH
Original_PH
Start
monitoring
New_PH
HI NR
Time
PV
Re-
notification
Purpose
This logic re-notifies longstanding true
HI/LO alarm.
Re-notification logic
In case true HI/LO alarm is activated formonitoring period, PH/PL is changedmomently to SH/SL, so that PH/PL isannounced again.
HINR HI
Monitoring
period2Sec
Mean3 x Dev
HH
Reason of occurrence: Still function of CS3000 is not used
D) O ill ti l
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 31/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 31
D) Oscillation alarm
Monitoring
period
SL
SH
PL
Start
monitoring
PH
Time
PV
Start
masking
Purpose
This logic masks unnecessary HI/LOalarms by setting AOF in case PV is
oscillated due to the mismatch of PIDparameters.
Masking Logic
In case HI/LO alarms are notified one afterthe other for ordered times, Exapilot sets
AOF. (Select HH or HI, LO or LL)
Recovery Logic
In case HI/LO alarms are not notified forordered period, Exapilot sets AON.
(In case PID is not retuned, HI/LO alarms
are continuously masked)
AOF
Monitoring
period
1 2
AON AON
Occurrence
number
Stop
masking
1 2
LL
HH
HI HI
LO LO
PID is retuned
Reason of occurrence: PID parameter is unmatched
E) Repeating Annunciator message
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 32/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 32
E) Repeating Annunciator message
Monitoring
period
Start
monitoring
Purpose
This logic masks an unnecessaryannunciator which announced repeatedly.
Masking logic
In case annunciator is announced orderedtimes in monitoring period, AOF is set to
target annunciator (%AN). Then target tag isregistered as habitual.
ON
%ANNOFF
AON
Monitoring
period
TimeMonitoring
period
1 2 3
Occurrence
number
Start
masking
Recovery logic
In case annunciator is not announced formonitoring period, AON is set to target
annunciator (%AN).
Masking logic (After learning)In case registered tag announced
annunciator again, AOF is set without waiting.
Reason of occurrence: DCS sequence is not prepared
Stop
masking
AOF
F) Fault diagnosis and suppression of IOP alarm
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 33/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 33
F) Fault diagnosis and suppression of IOP alarm
Monitoring period
S
L
SH
Judgment
HI IOPRAW
Purpose
This logic detects true IOP/IOP- alarms
which announced due to range over.
Detection Logic
In case IOP/IOP- is happened after HI/HH
or LO/LL alarm is notified, and is recoveredafter ordered period, this logic shows thereason of IOP/IOP- alarm (range over).
Also target tag is registered as habitual.
Exclude logic
In case registered tag announces IOP/IOP-
alarm again, target tag is excluded from
watch list.
HHNR HH
HH
PH
HI
IOP
Start
monitoringMonitoring period
for IOP detection
Reason of occurrence: Range over (engineering problem)
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 34/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 34
Start
monitoring
(0%)SL
(100%)SH
IOP IOPRAW
Purpose
This logic masks unimportant IOP/IOP-
alarm which announced due to range over.
Masking logic
In case registered tag is in AON, and RAW
data of registered tag is greater than SH orsmaller than SL for monitoring period, AOFis set.
Recovery logic
RAW is returned between SL and SH, AONis set.
Normal
Range
IOP-
IOP
Normal
Range
Normal
Range
Time
AON
Stop
monitoring
Start
masking
Stop
masking
AOF
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 35/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 35
SL
IOP
Judgment5Sec
IOPRAWPurpose
This logic detects true IOP/IOP- alarm
which notified due to the failure of fieldtransmitter.
Detection logic
In case IOP/IOP- is happened even though
HI/HH or LO/LL alarm is not notified, orIOP/IOP- is happened immediately (within
5 seconds) after HI/HH or LO/LL alarm isnotified, this logic shows the reason ofIOP/IOP- alarm (failure of field transmitter).
Also target tag is registered as habitual.
Masking logic
In case registered tag announces IOP/IOP-alarm again, AOF is set continuously.
NRNR NR
HH
PH
IOP
JudgmentStart
monitoring
Startmonitoring
SH
Monitoringperiod
Monitoring period
HI
AON
Reason of occurrence: Failure of field transmitter
AOF
HH
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 36/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 36
SL
SH
Judgment
IOPRAW
PurposeThis logic announces the reason of trueIOP/IOP- (breaking of wire) alarms.
Detection Logic
In case IOP/IOP- is notified even thoughHI/HH or LO/LL alarms are not notified,
and IOP/IOP- is not recovered for ordered
period, this logic shows the reason of alarmnotification.
NR
LL
PL
IOP-
Monitoring periodStart
monitoring
Reason of occurrence: Breaking of wire
(2) Dynamic alarm setting
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 37/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 37
(2) Dynamic alarm setting
Alarm threshold (PH/PL) should be changed dynamically according to thedrastic changes of set point (e.g. load change, grade change)
Exapilot Excel Link icon (option) reads optimum alarm threshold (PH/PL)to FCS automatically when SV is drastically changed
Exapilot Correlation Diagnosis icon (Advanced Alarm option) can monitorthe correlation between elapsed time and process variable (PV) online
Start up Grade A Grade B
GradeChangeShut down
PH=100
PL=80PH=SV + 5
PL=SV - 10
PH=SV + 10
PL=SV - 12
PH=200
PL=180 PH=SV + 4
PL
=SV – 6
PH=SV + 4
PL=SV - 2 TIME
PV
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 38/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 38
Case Branch icon
In case of
Grade A
Repetition
Out put to
DCS icon
A B C D E
GRADE AGrade A Grade B
Grade CGrade D
For the transient condition
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 39/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 39
For the transient condition
Correlation diagnosis icon
(3) Addition of pre-alert
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 40/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 40
(3) Addition of pre-alert
S
L
SH
PL
Start
monitoring
PH
Time
PV
Start
monitoring
Purpose
This logic announces pre-process alert incase;
-PH/PL is announced
-PV is increasing/decreasing-PV will reach HH/LL within ordered period
(e.g. within 5 minutes)
HH LO
LL
HH
NR HI NR LL
Notify
HH pre-alertNotify
LL pre- alert
Period of
notification
Period of
notification
Pre-alert function predicts an indication of HH/LLalarm before HH/LL is announced, and displays alert
message to operators to prevent ESD.
(4) Replacement to advanced alarm
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 41/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 41
(4) Replacement to advanced alarm
Various kinds of diagnosis templates (Standard/Option) – Fault diagnosis
• Field transmitter (e.g. Failure, Breaking of wire)
• Control valve (e.g. Sticking, Leakage, Clogging of strainer)• Pump (e.g. Trip)• Pipe (e.g. Clogging, Leakage)• Storage tank (e.g. Leakage)
– Overload monitor• Pump• Compressor• Turbine• Centrifuge• Blower• Agitator
– Operation efficiency monitor• Heat exchanger (e.g. Energy effectiveness)• Distillation tower (e.g. tray performance, Temp. distribution)• Reactor
– Quality monitorDetect an early sign of abnormality faster than it’s detected by DCSalarmsNotify the reason of alarm and adequate countermeasure to operatorsSend e-mail to relevant peopleExecute countermeasure automatically if necessary
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 42/50
Application examples
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 43/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 43
Application examples
This logic detects the abnormality of cylinder valve in
reciprocating compressor by comparing the difference
between estimated outlet temperature and measured outlet
temperature.
In case cylinder valve is broken or quantity of cooling water
is insufficient, the outlet temperature will be risen due to
back flow inside of cylinder.
Example1: Reciprocating compressor diagnosis
Example2: Correlation diagnosis
Correlation diagnosis icon
T TTI101.PV TI102.PV
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 44/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 44
Exapilot can define pre-alert which can detect early
sign of process abnormality before it is detected byprocess HI/LO alarms.
Example3: Reactor temperature distribution diagnosis
TI102.PH
TI102.PV
1 hour
5 degrees
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 45/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 45
P
P
PI101.PV
PI103.PV
P
PI102.PV
Low pressure steam
(-0.1 MPa <= PI101.PV-P102.PV <= 0.1 MPa)
(-0.1 MPa <= PI101.PV-P103.PV <= 0.1 MPa)
Guidance message
Example4: Pressure indicator diagnosis This logic detects the abnormality of pressureindicator by checking the difference of threepressures.
Furnace
FI103.PV
FI101.PV
FI102.PV
TI100.PV
TI200.PVLowMaterial A
LowMaterial B
FuelGas
XI103.PV
Example5: Furnace incomplete combustion diagnosis
This logic detects early sign ofincomplete combustion infurnace unit before DCS HI
alarm detects it, by monitoring
the difference between “Fuelgas calorie” calculated using
fuel gas flow & gravity and“Furnace duty” calculatedusing flow & temperature of
furnace unit.
(5) Prevention of miss-operation
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 46/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 46
(5) Prevention of miss operation
Incorrect action must be detected ASAP to preventserious trouble
Exapilot Advanced Alarm can detect various kinds ofmiss-operation by monitoring operator’s behavior
Example: Miss of tag mode change
IFFIC100.MODE is changed to “MAN”
3 minutes lapsed
FIC100.MODE is still in “MAN”
THENExapilot changes tag mode to “AUT”
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 47/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 47
3.2 Operator training system
Training system
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 48/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 48
Training system
Use Exapilot and CS 3000 test function (WDA)
No need to modify existing DCS application
Low cost system
Simple process model can be made in Exapilot
– Dead time – Time lag
– Material balance, etc.
General training using HIS windows
Training for transition operation using Exapilotwindow
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 49/50
Process Operation Centre, Yokogawa Engineering Asia
Copyright © by Yokogawa Engineering Asia 5/13/2005 3:09:41 PM Page 49
Simulate the material balance
between valve position
and tank level
Simulate the material balance
between valve position
and tank level
FIC
FIC
Level
TIC
Field
controller
Hotwater
CENTUM CS 3000 Test function
Simulate a field
temp. controller
Simulate a field
temp. controller
Temp
Exapilot
Read PV/MV/SV
Write RAW
Read PV/MV/SV
Write RAW
Dead time
Time lag
Dead time
Time lag
Exapilot application for process simulation
Exapilot application for automation of transition operation
Read PV/MV/SV/PH/PL/ALRM
Write SV/MV/PH/PL
Read PV/MV/SV/PH/PL/ALRM
Write SV/MV/PH/PL
8/13/2019 Process Alarm Management
http://slidepdf.com/reader/full/process-alarm-management 50/50
Thank you for your attention.Thank you for your attention.