警報合理化
警報合理化服務在運行期間收集並分析警報及事件，以找出個別警報的根本原因並制定解決方案。同時提供基於 EEMUA#191 的警報系統設計服務，並協助定期審查以持續改進。
運營卓越轉型的關鍵領域
運營卓越轉型是 Yokogawa 與 KBC 共同創新的解決方案與服務組合。我們透過諮詢與數位技術，為業務自動化的四大領域提供完整解決方案。
運營風險管理
Yokogawa 的運營風險管理負責在個體及流程層面可靠且無風險地管理安全、健康與環境風險，涵蓋設計、可視化及協調工廠生產與業務系統的完整流程。
運營風險管理的核心能力
- 流程安全管理：維持運營許可（License to Operate）、保護企業聲譽，並透過遵循運營完整性流程創造價值，防止泄漏或重大損失
- 個人安全管理：提供安全操作規範以改善行為與文化，保護人力資產
- 環境管理：通過運營完整性保護環境，確保符合環境、法規及內部要求
- 社區關係：建立流程與規範以溝通及實施應急計畫，增進與社區的互動
- HSSE 報告與合規：透過流程、倡議及 KPI 的監控、學習與持續改進，確保 HSSE 目標及合規要求可見並達成
- 工廠規範與安全：提供保護資產及基礎設施的流程與策略，並控制對易受影響的流程與設備的存取
結合 Yokogawa 產品組合與 KBC 諮詢服務，我們為客戶提供最佳實務與領域知識，使其能改善運營，並提供支持此類活動與倡議的數位平台。我們的運營風險管理範圍不僅涵蓋組織內的局部改善，也涵蓋工廠運營的最佳化，以實現安全、可靠性與可操作性的持續提升。
·供應鏈優化
- 根據產品市場需求優化供應管理，無論是地上油料或煉油/化工資產的原料。為操作人員提供靈活性以充分利用市場條件。
·資產運營與最佳化
- 優化實體資產潛力，提升產量並最大化高價值產品產出，同時降低能源等可變成本。
- 按時按預算完成大小資本支出項目，以推動增長並滿足環境要求。
·資產管理與完整性
- 確保資產可靠性與可用性，同時控制維護成本。確保資產始終符合期望並可抓住短期市場機會。
警報合理化
隨著工廠運營變得更加複雜，適當的警報提示對工廠運營至關重要。Yokogawa 的警報合理化服務提供必要的工程或諮詢，以維持整個設施生命周期中定義的警報系統性能。
客戶挑戰
避免低效警報帶來的風險
近年來，工廠出現了警報洪水現象，導致重要警報被忽略，同時大幅增加操作人員的工作量。在有限的人力資源下，要實現更安全、更穩定且高效的工廠運營變得越來越困難。因此，警報驗證、優化與管理的必要性被廣泛認識為重要的對策。實施警報管理並非易事，因為管理及協調持續改進工作需要跨維護、工程、操作與流程控制等多個部門的資源協調。
我們的解決方案
經驗引導警報編寫流程
Yokogawa 的警報合理化服務旨在維持工廠整個生命周期的警報系統性能。我們的服務分三個階段：
- 基本煩擾警報減少：預備服務，用於識別現有煩擾警報的根本原因並採取適當對策以減少其發生
- 基於 IEC-62682/ISA18.2/EEMUA #191 的警報系統設計：主要服務，依據 EEMUA 指南及 ISA18.2/IEC-62682 標準建立一致的警報系統設計理念，並將其整合進 CAMS（整合警報管理系統）
- 基於運營狀態的警報管理：額外服務，根據不同運營狀態管理警報閾值及警報抑制
客戶可直接進入對應其警報合理化活動現況的階段。
客戶效益
優化警報帶來高水準的安全性
典型效益包括：
- 優化警報訊息，準確送達合適的人員及時間
- 操作人員在警報上花費的時間減少，可將更多精力放在真正的流程問題上
- 降低潛在風險，例如：
- 嚴重的工廠損壞
- 產量損失
- 環境事故
- 危及生命
Details
Yokogawa's alarm rationalization service is based on standardized Six Sigma DMAIC methodology. This provides clear and effective steps to achieve a defined target while ensuring consistent and high levels of service quality.
| Phase 1 Fundamental nuisance alarm reduction |
Phase 2 EEMUA #191-based alarm system design |
Phase 3 Operational state-based alarm management |
|
|---|---|---|---|
| 1. Define | Establish cross-section task force Set target alarm system performance in steady-state operation |
Establish cross-section task force Set target for alarm system performance during plant upset Hold on-site CAMS for HIS training for team members |
Establish cross-section task force Set target for alarm system performance in steady-state operation Hold on-site AAASuite training for team members |
| 2. Measure | Acquire A&E logs for multiple operational states | Acquire necessary information regarding current design policy Acquire A&E logs for past plant upset (where possible) |
Acquire A&E logs and historical trends for multiple operational states |
| 3. Analyze | Sort acquired A&E logs Identify root causes of nuisance alarms through team discussion Decide proper countermeasures to reduce them |
Analyze acquired information to identify improvements Establish new design policy based on EEMUA #191 guideline |
Analyze acquired data to decide target operational states and tags Analyze acquired data to decide proper alarm threshold or AON/AOF condition Consider application of DCS sequence program for automatic switchover |
| 4. Improve | Take practical countermeasures within two months | Incorporate new design policy in CAMS for HIS within two months | Incorporate new policy in AAASuite package Incorporate DCS sequence logic for automatic switchover Debug implemented application with FCS test function |
| 5. Control | Evaluate improvement effect Confirm remaining actions Report on results of service |
Evaluate improvement effect Report on new design policy |
Evaluate improvement effect Report on new design policy |
*1: This is a consulting service for CAMS for HIS (Phase 2)/AAASuite (Phase 3) installation.
*2: This service is provided by executing the above five steps of the DMAIC cycle.
參考
Alarm management is not just a project that has a start and end date; it's a continuous cycle. Once the alarm system has been reviewed and improvements have been identified, we must check that controls are in place to ensure the alarm system remains functional. The key is to ensure that the system is continuously monitored and any changes are fully documented. There are seven key steps for alarm management. Rationalization is one of those critical steps.
As plant operation becomes more intelligent and complex, the alarm system for safe and stable operation is becoming increasingly important. An alarm warns operators of an abnormal situation in a process and urges them to respond to it.
In recent years, safety and profitability have become ever more important in the process industry due to fierce global competition. Greater emphasis is being placed on highly efficient plant operation for reducing the increasing energy bill.
影片
Dr. Maurice Wilkins - executive advisor at Yokogawa speaks with Alastair Greener from the Business Reporter at the Daily Telegraph and shares his thoughts on Process plant operators, automation and how they need to work together in a crisis.
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