EEMUA PUB NO 191-2013 Alarm Systems - A Guide to Design Management and Procurement (Edition 3).pdf

1、 Alarm systems A guide to design, management and procurement PUBLICATION 191 Edition 3 Released by IHS. NOT FOR RESALE THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION Alarm systems A guide to design, management and procurement PUBLICATION 191 Edition 3 Copyright 2013 The Engineering Equipm

2、ent and Materials Users Association. A company limited by guarantee. Registered in England. Company number 477838. ISBN 978-0-85931-192-2 Imprint reference 09-2013 Registered and Trading Address 63 Mark Lane London EC3R 7NQ Telephone: +44 (0)20 7488 0801 Fax: +44 (0)20 7488 3499 E-mail: saleseemua.o

3、rg Website: www.eemua.orgEEMUA Publication 191 Alarm systems: a guide to design, management and procurement EEMUA ii ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION About EEMUA The Engineering Equipment and Materials Users Association is usually known by its initials, EEMUA. EEMUA is governed

4、by a Council of members. This Council is responsible for the policies, financing, membership, and strategy of the Association. Any organisation that is a substantial user or purchaser of engineering products is eligible to apply to become a member of EEMUA. Membership is subject to the approval of C

5、ouncil. EEMUA Aims EEMUA aims to improve the safety, environmental and operating performance of industrial facilities in the most cost-effective way, pursuing and promoting leadership in industrial asset management by sharing engineering experiences and expertise, and by the active, enlightened prom

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9、mainly carried out by members representatives on EEMUA Technical Committees, Working Groups, and Forums, supported by EEMUA staff. Incorporation, Membership and Other Information For the purposes of conducting its business, EEMUA is incorporated in England and Wales as a company, limited by guarante

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11、ation. The full list is also on the Associations website, including details of on-line shopping facilities. To enquire about corporate Membership, write to enquirieseemua.org or call +44 (0)20 7488 0801. EEMUA Publication 191 Alarm systems: a guide to design, management and procurement EEMUA iii ABO

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20、ure editions of this Publication. New editions are publicised on the EEMUA website. Cover photograph, reproduced with kind permission of RWE npower. EEMUA Publication 191 Alarm systems: a guide to design, management and procurement EEMUA iv EEMUA Publication 191 Alarm systems: a guide to design, man

21、agement and procurement EEMUA v Contents Foreword . xiii About this Guide . xv Core Principles and the Roadmap xxi 1 Introduction 1 1.1 What is an alarm system? . 1 1.2 Key design principles 2 1.3 Alarm system management philosophy/Company Standard 5 1.3.1 Corporate considerations . 5 1.3.2 Site con

22、siderations . 5 1.4 Financial considerations 7 2 Principles of alarm system design . 9 2.1 The design process 9 2.2 Where do requirements for alarms come from? 11 2.2.1 Alarms 12 2.2.2 Alerts . 13 2.2.3 The difference between an alarm, an alert and a prompt 14 2.2.4 Alerts as an alternative to contr

23、ol by alarms . 14 2.2.5 Comparison of alarms, alerts and prompts . 15 2.3 Risk assessment 17 2.3.1 The need to identify and minimise risks . 17 2.3.2 Risk reduction 17 2.3.3 Safety related alarms - principles 18 2.3.4 Design and engineering of safety related alarms . 19 2.3.5 Proof testing 23 2.3.6

24、Summary 24 2.4 Generation of alarms 24 2.4.1 Types of alarms . 24 2.4.2 The selection of alarm settings . 27 2.5 Structuring of alarms 29 2.5.1 Prioritisation 29 2.5.2 Logical processing of alarms. 32 2.6 User centred design . 32 2.6.1 The role of the operator/production staff 32 2.6.2 The type of p

25、rocess 34 2.7 Designing for operability . 39 2.7.1 Improve the management of alarm overloads . 40 3 Implementing a system of alarm management . 43 3.1 Alarm systems management organisation 43 3.1.1 Steering committee 44 3.1.2 Engineering specification . 44 3.1.3 Alarm management philosophy document

26、44 3.1.4 The alarm co-ordinator 45 3.1.5 Alarm assessments (rationalisation) 45 3.1.6 Alarm database 45 3.1.7 Alarm analysis tools 49 3.1.8 Measuring alarm metrics . 49 3.1.9 Summary alarm metrics 50 3.1.10 Detailed alarm metrics 50 EEMUA Publication 191 Alarm systems: a guide to design, management

27、and procurement EEMUA vi 3.1.11 Operations reporting and feedback action . 50 3.2 Fostering a culture of improvement 50 3.3 The improvement (rationalisation) process for a specific alarm system 51 3.3.1 System capability . 51 3.3.2 Problem identification 51 3.3.3 Review team/philosophy document . 54

28、 3.3.4 Supporting documentation . 54 3.3.5 Plant area categorisation . 55 3.3.6 Unit/plant/site review 55 3.3.7 Integration 57 3.3.8 Monitor/improvement . 57 3.3.9 System tuning . 58 3.4 Assessment of existing alarm system status 58 3.4.1 How useful is the alarm system 59 3.4.2 Gaining the opinions

29、of the users 60 3.4.3 Understanding the alarm system performance 60 3.4.4 Determine how well alarms are managed . 60 3.5 Detailed assessment 60 3.6 Initial assessment of individual alarms 61 3.6.1 Assessment of individual alarms on an existing system 61 3.6.2 Assessment of individual alarms for a ne

30、w system 62 3.6.3 What if questioning . 63 3.7 Alarm management philosophy document . 63 3.7.1 Allocation of roles and responsibilities for design of the alarm system 64 3.7.2 Identification of the alarm system users and their needs 64 3.7.3 Definition of what an alarm should be 64 3.7.4 Definition

31、of the safety role of the alarm system . 65 3.7.5 Define how any alarms are to be registered 65 3.7.6 Definitions of alarm system performance targets . 65 3.7.7 Rules for prioritisation of alarms . 65 3.7.8 Alarm system configuration 66 3.7.9 Checklist for designers on the information to be recorded

32、 . 66 3.7.10 Dictionary of terms and abbreviations to be used in alarm messages 66 3.7.11 Guidance to sub-contractors on the design of alarms . 66 3.7.12 Guidance on content and structure of alarm response definitions . 67 3.7.13 Guidance on interpreting patterns of alarms . 67 3.7.14 Guidance on es

33、tablishing alarm equipment test frequencies 68 3.8 Training 68 4 HCI management techniques 71 4.1 Display options 71 4.1.1 Alarm annunciator panels 73 4.1.2 Alarm list displays 74 4.1.3 Graphically embedded alarm objects . 75 4.2 Overviews . 75 4.3 Audio/visual assistance to the graphical interface

34、. 76 4.4 Alerts . 78 5 Alarm configuration 81 5.1 Field derivation of alarms 81 5.2 Alarm processing hardware . 81 5.2.1 The commercial environment . 81 5.2.2 Reliability issues . 82 5.2.3 Functionality 83 EEMUA Publication 191 Alarm systems: a guide to design, management and procurement EEMUA vii 5

35、.2.4 Environmental requirements 83 5.3 Alarm response definition 84 5.4 Testing of alarms . 85 5.4.1 Management of testing 85 5.4.2 Example test methodology . 87 5.5 Suppression 87 5.5.1 Bulk suppression 87 5.5.2 Logical suppression . 88 5.5.3 General suppression rules 88 5.5.4 Implementation of sup

36、pression . 89 5.5.5 Authorisation and control . 91 6 Performance monitoring/improvement . 93 6.1 Introduction 93 6.2 Performance metrics 93 6.3 Benchmark values 95 6.3.1 Main benchmark values . 96 6.3.2 Steady state usability benchmarks 96 6.3.3 Abnormal (upset) state usability benchmarks . 97 6.3.4

37、 General usability benchmarks . 98 6.3.5 Summary of metrics and benchmark values . 98 6.4 Key performance indicators (KPIs) . 99 6.4.1 Primary KPIs 100 6.4.2 Secondary KPIs 101 6.5 Performance levels and alarm system states 102 6.5.1 Performance levels . 102 6.5.2 Alarm system states . 103 6.6 Valid

38、ation of metrics . 112 7 Buying a new alarm system . 113 7.1 Investment appraisal 113 7.2 Hardware 113 7.3 Specifying alarm functionality 114 7.4 Specifying engineering 115 7.4.1 Specification of design procedures 115 7.4.2 Specification of required performance 115 7.5 Contractual implications 116 7

39、.5.1 Allocation of activities . 116 7.5.2 Scheduling of activities 116 7.5.3 Contractual tests of acceptability 116 7.6 Ensuring usability 117 Appendix 1 The costs of poor alarm performance 119 A1.1 Three Mile Island . 119 A1.2 Milford Haven Refinery 119 A1.3 Channel Tunnel Fire 119 A1.4 Tosco Avon

40、Accident . 119 A1.5 Longford Gas Explosion . 120 A1.6 Grangemouth Refinery Scotland . 120 A1.7 First Chemical Corporation 120 A1.8 Texas City . 121 A1.9 Buncefield Oil Storage Depot . 121 A1.10 IChemE accident database . 121 A1.11 Nuclear power incident database 121 EEMUA Publication 191 Alarm syste

41、ms: a guide to design, management and procurement EEMUA viii A1.12 HSE accident analysis . 121 A1.13 HSE alarm survey . 122 A1.14 Abnormal Situation Management Consortium . 122 A1.15 Refinery study . 123 Appendix 2 Pertinent requirements 125 Appendix 3 Prioritisation methods . 127 A3.1 Potential sev

42、erity of consequence . 127 A3.2 Time to consequence 128 A3.3 Priority distribution of alarms . 129 A3.4 Prioritisation of safety related alarms 130 A3.5 Example methods for setting of priority . 131 A3.5.1 Method 1 - Priority matrix evaluation . 131 A3.5.2 Method 2 - Summating consequence . 135 A3.5

43、.3 Method 3 - Taking maximum consequence . 137 A3.5.3 Method 4 - General alarm assessment . 139 Appendix 4 Logical processing of alarms 145 A4.1 General comments . 145 A4.2 Grouping 145 A4.3 Suppression 146 A4.3.1 Redundancy logic . 146 A4.3.2 Eclipsing 146 A4.3.3 Out of service plant 146 A4.3.4 Ope

44、rating mode . 147 A4.3.5 Major event . 147 A4.4 Automatic alarm load shedding 148 A4.5 Alarms from equipment under test . 149 Appendix 5 Repeating and fleeting alarms . 151 A5.1 Why repeating alarms occur 151 A5.2 Engineering of signals . 152 A5.3 Filtering 152 A5.4 Transient suppression . 153 A5.5

45、Deadband . 153 A5.6 De-bounce timer 154 A5.7 Counter 155 A5.8 Shelving . 156 A5.9 Release (One-shot shelving) 157 A5.10 Auto-shelving 157 A5.11 Single line annunciation 158 A5.12 Logging of repeating alarms . 159 A5.13 Summary 159 Appendix 6 Alarm management in batch plants . 161 A6.1 Batch plant op

46、eration . 161 A6.1.1 Alarm thresholds 162 A6.1.2 Replacement of batch with semi-batch or continuous processes . 162 A6.2 Operator information 163 A6.3 Alarm rates . 163 A6.4 Application of alarm priorities in batch processes 165 A6.5 Design of the alarms 165 A6.6 Generation of alarms 166 A6.7 Manage

47、ment of alarm limits thresholds . 166 EEMUA Publication 191 Alarm systems: a guide to design, management and procurement EEMUA ix A6.8 Sources of nuisance alarms . 167 A6.9 Sources of alarm floods. 167 A6.10 Getting information to remote operations 167 Appendix 7 Alarm management in geographically d

48、istributed plant . 169 A7.1 Distributed process operation 169 A7.2 Operator workload . 170 A7.3 Alarm system performance and KPIs . 171 A7.4 Application of alarm priorities in distributed processes . 171 A7.5 Generation of alarms 172 A7.6 Telemetry issues 174 A7.7 Getting information to remote resou

49、rces . 175 Appendix 8 Usefulness questionnaire . 177 A8.1 How many alarms are useful? 178 Appendix 9 Operator questionnaire 181 Appendix 10 Supporting checklists 187 A10.1 Storage and management . 187 A10.2 Threshold setting . 187 A10.3 Checklist for a good alarm . 187 A10.4 Alarm configuration information . 188 A10.5 Alarm priority information 188 A10.6 HAZOP checklist . 189 Appendix 11 Design of alarm list displays 191 A11.1 Alarm states 191 A11.2 Content of alarm entry 192 A11.3 Positioning of new alarms 194 A11.4 Alarm acceptanc