Data classification and performance evaluation for the most commonly-used univariate alarm systems

Alarm systems are critically important for safe and efficient operations of industrial plants, but many industrial alarm systems are suffering from too many nuisance alarms. This paper proposes a method to classify normal and abnormal data segments and evaluate performance indices for the most commonly used univariate alarm systems. The proposed method consists of three steps. First, piece-wise linear representations are exploited in separating historical data samples of an analog process variable configured with alarms into data segments with same qualitative trends. Second, data segments are classified into normal, abnormal and unclassified conditions via a mean hypothesis test; a required assumption is that data segments in normal and abnormal conditions have different mean values being distinguishable from alarm thresholds. Third, based on the normal and abnormal data, performance indices of univariate alarm systems are calculated, including two newly formulated ones as the false alarm duration ratio and the missed alarm duration ratio. The effectiveness of the proposed method is illustrated by numerical and industrial examples.     

Combining FAP,MAP and correlation analysis for multivariate alarm thresholds optimization in industrial process

In the real industrial process, alarm threshold optimization is an important part of alarm system rationalization. If the design of alarm threshold is unreasonable, it would result in nuisance alarms, among which the critical alarms are overwhelmed. In order to alleviate this phenomenon, we propose a method of multivariate alarm thresholds optimization to reduce the nuisance alarms. Firstly, causal relationship between process variables is constructed based on the time delay estimation method, thus we can determine the alarms propagation path and then select the optimized variables. Secondly, in order to guarantee both the process safety and correlation consistency, three factors - false alarm probability (FAP), missed alarm probability (MAP), and the correlation between the alarm information and process information – are combined to establish the objective function of the optimization process for the first time. Then, the optimal thresholds are obtained by the genetic algorithm. Finally, the validity and effectiveness of the developed method are illustrated by the Tennessee Eastman process.     

Alarm management optimization in chemical installations based on adapted HAZOP reports

Most current alarm systems used in chemical installations show poor performance due to alarm flooding. This study focuses on alarm management systems optimization using the deviation propagation relationship hidden in the hazard and operability study (HAZOP) report, which can be transformed into a critical information source for alarm optimization management. More concretely, this means matching the alarm tag number with the process deviations in the deviation column, possible cause column, and consequence column. Furthermore, a backtracking method and a reasoning method were established to identify the initial alarm and associated alarms. Besides, a root fault diagnosis was carried out. A method of detecting hardware faults and unreasonable alarm thresholds is established using alarm causality corresponding to the deviation causality and associated alarm generation-skipping tracing method. According to the severity of the consequence corresponding to the deviation, a determined alarm priority method is constructed. The results show that the deviation propagation relationship in the HAZOP report is clear, and the topological relationship is easy to build based on the deviation propagation relationship. With comprehensive and in-depth HAZOP analysis reports in China, the alarm management optimization technology based on adapted HAZOP reports shows good prospects for application and promotion.     

Integrating probabilistic signed digraph and reliability analysis for alarm signal optimization in chemical plant

The alarm system given in industrial plants are massive and complex. Under such condition, critical alarms are overwhelmed by false and unnecessary alarms and thus result in severe safety issues. To address the problem, this paper proposes a probabilistic signed digraph (PSDG) based alarm signal selection method that requires achieving maximal system reliability. In this method, a PSDG model is firstly constructed to visualize the causal relations between process variables. Then the criteria of observability and identifiability are imposed to determine the candidate alarm variables that can qualitatively distinguish all assumed faults. Instead of selecting the minimum number of combinations of candidate variables, the alarm variables are optimized by a reliability formulation that takes into account the missed alarm and false alarm probabilities of the system; this formulation is solved by the receiver operating characteristic (ROC) graph. Finally, the developed methodology is illustrated using a Tennessee Eastman process.     

基于数据驱动的石化装置静态报警抑制策略研究

由生产状态变化引起的误报警频发,为解决现有针对基于状态报警的抑制方法缺乏完整性与定量分析的问题,提出了新的报警抑制策略。通过分析报警记录等数据库,对引起报警的生产条件进行结构化整定并量化,利用分类筛选与数据过滤找出基于状态的报警,再结合关联性分析和概率判断,建立了基于数据驱动的静态报警抑制策略。使用现场数据的试验证明了该方法的有效性。     

A risk-based approach to design warning system for processing facilities

Alarm flooding is a major safety issue in today's processing facilities. Important recommendations are available for alarm management; however, they are often violated in practice, especially in the alarm systems implemented through the distributed control system. An effective process alarm prioritization and management system is desired for a safe and effective operation of a process facility.In present work, authors address two main issues related to an alarm system – the reliability and the prioritization of the alarms. The main objective is to deal with the alarm-flooding problem in process facilities. A multi alert voting system based on sensor redundancy approach is proposed to improve the reliability. A quantitative risk-based alarm management approach is proposed to address the flooding issue. In the risk-based approach, an integrated model consisting of the probability (P), the impact (I) of the potential hazards, and the process safety time is proposed to prioritize these raised alarms.The proposed approach is further explained by a reactor system with pressure and temperature variable monitoring and controls, where the hazards associated with two alerts caused by over high pressure and over high temperature are analyzed and integrated with response time for alarms generation and prioritization.     

基于贝叶斯估计的多探测器火警判定方法研究*

为应对感烟探测器的大量误报对消防应急响应带来的挑战,考虑目前以感烟探测器为主的火警设施误报率高且短期内难以全部更换的特点,提出基于贝叶斯估计的多探测器火警判定方法,通过多个探测器的报警时间间隔计算火源位置的后验概率分布,并提出火警真实度概念,为火警判定提供依据。结果表明:使用多探测器耦合模型时每增加1个探测器可将误报率降低约4个数量级,该方法在探测器正常、部分失效、误报的情景下均能有效判别火警。     

Comprehensive alarm information processing technology with application in petrochemical plant

During the abnormal plant conditions, too much information is produced due to momentary plant excursions above alarm limits. This flood of information impedes correct interpretation and correction of plant conditions by the operator. Existing techniques for the design of alarm systems mostly have weak ability to handle complex hazard scenarios and increase the probability of larger safety issues. In this paper, a comprehensive alarm information processing (AIP) technology is introduced, called multi-round alarm management system (MRAMS), including several processing strategies: AIP based on single sensor, AIP based on sensor group, root cause diagnosis based on Bayesian network, sensor fault judgment method and false alarm inhibition method. In case studies, both simulation experiment and pilot application on a real petrochemical plant are presented. Results indicate the MRAMS is helpful in improving the accuracy of correctly diagnosing the root causes and hence avoiding false and redundant alarms. By adopting this new technology, the safe and reliable operation of the plant can be achieved, and the economic loss brought by improper alarms can be reduced.     

基于化工生产过程历史数据的报警优化方法研究

为了有效降低报警装置漏报率和误报率,基于化工生产的过程历史数据,探讨了报警优化的两种方法。以误报率和漏报率为优化指标,建立报警阈值目标函数,从最小化目标函数的角度出发,采用数值优化的方法进行报警阈值的优化设计。基于报警时长的变异系数,应用自适应报警延时方法来降低报警数量。实例研究表明,应用基于化工生产过程历史数据的方法,可有效减少无效报警数量,降低误报率和漏报率,提高报警质量,对于提高石化生产过程的安全性具有积极意义。     

多传感器耦合区域火灾报警技术研究

早期预警与低误报率一直是建筑火灾探测面临的挑战与难题。已有研究多针对特殊场所特定燃烧产物或多种传感器耦合,普适性不强,探测设备成本高,无法大规模应用。通过将火灾烟气蔓延规律与探测器信号时空分布融合,在不增加探测器数量和分布的情况下,提出了一种基于建筑结构微元的多传感器耦合区域火灾报警模型。对典型火灾场景的烟气蔓延情况进行了模拟分析,狭长结构中探测器信号强度变化具有一定的规律性。应用区域火灾报警模型后,报警时间较传统模式提前了14.7%,基本杜绝了单个探测器误报引发建筑物火灾报警的问题。结果表明:多传感器耦合探测模式显著缩短了火灾报警时间,降低了火灾探测误报率,实现了火灾的早期准确识别与预警。     

潮湿引起感烟火灾探测器误报研究

针对潮湿现象成为典型的火灾探测误报源 ,在火灾探测综合模拟实验平台中 ,通过收集水沸腾形成的水雾进行加湿 ,研究了冬季与夏季潮湿环境 ,对散射型光电感烟火灾探测器的发生误报影响。通过比较探测器的输出值与其附近湿度变化曲线 ,从原理上分析了误报发生的原因。实验结果表明 :在气温较低的冬季 ,水蒸气较易形成液态小水珠 ,容易导致感烟探测器误报警 ,而在夏季由于气温较高 ,这种情况较难发生。对相对湿度较高或达到饱和湿度 ,以及非火灾因素的雾气或微细水珠 ,对感烟探测器可靠性的影响 ,开展下进一步的工作进行了展望     

Fault diagnosis of pipeline and pump unit systems using status coupling analysis

Earlier studies on fault diagnosis of the pipeline and pump unit systems (PPU) relied mainly on independent equipment analyses, which usually lead to false alarms because of the loss of information fusion. The aim of this study is to utilize the status coupling relationship to improve fault detection sensitivity and reduce false alarm rate. A real-time status identification of related equipment step is added between capturing abnormal signals and listing out diagnosis results. For example, when the pipeline pressure fluctuation is found abnormal, a status analysis of pump units is performed immediately, if the pump units are proven to be operational normally, then the pipeline leak alarm is acknowledged valid. The logical reasoning algorithm is used to capture abnormal conditions of pipeline pressures. The pump unit faults are captured by combining information from multiple sources. Field applications show that the proposed method significantly improves the PPU fault detection capability on fault detection sensitive and accuracy.     

Hazards equal trips or alarms or both

Anyone who has been involved in the application of IEC 61508 and IEC 61511 by undertaking the Safety Integrity Level (SIL) determination for Safety Instrumented Systems (SIS) will appreciate the amount of effort and tenacity that is required to undertake the task. SIL determination of Safety Instrumented Systems requires considerable commitment and tenacity to get the job done, but it is like climbing to the top of a hill only to be faced with a mountain when we come to consider what is involved in reviewing or configuring a typical alarm system.A medium sized process facility may have a few hundred or so primary Safety Instrumented Functions (SIF) or trips configured into a Safety Instrumented System, but the number of alarms configured into a process control system (PCS), that need to be assessed and prioritised, can often run into the thousands.There is synergy between safety instrumented functions and alarms because they both make a contribution to reduce the risk of having unwanted events, and both need an assigned appropriate criticality.This paper details various methods of criticality assessment which have been successfully applied to set the appropriate priority, identify the critical alarms that need to be upgraded to trips and to rationalise those of no value. It will also cover the use of software tools which can significantly reduce the effort involved in this process.     

A cost analysis of a smoke alarm installation and fire safety education program

INTRODUCTION: While smoke alarm installation programs can help prevent residential fire injuries, the costs of running these programs are not well understood. METHOD: We conducted a retrospective cost analysis of a smoke alarm installation program in 12 funded communities across four states. Costs included financial and economic resources needed for training, canvassing, installing, and following-up, within four cost categories: (a) personnel, (b) transportation, (c) facility, and (d) supplies. RESULTS: Local cost per completed home visit averaged 214.54 dollars, with an average local cost per alarm installed of 115.02 dollars. Combined state and local cost per alarm installed across all four states averaged 132.15 dollars. For every 1% increase in alarm installation, costs per alarm decrease by 1.32 dollars. CONCLUSIONS: As more smoke alarms are installed, the average installation cost per alarm decreases. By demonstrating effective economies of scale, this study suggests that smoke alarm programs can be implemented efficiently and receive positive economic returns on investment.     

基于BP神经网络的受限空间火灾联合探测方法

针对航空受限空间火灾探测高误报的问题，在现有技术成果基础上对多种火灾探测方式进行研讨，并提出1种基于BP神经网络技术的飞机机身内部受限空间火灾联合探测报警方法。该方法结合现有烟雾感应、气体传感器探测等常用火灾探测技术，以红外热成像探测为辅助手段，采用神经网络实现数据融合，对模拟实验舱火灾烟雾进行联合探测，在单一火灾探测方式基础上提高了探测准确率。     

水蒸气引起感烟火灾探测器误报研究

针对水蒸气这种典型的火灾探测误报源．在自行研制的火灾探测综合模拟实验平台中,通过收集水沸腾形成的水雾模拟水蒸气干扰源,研究了冬季与夏季,即不同环境温度务件下,水蒸气对散射型光电感烟火灾探测器的误报影响。通过比较感烟火灾探测器的输出值与其附近湿度变化曲线,分析了误报发生的原因。结果表明在气温较低的冬季,水蒸气较易形成液态小水珠,容易导致感烟火灾探测器误报;而在夏季由于气温较高,这种误报不易发生。     

Perceptions of implied hazard for visual and auditory alerting signals

Visual and auditory alerts are increasingly important and have many applications, particularly in the presentation of hazard information in transportation and many industrial systems. This paper is concerned with the factors that govern the relative effectiveness of alerting signals involving various combinations of visual and auditory signals. The visual variables were colour, flash rate, and flash mode, combined with or without an auditory alarm. It was found that the subjects associated different levels of hazard with different alerting light colours, flash rates, flashing modes, and with combinations of auditory and visual alerts. A red flashing light was perceived as the most effective hazard warning colour, with yellow and blue warning lights indicative of less hazardous situations. The faster the flash rate, the greater is the hazard perceived. A flash rate of 60 fpm (flashes per minute) was not as effective as the rates of 180 and 240 fpm, and 240 fpm was the most effective. This implies that hazard warning signal should flash at well above 60 fpm. Having a breakup in the flashing pattern so as to provide a double or triple flash mode also increases the effectiveness of the signal. There were significant interactions between the alert variables used. The difference in perceived hazard levels for the colours blue and yellow were statistically non significant, but blue was more effective in conveying hazard message than yellow at the high flash rates. When accompanied with auditory alarms, blue and yellow were perceived to convey the same perception level of hazard as red without auditory alarms. The effect of colour on perceived hazard was also found to vary with flash mode. As compared to either visual signal alone or a visual signal with other types of acoustic alarms, a siren type of auditory alarm was found more effective for eliciting perception of hazards. There was evidence that presenting alerting signal in triple-flash mode and at high flash rate could be annoying and might not help improving hazard awareness.     

Evaluation and comparison of alarm reset modes in advanced control room of nuclear power plants

An automation function has been widely applied in main control room of nuclear power plants (NPPs). The alarm system of fourth nuclear power plant (FNPP) in Taiwan is also going to be developed with automatic technology that is expected to support the operators’ performance and reduce the number of alarms. In this study, an experiment with a training simulator as an advanced alarm system was conducted to compare the effects of different alarm reset modes on performance and subjective ratings. The objective was to evaluate the practicability of alarm system with only auto-reset function in FNPP. Results revealed that, using the auto-reset mode, participants had lower task load index (TLX) on effort in the first test trial and was more satisfied under multi-task condition. In contrast, using manual reset mode, participants were more satisfied on alarm handling, monitoring, and decision making. In other words, both reset modes are necessary to assist the operator in different aspects, but with only single reset mode is insufficient. The reset function in advanced alarm system therefore should be very flexible.     

相关关系和因果关系在事故分析中的应用——研究综述与启示

从事故中吸取教训是安全科学的主要任务,回顾拆解曾经的研究成果,从理论基础研究和应用实践研究两个方面进行了文献综述,以期达到总结前期成果和启示后续研究的目的。结果表明,在横向研究中,一方面在全学科的宏观层面,相关和因果的研究在经济与管理科学和社会科学中的开展较为成熟,而在安全科学与灾害防治领域还处于发展阶段。同时自2003年至2012年,是相关关系和因果关系研究成果的快速发展时期;另一方面在生产安全事故范围的微观层面,相关和因果的研究相对集中于事故控制阶段的相关关系的研究;在纵向研究中,对于生产安全事故分析时需要进行的描述、解释、预测和控制4个阶段中在选取相关关系和因果关系时有所侧重,在事故描述阶段偏重使用相关关系;在事故解释阶段,如果是解释事故发生的可能性主要偏重使用因果关系。如果是解释事故发生的损失程度主要偏重使用相关关系;在事故预测阶段,偏重相关关系;在事故控制阶段偏重因果关系。