Operator response to alarms is a critical layer of protection to prevent a plant upset from escalating to an incident. Poor alarm management has been cited as a contributor to numerous industry incidents and has gained attention from regulators (OSHA, FDA) and insurance companies. In addition to improving process safety, application of alarm management best practices can also improve operator performance. By ensuring that every alarm is meaningful to the operator and understood by them, the potential to ignore or miss critical alarms is reduced. This change leads to less unplanned downtime and improved operations.
This course will show how to implement alarm management best practices in your Rockwell control system through the use of tools such as Factory Talk Vantage Point, Alarms Builder, Alarm Shelving, conditional alarming, XL Reporter, and SILAlarm. It will also discuss how to make your PlantPAx system comply with the ISA-18.2-2016 standard “Management of Alarm Systems for the Process Industries” by following the alarm management lifecycle. Attendees will gain an appreciation for the alarm management capabilities available in their control system so that they can determine how to best apply to their operations.
The course prepares participants to support an alarm management program including tasks such as creating an alarm philosophy document, performing alarm rationalization, analyzing alarm system performance, alarm system maintenance, and resolution of alarm management issues.
What Attendees Will Learn
- How to create an effective alarm philosophy document
- Establishing objective criteria for determining what should be an alarm
- How to rationalize alarms to ensure every alarm is meaningful to the operator, prioritized consistently, and documented thoroughly
- Prioritization of alarms to ensure that operators can distinguish which alarms are most important
- Establish alarm setpoints based on design constraints, operating boundaries, and safe operating limits
- Similarities and differences between alarm rationalization and process hazard analysis (PHA)
- Effective design and implementation of safety alarms
- Techniques for improving the operator’s response through improved HMI design, the use of alarm shelving (manual suppression), and alarm response procedures
- How to suppress alarms from the operator when they are not relevant
- Considerations for creating effective alarm system testing and operator training programs
- Implementing an effective and useful management of change process
- How to measure alarm system performance to create a continuous improvement program
- How to identify and resolve common alarm management issues (e.g., nuisance alarms, and alarm floods)
Key Topics for Rockwell PlantPAx Users
- How to tailor your alarm philosophy to the capabilities of your control system.
- Robust and comprehensive alarming with P_Alarm
- Separation of non-alarm notifications (alerts, prompts, and messages) from alarms in their annunciation and display to the operator
- Nuisance alarm prevention via application of conditional alarming with P_Gate
- Prioritization and treatment of diagnostic alarms
- Populating Alarm Help directly based on the results of alarm rationalization
- Auditing & Enforcement to identify and correct changes in the PlantPAx alarm configuration
|Who Should Attend (Roles)||Who Should Attend (Responsibilities)|
Duration: 1 ½ days
- Printed Training Notes / Manual
- Option to take the Alarm Management Practitioner (AMP) Certificate Exam
- Two-week trial license of SILAlarm Rationalization Tool
- Alarm System Performance Assessment Report & Gap Analysis (System Dependent, one per site)