Professional Documents
Culture Documents
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Distribution
Managing Director
Deputy Manager Director(s)
Management Representative
Relevant Division Directors
QM Coordinators
Relevant Quality Manager(s)
M.Yousefi
1 25.04.2005 Issued For Implementation P.Khomarloo S.Hosseini M.Tavassoli
S.Rahimi Mofrad
0 21.07.2002 Issued For Implementation P.Khomarloo S.Hosseini M.Tavassoli K.Payvar
A 08.03.2002 Issued For Approval J.Ovaici S.Hosseini M.Tavassoli -
Rev. Date Description Prepared Checked Approved Authorized
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Table of Contents
1. Purpose ................................................................................................................3
2. Applicable Documents ..........................................................................................3
3. Definition ...............................................................................................................4
4. Overview ...............................................................................................................4
5. General Requirements ..........................................................................................5
6. Procedure .............................................................................................................6
6.1. Level Instrument ........................................................................................................... 6
6.1.1. Atmospheric Storage Tank (Also Can Be Used For Spherical Tank) ................... 6
6.1.2. Tower: (Distillation, Absorption and Extraction) .................................................... 7
6.1.3. Surge Drum (Horizontal) ....................................................................................... 7
File Ref.:\\Sazeh-001\QMS-DMS\Company Procedure\ED\ED MASTER\EDP MASTER\FS MASTER\PCD-FS-046-REV-1\PCD-FS-046-REV-1-Alarm Set Point.doc
1. Purpose
This working instruction represents the method for determination of set point of Alarm &
Switch / Interlock for some instruments, which used in gas and oil refinery and
petrochemical plants and is prepared for using in process department. Determination of
setting of Alarm and Switch is very important for plant safety, Because Alarm and
Switching/ Interlock instrument system protects plant form probable accidents. These data
will be used in operating manual and also, in latter for adjusting alarm and switch in
instrument control panel.
Process and system alarms are intended to assure efficient process-plant operations and
even, occasionally, save lives. But in too many plants, the alarm system has paradoxically
evolved into a nuisance.
This working instruction does not consider special instrument alarm and switch in package
units and also in licensed equipments.
Any information/data given in this work instruction is to be considered only as a guide. The
File Ref.:\\Sazeh-001\QMS-DMS\Company Procedure\ED\ED MASTER\EDP MASTER\FS MASTER\PCD-FS-046-REV-1\PCD-FS-046-REV-1-Alarm Set Point.doc
user could manipulate the given information according to the project specification outlined.
How many alarms are currently configured in the system or process you manage or that
you are designing? 25? 100? 1,000? How many of those alarms would go off in the first
minute of a process disruption or system shutdown? Would your facilitys operators know
which alarms to address first?
Now consider the finding that a typical operator can effectively deal with only one alarm
per minute during an upset. In light of this fact-of-life, it becomes easier to recognize the
value of alarm management in strengthening operational efficiency and averting costly
disruptions and incidents, often referred to as abnormal situations.
On the one hand, high alarm rates can promote a culture of operate by alarm, whereby
the alarm system drives the operators and, therefore, the plant. But there is also a
converse risk: when alarms proliferate, their collective value as a tool for diagnosing and
preventing problems declines. The alarms become a nuisance to operators, who
eventually will ignore or turn them off if the chattering (repeated activation) continues.
During normal operation, it is not uncommon to have one alarm activated every one to two
minutes, with some alarms chattering throughout a shift. When incidents occur, there can
easily be 30 to 50 alarms per minute 600 alarms per minute in extreme cases.
2. Applicable Documents
Reference documents are as follows:
- PFD
- Instrument Data Sheet
- P&ID
- Heat and Material Balance Table
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3. Definition
LAHH: Level Alarm High High: Shut - Down / One Switch Operates
LAH: Level Alarm High: Only Alarm
LALL: Level Alarm Low Low: Shut Down / One Switch Operates
LAL: Level Alarm Low: Only Alarm
D: Inside Diameter of Drum
L: Length of Drum
OP: Operating Pressure
OT: Operating Temperature
OFR: Operating Flow Rate
PDAH: Pressure Differential Alarm High
File Ref.:\\Sazeh-001\QMS-DMS\Company Procedure\ED\ED MASTER\EDP MASTER\FS MASTER\PCD-FS-046-REV-1\PCD-FS-046-REV-1-Alarm Set Point.doc
4. Overview
Alarm improvement projects are most successful when operators and engineers work
together. Start by forming a cross-functional team that will be the steering committee for
the project in pre-commissioning and commissioning duration. Sites that have
successfully implemented alarm improvement projects typically have included
representatives from the operations, process engineering, and safety departments, as well
as control engineering and instrumentation personnel, on their teams.
To determine the content of the alarm philosophy, the cross-functional team must
collectively answer the following questions:
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It is likely that in answering these questions, the team will grapple with some basic
philosophical and operational issues. But once the philosophy has been completed, it will
lay the groundwork for more-consistent and more-relevant alarming practices.
Although these ideas are captured in an official site document, that document should not
be regarded as immutable. A correctly prepared alarm philosophy is a living document
that needs to be refreshed, updated and changed as processes, technologies and
business objectives evolve.
Once the team reaches consensus on an alarm philosophy, its time to measure how well
the alarm system already in place is functioning.
In pre-commissioning and commissioning duration, the sequence of activities during this
File Ref.:\\Sazeh-001\QMS-DMS\Company Procedure\ED\ED MASTER\EDP MASTER\FS MASTER\PCD-FS-046-REV-1\PCD-FS-046-REV-1-Alarm Set Point.doc
5. General Requirements
The process engineer is responsible for determination of set points reflected on the Alarm
and set point List. Also any change in the data is responsibility of lead process engineer
and process department manager
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6. Procedure
The set point determination of alarm and switch for the following instruments types will be
considered:
- Level instrument
- Pressure instrument
- Temperature instrument
- Flow instrument
- Miscellaneous
Level alarm and switch / interlock set point for tanks, drums and towers shall be specified
based on the relevant sizing procedures, but generally the following guidelines can be
used.
6.1.1. Atmospheric Storage Tank (Also Can Be Used For Spherical Tank)
H= Height of tank
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H = Height of liquid stored in bottom of tower / height of transmitter top nozzle to tower
File Ref.:\\Sazeh-001\QMS-DMS\Company Procedure\ED\ED MASTER\EDP MASTER\FS MASTER\PCD-FS-046-REV-1\PCD-FS-046-REV-1-Alarm Set Point.doc
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H = Height of Drum
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H = Height of Pit
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6.2.4. Tower
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6.3.1. Heater
File Ref.:\\Sazeh-001\QMS-DMS\Company Procedure\ED\ED MASTER\EDP MASTER\FS MASTER\PCD-FS-046-REV-1\PCD-FS-046-REV-1-Alarm Set Point.doc
6.3.2. Reactor
6.3.3. Tower
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6.3.4. Utility
Utility items:
- Cooling water return
- Hot oil supply
- Sea water return
File Ref.:\\Sazeh-001\QMS-DMS\Company Procedure\ED\ED MASTER\EDP MASTER\FS MASTER\PCD-FS-046-REV-1\PCD-FS-046-REV-1-Alarm Set Point.doc
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TAH = 80-90C
6.3.7. Compressor
File Ref.:\\Sazeh-001\QMS-DMS\Company Procedure\ED\ED MASTER\EDP MASTER\FS MASTER\PCD-FS-046-REV-1\PCD-FS-046-REV-1-Alarm Set Point.doc
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6.4.2. Heater
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6.4.4. Pump
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6.5. Miscellaneous:
6.6. Reference
7. Attachments
None
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