Remote locations with industrial assets that don't have anyone locally monitoring performance need alarms (for starters). Alarms can be used to monitor data for anything out of the ordinary, catching smaller deviations, and alerting an operator to a possible situation before it escalates. When it comes to effective remote operations management, there are few better tools available than alarming capabilities.
However, while alarms are a great feature that can help avoid damage to equipment or prevent financial loss, effective alarm management requires work. I’ve seen it happen many times where operators learn to ignore alarms that are poorly set up or improperly maintained, completely invalidating their ability to act as an early warning system. If given the appropriate time and attention, the obstacles preventing effective alarm management can be overcome and then demonstrate the many benefits alarms can provide.
The biggest obstacles operators face when dealing with alarms is as follows:
1. Planning
This is the design stage, where the overall system and methodology is thought out and documented. This step does take time and the involvement of the operations team (being familiar with all of the dynamics). Considerations should include:
- Which locations to alarm, and what values to monitor
- How (and who) to notify with the alarm, and when
- What to do once an alarm is received
- When to review alarms
2. Execution
Once an alarm philosophy has been agreed upon and documented, there is still the hurdle of configuration. With many different hardware solutions, there is no one method for setup. This is where expertise is generally required to avoid poorly configured alarms. Devices that support alarming can be active or passive, with single or multiple levels of priority, possibly with alarm exceptions, cryout, scheduling, escalations, contact groups, etc. Often, these requirements overwhelm, hindering implementation.
3. Notification
With all the communications technology available today, deciding on the method of notification can be challenging. Messages can be sent electronically via text (SMS), or voice (text-to-speech or call center), or simply an email alert. The problem with most methods is the lack of confirmation that alarm was actually received. That is why some companies have chosen to use services like call centers.
Notification plans should also include an escalation path. Should a contact be unable to receive an alarm due to poor reception for example, then the alarm notification should be escalated and the next in line advised. Dealing with shift schedules can likewise be difficult. Alarm systems can sometimes deal with multiple contacts, contact groups or changing shifts. When this happens, the alarms need to be reconfigured or the alarm will be misdirected.
4. Upkeep
Deficiencies in the alarm philosophy can occur over time as wells change priority, technology progresses, and operations restructure. It is important to rationalize the need for alarming at each level as well as the status at each location. As wells change over time and enter into different flowing states, these changes require constant adjustment of alarm set-points and possibly even switching sensors monitored. Even personnel changes require updating, and dealing with schedules or contact groups can add further complication.
5. Change Management
Once a system is in place, there should be a regular review to ensure optimal conditions are maintained. As mentioned, maintenance of alarm setup is vital to avoiding bad alarms. Who should be left to this sizable task though? There is not always enough time for an operator to manage alarms, thereby rushing the process. This can result in limited or no alarms, false alarms, or a flood of alarms. If left unchecked, alarming can drop off due to deactivation of poorly performing alarms (due to incorrect setup).
Change Management ensures proper execution of the alarm system and methodology. Required changes go through an approval process that is documented for audit purposes. Key performance indicators are assessed regularly to confirm the benefit of alarming at each level.
Summary
Many of these obstacles are enough to prevent companies from effectively adopting alarms and thus realizing the true value of alarming. Alarms are meant to support operators, not hinder them. Thankfully, when you recognize these obstacles before they happen, there are solutions to overcome them.
