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Module 5 Part-3

The document discusses the importance of Database Management Systems (DBMS) in industrial automation, highlighting various types of databases such as relational, NoSQL, and time-series databases. It also covers the role of Alarm Management Systems in ensuring safety and operational efficiency, detailing their design standards, common problems, and a seven-step approach to effective alarm management. Challenges in industrial database management, including big data handling and cybersecurity threats, are also addressed.

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Devang Patel
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6 views

Module 5 Part-3

The document discusses the importance of Database Management Systems (DBMS) in industrial automation, highlighting various types of databases such as relational, NoSQL, and time-series databases. It also covers the role of Alarm Management Systems in ensuring safety and operational efficiency, detailing their design standards, common problems, and a seven-step approach to effective alarm management. Challenges in industrial database management, including big data handling and cybersecurity threats, are also addressed.

Uploaded by

Devang Patel
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Module 5

Manufacturing Execution System (MES)


and
Enterprise Resource Planning (ERP)

Prof. Nisy Elsa Mathew 1


Database Management System
➢ Database management plays a crucial role in handling large volumes of real-time
and historical data.
➢ It ensures efficient data storage, retrieval, security, and analysis in industrial
control systems.

Types of Databases Used in Industrial Automation

1. Relational Databases (SQL-based)


• Examples: MySQL, PostgreSQL, Microsoft SQL Server.
• Used for structured data storage with predefined schemas.
• Suitable for alarm logs, maintenance records, and batch processing.
Database Management System
2. NoSQL Databases (Non-relational)
Examples: MongoDB, Cassandra, InfluxDB (time-series database).
Handles unstructured or semi-structured data like sensor readings and IoT
data.Ideal for real-time applications and scalable architectures.

3. Time-Series Databases
Examples: InfluxDB, TimescaleDB.
Optimized for storing and analyzing time-stamped data like temperature,
pressure, and machine status.
Commonly used in SCADA and predictive maintenance systems.
Industrial Applications of Database
Management

Predictive Maintenance: Analyzes machine data to detect potential failures before


they occur.Reduces downtime and maintenance costs.
Alarm Management & Event Logging:Stores and categorizes alarm events for root
cause analysis.Helps in refining alarm settings to avoid nuisance alarms.
Production Monitoring & Quality Control:Tracks production data, machine
efficiency, and defects.Ensures consistency in manufacturing processes.
Energy Management & Optimization: Monitors energy consumption
patterns.Helps industries reduce power costs and enhance sustainability.
Challenges in Industrial Database
Management

Big Data Handling: Managing massive real-time data efficiently.


Cybersecurity Threats: Ensuring protection from data breaches and cyber-
attacks.
System Downtime & Data Loss: Implementing redundancy and backup
strategies.
Data Standardization: Integrating multiple industrial protocols and formats.
Alarm Management System
The purpose of alarm management system is to alert the operator to relevant abnormal operating
situations. They include situations that have a necessary or possible operator response to ensure:

• Personnel and Environmental Safety,


• Equipment Integrity,
• Product Quality Control.

Alarms were added to alert the operator to a condition that was about to exceed a design limit, or had
already exceeded a design limit.

Additionally, Emergency Shut Down (ESD) systems were employed to halt a process that was in danger of
exceeding either safety, environmental or monetarily acceptable process limits
Alarm Indications and Visualization
Annunciator horns alert operators to Panel boards are organized to reflect the
abnormal conditions. They provide plant's process flow. This layout aids
audible warnings that indicate the operators in quickly identifying issues
severity of the situation. within the system.
• Green → Normal operation
• Yellow → Caution, potential issue
• Red → Critical condition, immediate Instrumentation design incorporates
attention required behavioral psychology for optimal
information processing. It ensures that
Alarm lights use color coding to convey operators can quickly assess the status of
the status of the system. Green the plant.
indicates normal operation, yellow
signals caution, and red denotes
danger.
Why Alarm Management System?
• Alarm management is usually necessary in a process manufacturing environment that is
controlled by an operator using a supervisory control system, such as a DCS, a SCADA or a
programmable logic controller (PLC).
• Since humans can only do one thing at a time, there need to be a way to ensure that alarms
are presented at a rate that can be assimilated by a human operator, particularly when the
plant is upset or in an unusual condition.
• Alarms also need to be capable of directing the operator’s attention to the most important
problem that he or she needs to act upon, using a priority to indicate degree of importance
or rank, for instance.
• To ensure a continuous production, a seamless service, a perfect quality at any time of day
or night, there must be an organisation which implies several teams of people handling, one
after the other, the occurring events.
Alarm Management System

01 02 03
Alarm systems alert Alarm systems are not However, where a risk reduction
operators to plant conditions, normally safety related, but of better than 10-1 failures on
such as deviation from do have a role in enabling demand is claimed then the
normal operating limits and operators to reduce the alarm system, is a safety related
to abnormal events, which demand on the safety related system which requires a suitable
require timely action or systems, thus improving safety integrity level (SIL 1 or SIL
assessment. overall plant safety. 2 as defined by IEC61508).
Safety Related Alarm Systems
Design Standards: Alarm System Independence
Safety-related alarm systems must be Alarm systems should be independent
designed according to IEC 61508 from process control systems unless
standards. designated as safety-related.
This ensures compliance with necessary This independence is vital for
safety requirements. maintaining safety function integrity.

Safety Integrity Levels Risk Reduction Claims:


Safety integrity levels (SIL 1 or SIL 2) are If risk reduction claims exceed a certain
crucial for alarm systems. threshold, the alarm system is deemed
They indicate the reliability in preventing safety-related.
hazards. It must meet specific safety integrity
levels.
Alarm System Guidance in Regard to Safety
Related Alarm Systems:
• The alarm system should be designed in accordance with IEC 61508 to safety integrity level(SIL) 1 or
2, with the designated reliability;
• The alarm system should be independent from the process control system and other alarms unless
it has also been designated safety related;
• The operator should have a clear written alarm response procedure for each alarm which his simple,
obvious and invariant, and in which he is trained;
• The alarms should be presented in an obvious manner, distinguishable from other alarms, have the
highest priority, and remain on view at all times when it is active;
• The claimed operator workload and performance should be stated and verified.
Common Alarm Management Problems
Nuisance Alarms: Alarm Settings
Nuisance alarms can lead to operator Incorrect alarm settings can contribute
desensitization. to alarm overload.
They often arise from faulty hardware or Regular rationalization and
incorrect settings. management of change are necessary.

Insufficient Training Alarm Flooding:


Insufficient training can leave operators During upsets, operators may face an
unprepared for alarm responses. overwhelming number of alarms.
Clear alarm response procedures are This can result from poor prioritization
essential for effective management. of alarm signals.
7 Steps to Alarm Management
Step 1: Create and adopt an alarm philosophy: A comprehensive design and guideline document is
produced which defines a plant standard employing a best-practise alarm management methodology.

Step 2: Alarm performance benchmarking: Analyze the alarm system to determine its strengths and
deficiencies, and effectively map out a practical solution to improve it.

Step 3: “Bad actor” alarm resolution: From experience, it is known that around half of the entire alarm
load usually comes from a relatively few alarms. The methods for making them work properly are
documented, and can be applied with minimum effort and maximum performance improvement.

Step 4: Alarm documentation and rationalisation (D&R): A full overhaul of the alarm system to ensure
that each alarm complies with the alarm philosophy and the principles of good alarm management.
7 Steps to Alarm Management
Step 5: Alarm system audit and enforcement
DCS alarm systems are notoriously easy to change and generally lack proper security. Methods are
needed to ensure that the alarm system does not drift from its rationalised state.

Step 6: Real-time alarm management: More advanced alarm management techniques are often needed
to ensure that the alarm system properly supports, rather than hinders, the operator in all operating
scenarios. These include Alarm Shelving, State-Based Alarming, and Alarm Flood Suppression
technologies.

Step 7: Control and maintain alarm system performance: Proper management of change and longer
term analysis and KPI monitoring are needed, to ensure that the gains that have been achieved from
performing the steps above do not dwindle away over time. Otherwise they will; the principle of “entropy”
definitely applies to an alarm system.

Reference: https://instrumentationtools.com/alarm-management-system/
Alarm Management Problems

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