Interacting with alarms is one of the basic functions your operators expect from their human-machine interface (HMI) software. However, if you’re only using the standard alarming functions, your operators might be missing out on lesser-known features that could help you save time and ease troubleshooting. We examine five FactoryTalk alarms and events functions that are often overlooked but could be helpful to operators.

1. Associated tags
In an HMI system, it’s useful to have additional system information associated with an alarm for streamlined reporting and more effective alarm handling. An alarm can be associated with up to four tags that are recorded in the alarm history log and also embedded in the alarm messages visible in an alarm summary or banner. By associating tags to include process data with event information and alarm messages, operators can receive relevant information automatically that describes what the system’s environment looked like when the alarm was triggered. For example, if you have a pump alarm associated with a flow-meter output value, a tank weight, and two process valves, you’d typically have to review trending data and activity reports to understand what might have contributed to an alarm becoming active. With associated tags, you get all pertinent information in one transaction which saves time and effort because it eliminates the need to run multiple reports and correlate the data in separate databases.

2. Alarm commands
Addressing the cause of an alarm in a time-efficient manner is a top priority for operators. However, an HMI system that correctly identifies alarm conditions does no good if the operator still has to click through multiple screens and open new programs to access the controls needed to correct the problem. Recent advancements allow new HMI software applications to be configured to execute a command when the user double-clicks on the alarm in the alarm summary. For instance, an operator can double-click an active alarm and have the appropriate screen displayed for them to take corrective action. This is especially effective in a large HMI system where the operator must have access to a process screen or device faceplate to understand the area of concern before taking action.

3. Preconfigured control-status alarms
HMI software should be tightly integrated with plant-floor controls and enable you to capture additional data beyond alarm and event information. Collecting data related to environmental factors, such as problems with controllers and other equipment, can help operators better understand what is happening in the system. Newer HMI applications incorporate preconfigured control-status alarms that indicate when an issue with a controller or its connection arises. In addition, operators should be able to run reports showing in-depth detail regarding the conditions of the alarm. For example, with preconfigured control-status alarms, when an operator sees that data isn’t updating into its system, he can review the alarm summary and immediately see that the controller is in program mode and not run mode. This saves the operator time because he’s no longer trying to figure out if something needs correction.
4. Alarm classes
When viewing many different alarms, it can be a time-consuming task to group like alarms together. Effectively organising alarms in an alarm summary or report can be simple when using alarm classes in some applications. The alarm class is a text string of up to 40 characters that operators enter when configuring an alarm. At run time, the value of the alarm class is recorded in the alarm history log, and the content is filtered based on the value of the alarm class. This enables you to easily sort or filter your alarms by function including, whether for valves that fail to open or close, pressure, temperature, equipment running or tank levels.

5. Remote alarm annunciation and escalation
The last often underutilised alarm-and-event function provides operators with remote access and control capabilities. Specter Instruments, a participating Encompass Product Partner in the Rockwell Automation PartnerNetwork, incorporates a FactoryTalk alarms and events subscriber plug-in for its Win 911 product. With remote alarm annunciation and escalation a FactoryTalk system notifies operators of alarms via text to speech (calling an operator’s cell phone), text pages, email or through voice-over TAPI modem. If the operator can’t be reached, the Win 911 product can use the escalation function if the nominated response rate is exceeded. For example, if the system gets no response when an operator is contacted, the system will escalate to the line supervisor. If the line supervisor doesn’t respond, the system will escalate to the plant manager, and so on until someone is reached who can address the alarm. Because the system is contacting people at home, it also gives employees the ability to remotely acknowledge and address the alarms.

Poorly managed alarms and events can be disasters waiting to happen. Use these hidden tools and start streamlining your alarm management.

Uncover more hidden alarm and event capabilities

Visit these websites to discover more alarm and event opportunities:

• Key features presentation of FactoryTalk Alarms and Events on SlideShare: http://slidesha.re/x4b4Jm

• FactoryTalk Alarms and Events photos on Flicker: http://bit.ly/xOiUGG

• Rockwell Automation Manufacturing Intelligence: http://discover.rockwellautomation.com/hmi