A new method for defining and managing process alarms and for correcting process operation when an alarm occurs

Abstract

A new mathematical treatment of alarms that considers them as multi-variable interactions between process variables has provided the first-ever method to calculate values for alarm limits. This has resulted in substantial reductions in false alarms and hence in alarm annunciation rates in field trials. It has also unified alarm management, process control and product quality control into a single mathematical framework so that operations improvement and hence economic benefits are obtained at the same time as increased process safety. Additionally, an algorithm has been developed that advises what changes should be made to Manipulable process variables to clear an alarm. The multi-variable Best Operating Zone at the heart of the method is derived from existing historical data using equation-free methods. It does not require a first-principles process model or an expensive series of process identification experiments. Integral with the method is a new format Process Operator Display that uses only existing variables to fully describe the multi-variable operating space. This combination of features makes it an affordable and maintainable solution for small plants and single items of equipment as well as for the largest plants. In many cases, it also provides the justification for the investments about to be made or already made in process historian systems. Field Trials have been and are being conducted at IneosChlor and Mallinckrodt Chemicals, both in the UK, of the new geometric process control (GPC) method for improving the quality of both process operations and product by providing Process Alarms and Alerts of much high quality than ever before. The paper describes the methods used, including a simple visual method for Alarm Rationalisation that quickly delivers large sets of Consistent Alarm Limits, and the extension to full Alert Management with highlights from the Field Trials to indicate the overall effectiveness of the method in practice.