Armour Managingthealarmmanager Gladstonepower

7/30/2019 Armour Managingthealarmmanager Gladstonepower

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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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2

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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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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5

CONTROLSYSTEMSOVERVIEW

FOXBORO I/A DCS (SINCE 1994)

8 CONTROL DESKS

OVER 30,000 I/O, 3600 ALARMS/UNIT

CENTRALISEDCONTROL ROOM


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6


7/287

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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20


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21

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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25

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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