June 2025
Process Controls, Instrumentation and Automation
The implementation and automation of an alarm management system in a complex control environment at KNPC’s Mina Al-Ahmadi refinery
This work details how the integration and automation of alarm management system applications at Kuwait National Petroleum Co.’s Mina Al-Ahmadi refinery have resulted in numerous benefits that have optimized plant operations.
Kuwait National Petroleum Co.’s (KNPC) Mina Al-Ahmadi (MAA) refinery is a complex refinery employing different distributed control systems (DCSs) installed in multiple control rooms. One of the main objectives of process control and automation is to employ process control applications and tools for safe, optimum and enhanced operations. Due to the recent advancements in process control and operations technologies, the MAA refinery also strives to acquire the latest state-of-the-art technology to assist operations with optimum performance in a safe environment.
In the recent past, the MAA refinery has implemented alarm management system (ALMS) applications and associated tools to retrieve, store and historize process unit alarms and events data from different DCSs. ALMS data is utilized to create reports, develop key performance indicators (KPIs) as per international standards, and conduct alarm rationalization and incident investigations.
Due to the complexity of control rooms and the installation of multiple DCSs, implementing and integrating ALMS with the DCSs were achieved by utilizing different types of interfaces and gateways. Additional efforts were made to ensure the seamless and safe transfer of ALMS data and events from operational technology (OT) to informational technology (IT) environments within the realm of OT and IT cybersecurity.
The implementation strategy. Based on communication protocols and interfaces, multiple alarm collectors were installed and configured to Level 3 (L3) to interface with the DCS devices and gateways resident on L2 and L3. The MAA refinery utilizes two different ALMS software across five main control rooms, numerous field auxiliary rooms (FARs) and remote control rooms. The primary role of alarm collectors is to collect process alarms and events, operator actions, system alarms, diagnostic alarms, and instrumented protective systems/fire and gas systems (IPSs/FGSs) sequence of events.
Multiple archivers are installed on L3.5 (DMZ) to segregate and store alarms’ data from different control rooms and DCSs (FIG. 1). Archivers are configured to retrieve alarms data from the collectors. It then processes messages with different formats received from the collectors and stores in the archiver database. The design and number of archivers are based on the size of the databases and long-term historization—this allows end users to access current and historized alarms data with ease and enables fast response.
A cross domain server is integrated with all archivers to provide data and reporting tools to refinery-wide users via applications and a graphical user interface (GUI) on a web platform (FIG. 1).
FIG. 1. Multiple archivers are installed on L3.5 (DMZ) to segregate and store alarm data from different control rooms and DCSs.
Some of the tools available to the end user include:
- The availability of online DCS alarms data (historic and current) for analysis and reporting
- The generation and customization of different types of reports, KPIs and alarms data, which can be exported to Excel for further analysis and troubleshooting
- Graphical representations of different types of alarms and KPIs.
KPIs. ALMS KPIs have been customized utilizing ALMS software and associated tools to reflect compliance with international standards and guidelines. These KPIs are automated and reported to all the stakeholders for follow up, recommendations and necessary actions. These KPIs assist in ascertaining bad actors, and subsequent actions allow refinery personnel to achieve desired targets as per international standards [e.g., the Engineering Equipment and Materials User Association (EEMUA) 191 and International Society of Automation (ISA) 18.2]. Some KPIs of the ALMS are shown in FIG. 2.
FIG. 2. A few KPIs of the ALMS.
ALMSs play an important role in safety, optimization and enhanced operations in industrial processes. The implementation and integration of ALMSs across various systems pose unique challenges.
Key challenges. Key challenges include:
- Integration with legacy systems: The integration with old DCSs that lack standard data formats or have restricted communication capabilities and do not support the latest and standardized communication protocols like open platform communication (OPC) and open database connectivity (ODBC).
- Alarm database size: Proper sizing of alarm database to ensure that alarms data transfers from the collectors to archivers are seamless with no extended delays.
- Alarms categorization: Careful planning and designing are required to ensure that the ALMS database is populated with the required alarms, so the database does not get overloaded with unnecessary alarms and messages.
- Configuration and maintenance: Complex ALMS setups require specialized expertise in SQL, DCS configuration, network configuration and software (e.g., OPC, ALMS, backup and recovery) that end up increasing resource demands. This requires close coordination between IT and OT teams.
Best practices. The following are some best practices:
- Data standardization: Conduct detailed assessment of existing DCSs and interfaces to define a clear plan for communication protocols. Standardize the message format at the DCS level, and use the latest and open protocols (e.g., OPC, ODBC). Establish a robust rule file that can process events and messages to avoid junk data being stored in the ALMS database.
- ALMS server virtualization: The virtualization of ALMS servers is highly recommended to ensure high availability and uptime of the ALMS, as well as quick and easy recovery of ALMS applications in case of errors and/or corruption. This includes dynamic online allocation of resources to meet ALMS database requirements and expansion.
- End user training: Provide training to end users for maximum usage of ALMS applications and associated user tools.
Automating the MAA refinery’s ALMS has resulted in the reduction of nuisance and chattering alarms, has provided a way to benchmark against international standards, and has increased operator efficiency by eliminating distractions from unwanted alarms or nuisance alarms where no action is required from the control room operator. Automation and the continuous availability of process and instrument alarms data for refinery-wide users have also assisted in engaging a proactive approach to the alarm rationalization, maintenance and troubleshooting of field devices to ensure safe and continuous operations to reap maximum benefits and profits.
Takeaway. With the recent advancements in technology and availability of control support applications, the role of ALMSs has taken a center stage to fulfill the requirements of safe and enhanced operations. ALMSs have become imperative to ensure compliance with international standards for insurance-related commitments and safe operations. ALMS KPIs assist in ascertaining bad actors on a continuous basis. Subsequent actions allow refinery personnel to achieve their desired targets as per international standards.
Unique challenges were posed due to the complexity of the control rooms and installations of multiple DCSs at KNPC’s MAA refinery. The implementation and integration of ALMSs with the DCSs was achieved by utilizing different types of interfaces, gateways and communication protocols. Additional efforts were made to ensure a seamless and safe transfer of ALMS data and events from OT to IT environments within the realm of OT and IT cybersecurity.
The integration and automation of ALMSs at the MAA refinery have resulted in numerous benefits that have optimized plant operations.
The Authors
Ahmed Maqbool is a Specialist Process Control Engineer at KNPC’s MAA refinery. He has 28 yr of experience in various fields of OT technology. His key areas of expertise includes process control, control systems design, advanced process control, data acquisition systems, ALMSs, real-time databases, ICSS cybersecurity and systems integration. He has initiated and worked on numerous projects to introduce and integrate state-of-the-art technologies in the OT environment. He earned MS degrees in chemical engineering and computer science from Florida Institute of Technology in Melbourne, Florida.
Shekha Al-Mansour is a Senior Process Control Engineer at KNPC’s MAA refinery. She has associated with the oil and gas industry for the last 15 yr. She earned a Bch degree in chemical engineering from Kuwait University. She has worked in various process units in the MAA refinery to support and maintain DCS and advanced process control applications. She has been actively involved in the successful development, modeling and commissioning of several advanced process controllers in various units of the refinery. She is also a member of the IT/OT Cybersecurity team to audit and implement recommendations to ensure cybersecurity compliance of OT systems.
Markand Krushnaprasad Joshi is a Process Control Engineer at KNPC’s MAA refinery. He has more than 17 yr of experience in advanced process control and automation. He plays a key role in major refinery projects related to the enhancement of control systems, automation, ALMS upgrades, process unit optimization and OT cybersecurity compliance. Before joining KNPC, Joshi worked as an advanced process control consultant, implementing advanced process control solutions across multiple refinery processing units on various DCS platforms.
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