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The Real World Impact of ISA 18.2on Process Industries
Kevin BrownMatrikon Inc.
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Agenda
Introduction What is Alarm Management
What is a Lackof Alarm Management
OH&S & Legislation
An Example Plant Incident Demystifying Standards & Guidelines
ISA 18.2 Compliance
Alarm Management Lifecycle
Steps to Compliance Questions
Operators on alert
Operator response, alarmstandards, protection layers
keys to safe plantsIntech, September 2009
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Kevin Brown - Introduction
Manager North America Alarm Management Team 4.5 years at Matrikon
Completed projects from upgrades to $2.8 MM
Audits
Alarm Philosophy development Facilitate alarm rationalization
Spent 20 years in plants in process control Experience with different computer control systems
Bailey, Taylor, Advant, GE, Allen Bradley, Metso, TDC3000
Experience with Historians
Simsci, MOPS, OSI PI
DMZ network design and setup
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Matrikon Alarm ManagementMatrikon has 20 years experience and is the Global Leader in the deployment of
Enterprise Wide Alarm Monitoring Solutions with the worlds leadingcompanies,innovation, safety, commitment to
value and high ethical standards
http://www.dupont.com/asphalt/http://www.basf.com/8/2/2019 MTK - The Real World Impact of ISA 18.2 on Process Industries
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550 employees 300+ consultants with
extensive domainexpertise
Complete services, fromplanning to execution
GlobalPresence
CompleteSolutionProvider
Company Overview
Consultants275+
R&D100+
Other150+
18 offices 17 Partners
Strong Presence inToronto (25 Consultants)
TSE: MTK
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What is Alarm Management?
Process by which alarms are engineered,monitored, and managedto ensure safe, reliableoperations
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What is Alarm Management?
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What else is Alarm Management?
Continuous lifecycle Plant maintenance/reliability
Good process control
Outcome of a risk assessment Related to equipment failure
A form of Enhanced/Advanced Control
Abnormal Situation Management It has been widely ignored for a long time
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What is a Lack of AlarmManagement?
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What is a Lack of Alarm Management?
Example: Texas City Oil Refinery 2005.
Precursors:
- Maintenance cut by 25%
- Only one Control Room Operator for the whole plant
- Failed level switches
- Level transmitter reading incorrectly no alarm- Workers within exclusion zone
- Decided against installing safety flares
Outcomes:
- 15 people killed
- Could have spent a couple of $m but ended up costing $1.6b
- Oil Refining industry are now relatively proactive in AM
(Ref.) http://www.texascityexplosion.com/
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Alarm Management: Its about Safety!
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An Example Plant Incident
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An Example Plant Incident
Plant is unstable, getting towards end of 12hr shift Tank containing hot material reaches HH level Trip on HH level interlock was disabled to replace the instrument and
inadvertently not re-enabled Operator misses the alarm because he/she is overloaded and there is an alarm
flood High level safety switches that trip the incoming pump have not been tested for
over two years and fail to operate Tank overflows and severely burns worker below
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Possible Outcome
Employee Impact
Possible Injury
Potential Fatality
Flow-on Family/Community effects
Employer Impact
Operational Downtime/Loss of Production
Investigation by the relevant authority Expert Witness in Court
1stQuestion to Employer: Did you comply with an ISA Standards or Internationallyaccepted Standard?
2ndQuestion to Employer: Did you follow known, good engineering practice?
In recent cases there has been more use of expert witnesses. What wouldan expert witness say in this case?
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Key Features ISA 18.2
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Key Features ISA 18.2
Large focus on an Alarm System Lifecycle Clear Alarm System Performance KPIs
Section on compliance
Alarm Philosophy what must be included
Alarm System requirements Specification
Identification
Rationalization
Advanced Methods Less examples are given
Complimentary to EEMUA 191
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Matrikon & ISA 18.2
Participation Mike Brown
Jeff Gould
Michael Marvan
Alan Armour
Section Leadership Operations
Maintenance
Management of Change
Sub-Committees Monitoring & Assessment Audit
Analysis (Annex)
ISAs Committee Website:http://www.isa.org/MSTemplate.cfm?MicrositeID=165&CommitteeID=4627
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ISA 18.2 Alarm Performance KPIs
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Industry Benchmarks: Room to Improve!
Other
900
35
180
25/40/35
5
Power
2000
65
350
25/40/35
8
PetroChem
1500
100
180
25/40/35
9
Oil & Gas
1200
50
220
25/40/35
6
ISA
144
5
10
80/15/5
1
Average Alarmsper Day
Standing (stale)
Alarms
Peak Alarmsper 10 Minutes
Average Alarms/
10 Minute Interval
Distribution %(Low/Med/High)
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Alarm Management Lifecycle
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Philosophy
Audit
Rationalization
Identification
Detailed Design
Implementation
Maintenance
Operation
Managementof Change
Monitoring &Assessment
D
C
E
AJ
B
G
HF
I
Alarm Management Lifecycle
Philosophy
Identification
Rationalization
Detailed Design Implementation
Operation
Maintenance
Monitoring & Assessment
Management of Change
Audit
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Entering the Lifecycle - Philosophy
Philosophy
Audit
Rationalization
Identification
Detailed Design
Implementation
Maintenance
Operation
Managementof Change
Monitoring &Assessment
D
C
E
A
J
B
G
H
F
I
Greenfield orBrownfield sites Objectives of the
alarm system Design it correctlyand keep it there
M it i &
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Philosophy
Audit
Rationalization
Identification
Detailed Design
Implementation
Maintenance
Operation
Managementof Change
Monitoring &Assessment
D
C
E
A
J
B
G
H
F
I
Entering the Lifecycle - Monitoring &Assessment
Focus onquantitative analysis
to determine gaps FollowMaintenance & MOCpaths to resolve
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Philosophy
Audit
Rationalization
Identification
Design
Implementation
Maintenance
Operation
Managementof Change
Monitoring &Assessment
D
C
E
A
J
B
G
H
F
I
Audit
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ISA 18.2 Compliance
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Alarm Management is now a Compliance Issue
Compliance: ANSI / ISA SP18.2 Similar to ANSI/ISA S84.01:
nationally recognized standard
qualifies as a nationally recognized standard for safety systems such thatOSHA recognizes as recognized and generally accepted engineering
practice Not a requirement to meet OSHA 1910.119 PSM requirements but bears
substantial weight with regard to implementing safety/alarm systems
burden of proof is on the User to demonstrate that they have followedgenerally accepted engineering practice
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ISA 18.2 Compliance.
Section 4.1: Conformance Guidance
To conform to this standard, it must be shown that each of the requirements in the normativeclauses has been satisfied.
Section: 4.2 Existing Systems (Grandfathering Clause)
For existing alarm systems designed and constructed in accordance with codes,standards, and/or practices prior to the issue of this standard, the owner/operatorshall determine that the equipment is designed, maintained, inspected, tested, andoperated in a safe manner.
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Historical Findings
Industry estimate: $10 Billion per year from abnormalsituations
Incident costs from $100K-$1 Million per plant per year
Refineries suffer a major incident once every three years
costing $80M Insurance companies show industry claims >$2.2 Billion
per year due to equipment damage (North America)
ASM Consortium Findings
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Personal Observations.
Many process plants in North America are not doingenough
Alarms form part of your plants layer of protection
There will be more prosecutions for OH&S breaches
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What Steps Can You Take?
Senior Management Sponsorship
Purchase ISA 18.02
Undertake an audit of your alarm system. Minimum do
Monitoring and Assessment Prepare a Philosophy Document and then Functional
Specifications
Prepare a Strategic Plan
Just Do it
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Questions?