A combined analysis of plant connectivity and alarm logs to reduce the number of alerts in an automation system

• The work groups alarms having the same cause in an industrial control system.
• It uses a model of the plant topology.
• It reduces the number of alerts presented by an alarm system to an operator.
• The work is illustrated with industrial control studies.
• Grouping reduced the alarm messages by 70–80% and provided better information.

A process alarm arises when normal operation limits are exceeded and an alarm management system alerts the operator of a process plant. Due to the material, energy and information flow in a plant, single disturbances can cause multiple consequent alarm messages, and the alarm messages may overload the operator by presenting many redundant alarms. This undesired situation is called an ‘alarm flood’. In such situations, the operator might not be able to fulfil his required tasks to keep the plant within safe operation limits and to find the root cause of the disturbance. The aim of the work presented in this paper is to reduce the number of alerts presented to the operator. If alarms are related to one another, those alarms should be grouped and presented as one alarm problem. For the implementation of the concept, a software prototype has been developed to perform this reduction automatically. The analysis process starts with the alarm history which is a log containing all past alarm messages. This is combined with the plant topology of the controlled system and a set of rules. The rules describe typical interrelations between alarm messages which have a common cause. The combination of these three elements yields an effective alarm management strategy that can help plant owners and operators to comply with standards for alarm management such as ANSI/ISA 18.2 (2009) and EEMUA 191 (2007) which set limits on the number of alarms per unit time for an operator. The effectiveness of the approach is illustrated by two industrial examples where a significant reduction of alarms has been achieved.