ISA TR18 2 6-2012 Alarm Systems for Batch and Discrete Processes.pdf

1、 TECHNICAL REPORT ISA-TR18.2.6-2012 Alarm Systems for Batch and Discrete Processes Approved 31 May 2012 ISA-TR18.2.6-2012 Copyright 2012 ISA. All rights reserved. 2 ISA-TR18.2.6-2012, Alarm Systems for Batch and Discrete Processes ISBN: 978-1-937560-18-8 Copyright 2012 by the International Society o

2、f Automation. All rights reserved. Printed in the United States of America. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise) without the prior written permission of

3、the publisher. ISA 67 Alexander Drive P.O. Box 12277 Research Triangle Park, North Carolina 27709, USA E-mail: standardsisa.org ISA-TR18.2.6-2012 Copyright 2012 ISA. All rights reserved. 3 Preface This preface is included for information purposes only and is not part of ISA-TR18.2.6-2012. This techn

4、ical report has been prepared as part of the service of ISA, the International Society of Automation, toward a goal of helping in the understanding and use of ANSI/ISA-18.2-2009 as applied to batch and discrete processes. To be of real value, this document should not be static but should be subject

5、to periodic review. Toward this end, the Society welcomes all comments and criticisms and asks that they be addressed to the Secretary, Standards and Practices Board; ISA, 67 Alexander Drive; P.O. Box 12277; Research Triangle Park, NC 27709, USA; Telephone (919) 549-8411; Fax (919) 549-8288; E-mail:

6、 standardsisa.org. The ISA Standards and Practices Department is aware of the growing need for attention to the metric system of units in general, and the International System of Units (SI) in particular, in the preparation of instrumentation standards, recommended practices, and technical reports.

7、The Department is further aware of the benefits to USA users of ISA standards of incorporating suitable references to the SI (and the metric system) in their business and professional dealings with other countries. Toward this end, the Department will endeavor to introduce SI and acceptable metric u

8、nits in all new and revised standards to the greatest extent possible. The Metric Practice Guide, which has been published by the Institute of Electrical and Electronics Engineers (IEEE) as ANSI/IEEE Std. 268-1992, and future revisions, will be the reference guide for definitions, symbols, abbreviat

9、ions, and conversion factors. It is the policy of ISA to encourage and welcome the participation of all concerned individuals and interests in the development of ISA standards. Participation in the ISA standards-making process by an individual in no way constitutes endorsement by the employer of tha

10、t individual, of ISA, or of any of the standards, recommended practices, and technical reports that ISA develops. This technical report is structured to follow the ISA Style Guide. THE USER OF THIS DOCUMENT SHOULD BE AWARE THAT THIS DOCUMENT MAY BE IMPACTED BY ELECTRONIC SECURITY ISSUES. THE COMMITT

11、EE HAS NOT YET ADDRESSED THE POTENTIAL ISSUES IN THIS VERSION. The following served as members of ISA18 Work Group 6 (WG6) to develop this technical report: NAME COMPANY Joseph Alford Consultant John Bogdan J. Bogdan Consulting LLC Bridget Fitzpatrick Mustang Engineering Tejas Ghiya Genentech Bill H

12、ollifield PAS Douglas Metzger DPM Consulting Graham Nasby Eramosa Engineering Inc. Alan Phipps Eli Lilly Gregory Ruklic Consultant Henry Salomons Dow Chemical Nicholas Sands DuPont Ruth Schiedermayer Object Technologies CEM, Inc. Marcus Tennant Yokogawa Bob Weibel TiPS, Inc. ISA-TR18.2.6-2012 Copyri

13、ght 2012 ISA. All rights reserved. 4 The following people acted as voting members of ISA18 in approving publication of this technical report: NAME COMPANY Donald Dunn, Co-Chair Aramco Services Co. Nicholas Sands, Co-Chair DuPont Erwin Icayan ACES Inc. Joseph Alford Joseph S. Alford LLC Stephen Apple

14、 IntelaTrac-Wonderware Mobile Solutions Joe Bingham AES Global Inc. Alex Boquiren Bechtel Corp. Alan Bryant Oxy Inc. John Campbell Consultant Bridget Fitzpatrick Mustang Engineering Max Hanson MCC Control Systems Bill Hollifield PAS Alan Hugo Capstone Technology Lokesh Kalra Chevron Edward Marszal K

15、enexis Michael Marvan Shell Canada Douglas Metzger DPM Consulting Ian Nimmo User Centered Design Services LLC Patrick ODonnell BP Douglas Rothenberg D. Roth Inc. Todd Stauffer Exida Co. David Strobhar Beville Engineering Inc. Angela Summers SIS-TECH Solutions LP Beth Vail URS SMS Bob Weibel TiPs Inc

16、. This technical report was approved for publication by the ISA Standards and Practices Board on 31 May 2012. NAME COMPANY D. Dunn, Vice President Aramco Services Co. E. Cosman, Vice President-Elect The Dow Chemical Co. D. Bartusiak ExxonMobil Chemical Company P. Brett Honeywell Inc. J. Campbell Con

17、sultant M. Coppler Det Norske Veritas Certification Inc B. Dumortier Schneider Electric J. Federlein Federlein however, selection of activities and practices for a given system is the responsibility of the systems designers, users, and/or support staff. It is intended that this guidance will be upda

18、ted over time as experience is gained. As such, while the general format of this guidance is expected to remain relatively stable, the specifics of its application and specific solutions are expected to evolve. ISA-TR18.2.6-2012 Copyright 2012 ISA. All rights reserved. 12 Introduction This technical

19、 report (TR) is one of several TRs developed to provide examples and discuss how to implement the requirements and best practices contained in ISA-18.2, Management of Alarm Systems for the Process Industries. This TR provides guidance to manufacturers, vendors, consultants, and practitioners at end-

20、user companies in describing how the standard applies to batch and discrete processes. Relevant techniques and examples are included. The technical report is organized into two parts. The first part is introductory in nature (Clauses 1-5). The second part, which is the main body of the technical rep

21、ort (Clauses 6-18), presents information and examples on how each of the alarm management lifecycle activities described in the standard, ISA-18.2, applies to batch and discrete processes. In order to facilitate use of this technical report as an extension of the standard, Clauses 6-18 refer to the

22、same lifecycle activities in both documents. Clause 6 in the TR, for example, corresponds to Clause 6 in ISA-18.2. Following the recommended guidance in this technical report will not necessarily ensure that alarm management problems will be avoided. It will, however, help to identify and address al

23、arm specification, design, implementation, and management opportunities that are important to batch and discrete processes. It can also help minimize the generation of nuisance alarms that could complicate and frustrate operators awareness, understanding, and response to abnormal situations. The gui

24、dance as presented in this document is general in nature and should be applied to each system, as appropriate, by personnel knowledgeable in the manufacturing process and control systems to which it is being applied. The guidance includes suggestions on appropriate applications that are generally ap

25、plicable; however, selection of activities and practices for a given system is the responsibility of the systems designers, users, and/or support staff. It is intended that this guidance will be updated over time with future revisions to this TR as experience is gained in dealing with the nuances of

26、 batch and discrete process alarms. As such, while the general format of this guidance is expected to remain relatively stable, the specifics of its application and specific solutions are expected to evolve. Purpose This technical report addresses the specification, design, implementation, and manag

27、ement of alarms and alarm systems for batch and discrete processes. It explains how ISA-18.2 applies to batch and discrete processes and contains several examples. This technical report was written to provide guidance for the use of ISA-18.2 for batch and discrete processes with due consideration of

28、 other guidance documents that have been developed throughout industry. Alarms for batch and discrete processes are often associated with additional design, implementation, and management considerations compared to those for continuous processes. This technical report is intended to include these ad

29、ditional considerations. ISA-TR18.2.6-2012 Copyright 2012 ISA. All rights reserved. 13 1 Scope 1.1 General applicability This technical report covers the application of alarm management principles in ISA-18.2 to batch and discrete processes. The general principles and techniques described in this te

30、chnical report are intended for use in the lifecycle management of an alarm system based on programmable electronic controller and computer-based human machine interface (HMI) technology. Use of this technical report should consider batch and discrete process alarms from all systems presented to the

31、 operator, which may include basic process control systems, annunciator panels, safety instrumented systems, fire and gas systems, and emergency response systems. 1.2 The alarm system A diagram of the scope of an alarm system, reproduced from Figure 1 of ISA-18.2, is shown here as Figure 1. The alar

32、m system serves to alert, inform, and guide operators regarding abnormal process conditions or equipment malfunctions. The alarm system may include both the basic process control system (BPCS) and the safety instrumented system (SIS), each of which uses measurements of process conditions and logic t

33、o generate alarms (see Figure 1). Abnormal situation information and response guidance for operators may be provided within the BPCS or SIS or by linkages to software outside the BPCS or SIS. The alarm system also includes an alarm log and a mechanism for communicating the alarm information to the o

34、perator via an HMI, usually a computer screen or an annunciator panel. There are other functions outside the alarm system that may be important to the effectiveness of the alarm system, such as an alarm historian. Figure 1 Alarm system dataflow (from ISA-18.2) Process Sensors Final control elements

35、BPCS I/O I/O SIS Panel Alarm log monitor HMI Interface Alarm system Operator Control & safety systems External systems Alarm historian Advanced alarm applications ISA-TR18.2.6-2012 Copyright 2012 ISA. All rights reserved. 14 Components and work processes associated with control systems that are cons

36、idered exclusions to the alarm system as shown in Figure 1 (e.g., sensors and final control elements, annunciator panels, fire detection and suppression systems, security systems, etc.) are described in ISA-18.2. 2 Normative references ANSI/ISA-18.2-2009, Management of Alarm Systems for the Process

37、Industries (referred to in this document as ISA-18.2). ANSI/ISA-84.00.01-2004 Parts 1-3 (IEC 61511-1, -2, and -3 Mod) Functional Safety: Safety Instrumented Systems for the Process Industry Sector (referred to in this document as ISA-84) ANSI/ISA-88.00.01-2010 Batch Control Part 1: Models and Termin

38、ology (referred to in this document as ISA-88) ANSI/ISA-95.00.01-2010 (IEC 62264-1 Mod) Enterprise-Control System Integration - Part 1: Models and Terminology (referred to in this document as ISA-95) 3 Definitions of terms and acronyms 3.1 Definitions Defined terms used in this technical report are

39、listed below. Synonymous terms, which are not used in this technical report, are listed in parentheses. Note 1 Most definitions listed here are copied from ISA-18.2. Those that are not from ISA-18.2 are shown in italics. Note 2 Some alarm terms that are frequently used in industry are not defined or

40、 used in ISA-18.2 or this technical report because they have multiple meanings and interpretations by different BPCS vendors. Examples include alarm enable, alarm disable, and alarm inhibit. 3.1.1 activate the process of enabling an alarm function within the alarm system 3.1.2 advanced alarming a co

41、llection of techniques (e.g., state-based alarming and dynamic prioritization) that can help manage alarm rates in specific situations 3.1.3 alarm an audible and/or visible means of indicating to the operator an equipment malfunction, process deviation, or abnormal condition requiring a response 3.1

42、.4 alarm attributes (alarm parameters) the settings for an alarm within the process control system (e.g., alarm setpoint, alarm priority) 3.1.5 alarm class a group of alarms with common alarm management requirements (e.g., testing, training, monitoring, and audit requirements) 3.1.6 alarm deadband t

43、he range through which an input is varied from the alarm setpoint necessary to clear the alarm 3.1.7 alarm flood (alarm shower) a condition during which the alarm rate is greater than the operator can effectively manage (e.g., more than 1 alarm per minute) ISA-TR18.2.6-2012 Copyright 2012 ISA. All r

44、ights reserved. 15 3.1.8 alarm historian the long-term repository for alarm records 3.1.9 alarm log the short-term repository for alarm records 3.1.10 alarm management (alarm system management) the processes and practices for determining, documenting, designing, operating, monitoring, and maintainin

45、g alarm systems 3.1.11 alarm message a text string displayed with the alarm indication that provides additional information to the operator (e.g., operator action) 3.1.12 alarm philosophy a document that establishes the basic definitions, principles, and processes to design, implement, and maintain

46、an alarm system 3.1.13 alarm priority the importance assigned to an alarm within the alarm system to indicate the urgency of response (e.g., seriousness of consequences and allowable response time) 3.1.14 alarm setpoint (alarm limit, alarm trip point) the threshold value of a process variable or dis

47、crete state that triggers the alarm indication 3.1.15 alarm system requirements specification the document that specifies the details of the alarm system design that are used in selecting components of an alarm system 3.1.16 alarm type (alarm condition) the alarm on a process measurement (e.g., low

48、process variable alarm, high process variable alarm, or discrepancy alarm) 3.1.17 alert an audible and/or visible means of indicating to the operator an equipment or process condition that requires awareness, that is indicated separately from alarm indications, and that does not meet the criteria fo

49、r an alarm 3.1.18 batch process (from ISA-88) a process that leads to the production of finite quantities of material by subjecting quantities of input materials to an ordered set of processing activities over a finite period of time, using one or more pieces of equipment 3.1.19 chattering alarm an alarm that repeatedly transitions between the alarm state and the normal state in a short period of time 3.1.20 classification the process of separating alarms into classes based on common requirements (e.g., testing, t