Alarm Management Siemens Welschen

Welcome
Ruud Welschen
Productmanager Process Control & Safety Systems
Ruud.Welschen@siemens.com
www.siemens.nl/DCS
Definition of an alarm
“A mechanism for informing an operator of an abnormal

process condition for which an operator action is required.”
page 2 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

Safety Concept of a Plant IEC 61511
Civil Civil protection

protection
Retention
basin Passive protection
Pressure-relief
valve, Active protection
bursting disk
Safety Safety
system Safety system (SIS)
(automatic) shutdown
Plant personnel
intervenes
Process alarm
Process control system
Basis Process
automation data
Standard behavior

Operator reactivity to alarms
100%
80%
60%
Reactivity
40%
20%
Ideal Critical Fatal

0%
1 10 100 1.000 10.000
Alarms per 10 minutes
Adapting requirements on the human capabilities

(Recommendation of NAMUR/EEMUA 191)

Levels of automation according to ISA 99
Level 4
Level 3
Level 2
Level 1
Level 0

Alarm management procedure
sensor DCS Historian Alarm management report
Adjust limits or logic

Difference in DCS or PLC approach
HMI HMI DCS PLC - Scada

Alarm presentation Alarmstatus
IF “1” text: “Alarm High”
Eventdriven 2 Sec polling
Controller
Alarmstatus 0101010101010101
I/O
I/O Alarmtext IW200 >100 SET M10.1 “1”

I/O Modules
I/O
I/O
Field Termination
1
2
3
Field wiring
Field devices

Basic DCS functionality
sensor engineer PID de-engineer actuator
sim SP
0-100%
4-20mA eng. 4-20mA
lim lim
alarm
Limit H/L

Extended DCS functionality
sensor engineer PID de-engineer actuator
sim SP
0-100%
4-20mA eng. 4-20mA
lim lim
alarm Urgency Shift planning Output
SMS
Limit H/L
Historian
Asset Management
Batch
Route Control
Safety Systems

Alarm types
Events: Process changes that have to be logged but no operator action is

required and is thus not defined as an alarm.
Process messages: signal process events of the automated process. Such

events include limit value violations of measured values and status information.
Process control messages: are fault messages caused, for example, by the
failure of a component or a wire break affecting a connected I/O signal. This
might be Asset Management messages.
Operating messages are generated each time process variables are

manipulated by an operator, for example, when a controller is switched to a
different mode.
System messages are all messages that are generated by the SIMATIC PCS 7
system and not by the process.
Alarm management techniques
- Include process variable information in alarmline

- Select priorities 0-16 for more important information
- Locking of messages in unused area’s or objects
- Use intelligent sensors for pre-alarming (incrustation level)
- Use build-in statistics for quick analyse
- Time filter for nuisance digital alarms
- Hysteresis filter for nuisance analogue alarms
- Time stamping of alarms in I/O card (1 ms stamping)
- First failure detection
- Manual hiding of specific alarms
- Dynamic state based hiding of alarms
- Integrate Batch alarms in DCS alarm system
- Integrate Safety alarms in DCS alarm system
- Use Plant Asset Management for alarming of non-intelligent devices

SIMATIC PCS 7 System Functions
Time Synchronization and Time Stamping
Possibilities of time synchronization

OS server is time master with
PC system time
Master Time signal via serial port (GPS / DCF 77 antenna)
Master Time signal via bus from external PC
SICLOCK
Time stamping
Process alarms
Analog block, e.g. "Analog value high"
Motor block, e.g. "Motor fault"
Time stamping cyclic in the AS
Precision: AS scan rate, e.g. 100 msec. *)
Error messages of the I/O
E.g. "wire break"
ET200M
Time stamping acyclic in the AS
Precision : approx. 20 msec.
Digital signals on the input/output station ET200iSP
Digital signals via IM153-2 / IM151-2
Precision : 1 msec.
Time master/slave

Operator System
Graphical User Interface
Alarm one line Overview

section
Navigation
window
Picture
Faceplate area
Alarm classes
- A Alarm (high / low)
- W Warning (high / low)
- S Control system
- O Operator input prompt
Button
area
Standard user interface (overview and Picture area, buttons, trends, alarms, faceplates)
is provided by the system - no engineering required !
Easy to operate due to hierarchical structure (top level is each process area) and simple
navigation
SIMATIC PCS 7 Operator System
Alarm Management: Loop in Alarm
Jump: from the overview alarm line directly to the picture / faceplate containing the alarm
Loop-in alarm
Alarm with highest priority A
in alarm line (overview)
Jump: from the alarm list directly to the picture / faceplate
Loop-in alarm
A
Alarm Management by quickly navigating to the source of the fault

PCS 7 Operator Station
Alarm statistics and analysis
Time between Time between coming

call up button how often coming and clearing and acknowledged
Integrated in PCS 7 standard alarm system

SIMATIC PCS 7 System Functions
OS Alarmlogging of operator actions
Message
Action performed or Type:
Old value / New value „Operator
With comment option Input“
Comment field to
Input reason of change
Date/time- Operator
Stamp Origin Name
Process
area

SIMATIC PCS 7 Engineering System
Process Object View: Comprehensive Filter Functions
1 2
2-level filter
function
Selective filtering of relevant parameters allows you to optimize

your configuration activities
Smart Alarm Hiding
State selector
Filter
Alarms Alarms
AS
Sensors
Logic Al
ar
Actors m
s

Smart Alarm Hiding
Group 1
Maint
Message Maint Run CIP …31x
Run
Cip
…31x
Group 2
Maint
Run
Cip
…31x

SIMATIC PCS 7 Operator System
Alarm Management: Alarm Hiding
Engineering
… than define „hiding rules“

Historian
OS-Clients External
• Messages
PC
• Batch-Protocols
• OS Reports
... Packages
• Alternative archive
values
Internet
Explorer
OS-Server
...
Batch-Server Central Archive
Server

Plant Asset Management Strategies
wear limit failure

Maintenance alert
wear wear
reserve
Incrustation
tRest
calibration point
“Not covered”
user adjustable user adjustable
Good Maintenance required Maintenance demanded Maintenance alarm
operating hours
tact tfailure
Component Level
Level Switch
Degrees of contamination

Plant Asset Management Strategies
Condition Monitoring of “non-intelligent” components

Monitoring of
- power consumption
- flow
- pressure across the pump
Detection of illegal operation states,
deviation from characteristic curves,
gradual deterioration of performance
Prediction of the remaining life-time
Common and unified symbols for representing the status of all assets
Announcement of request Request for maintenance
Good
for maintenance (low) unknown/not activated
Request for maintenance Request for maintenance

Simulation
(medium) activated
Function Maintenance alert Request for maintenance

control/ local (high) in process

SIMATIC PCS 7 Asset Management
Source for uniform visualization of all field device state
PROFIBUS PA – profile /
FF – status definition On maintenance station
xx Function check / local
override
xx O.K. Good device status
xx Update event
PA
xx Function check -p Maintenance alarm
xx Maintenance required ro
file
x Uncertain, Process related s pe
cif Maintemance demand
HART - status ic
de
xx Malfunction fin
itio
xx O.K. n
Maintenance request
xx Update event
xx More status available Siemens specific definition
xx e.t.c. Simulation
Specific - status finition
de
xx Wire break p e cific n Out of service
rs tio
xx O.K. Use ini
xx Low range limited def
ific Passivated
xx Short current e c
x Channel error sp
ile Local operation
r of
EDD – condition status -p
A
xx Simulation P Update event
xx Good.
xx Maintenance demand Device status unknown
xx Maintenance request
x Configuration change
Hierarchical Structure
Fast and easy-to-use operation guidance through complete hierarchy

by unified symbols
SIMATIC S7-400
and PROFIBUS
Network
status and selection of

underlaying hierarchy
ET 200M
diagnostic symbol
Station
of the component
Clear hierarchical structure PROFIBUS

devices
Plant overview
Overview all controllers
Controller (with sub-hierarchy)
PROFIBUS Assets
DP station (e.g. ET 200M) Faceplates
for intelligent
Intelligent field device devices

Uniform View: Identification
Uniform view for all assets according to their information capability
Diagnostic Direct callup of

Request status
status Maintenance status SIMATIC PDM
Direct callup of
HW Config
acyclic asset data, e.g.

cyclic information from via PDM
application

Decision Support
The system generates a maintenance proposal (request)

The service staff confirms or changes
Request Status
Maintenance Status
Diagnostic Status
Request status set by

the user

Asset Report
All important information concentrated

The same structure for all Assets
Asset – Status
Identity
Maintenance -
Status
Detailed diagnostic
Current massages

Asset Report as XML
All important information concentrated

The same structure for all Assets
Document Info
Maintenance -
Status
Current massages
Identity

Increased Focus on Overall Safety
IEC 61511 / S84-2004

Analyzing the entire Safety Instrumented Function (SIF)
Safety Certified Instruments
Tighter Integration of Safety Instrumentation
SIS DCS
PS
ESD action
Trip Point
Pressure
Alarm high
Pressure
SV PCV PT1 PT2
High Pressure Alarm
Process Control
Normal Pressure
Low level

SIMATIC PCS 7 Process Safety
Flexible Modular Redundancy (FMR)
Dual

DO
DO
AI
DI

DO
DI
AI
AI
Simplex

AI
Triple
1oo2 Valves
SIMATIC PCS 7 Process Safety
The “Right” Level of Integration
ENG HMI ENG
INTERFACED
DCS Gateway SIS
ENG HMI
INTEGRATED
DCS SIS
ENG HMI
COMMON
DCS SIS

SIMATIC BATCH
Online Operation, integrated alarming and operator action log
Start Hold Complete

Hold after Step Resume Abort
SIMATIC BATCH
Fulfills 21 CFR Part 11

SIMATIC Route Control
Example of a Material Transport
Source tanks Destination tanks
T1 T2 T3 T4 T5 T6 T7
Material transport

RC Block symbol & Faceplate
Block symbol
Route name & state
Pending messages
Route Control faceplate
Source / destination / via

Modes
Open:
SFC, Batch CC, RC Center

Route Control Center
Monitoring and Controlling your material transfers
Upper frame: List of all transfers

Bottom frame: Elements, modes, setpoint value
(command) and actual value (feedback of the
process)
Green: Ok, Yellow: mode pending, Red: Error /
page 36 timeout / mode error
11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7
Alarm Control Center...
early informing
early informing
by using an alarm management system
controlled alarm service

process management personnel
process failure
page 37 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7 x

Generating the event > direct from PCS 7
SICALIS PMC
Alarm Control
production management
process manage- Center...
systems
ment systems visualization
systems
... can be connected to
virtually any system to
send messages from this
logistic solutions system thanks to a lot of
available system specific
and
open interfaces.
building automation
systems
... Alarm Control Center
any other system

person and shift management
realization of basic personell / shift definitions with the
integrated shift and person management
08:00–17:00 day shift

MO ... FR
17:01–07:59
Alarm Control Center SA
&SU night shift
weekend
standby
possibility to connect to existing personell and shift management

systems

the output response to the requirements
…forwards error messages from

control and visualization systems
to any recipient (mobile phone SMS,
pager, DECT telephone, fixed net-
work telephone, facsimile, LAN
message to PC‘s and wireless
PDA‘s, printers, e-Mail, etc.).
control- / visualization
system Alarm Control Center any
further...
e-M@il
SIMATIC PCS 7 s
Takes you beyond the limits !
Thank you !

Alarm Management Siemens Welschen

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What are the different types of alarms discussed in the document?

What are the different types of alarms discussed in the document?

What are the different levels of automation according to ISA 99?

What are the different levels of automation according to ISA 99?

Welcome

“A mechanism for informing an operator of an abnormal

page 2 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

Civil Civil protection

page 3 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

Ideal Critical Fatal

Alarms per 10 minutes

Adapting requirements on the human capabilities

page 4 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

page 5 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

sensor DCS Historian Alarm management report

Adjust limits or logic

page 6 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

HMI HMI DCS PLC - Scada

IF “1” text: “Alarm High”

Eventdriven 2 Sec polling

I/O Alarmtext IW200 >100 SET M10.1 “1”

page 7 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

sensor engineer PID de-engineer actuator

page 8 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

sensor engineer PID de-engineer actuator

alarm Urgency Shift planning Output

page 9 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

Events: Process changes that have to be logged but no operator action is

Process messages: signal process events of the automated process. Such

Operating messages are generated each time process variables are

- Include process variable information in alarmline

page 11 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

Possibilities of time synchronization

page 12 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

Alarm one line Overview

in alarm line (overview)

Jump: from the alarm list directly to the picture / faceplate

Alarm Management by quickly navigating to the source of the fault

Time between Time between coming

Integrated in PCS 7 standard alarm system

page 15 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

page 16 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

Selective filtering of relevant parameters allows you to optimize

page 18 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

page 19 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

page 20 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

page 21 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

wear limit failure

user adjustable user adjustable

Good Maintenance required Maintenance demanded Maintenance alarm

page 22 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

Condition Monitoring of “non-intelligent” components

Request for maintenance Request for maintenance

Function Maintenance alert Request for maintenance

page 23 11 september 2008 Ruud.Welschen@siemens.com Simatic PCS 7

Fast and easy-to-use operation guidance through complete hierarchy

status and selection of

Clear hierarchical structure PROFIBUS