Transcript PPT Template

Slide 1
AV-11
Condition-Based Maintenance
Juan Collados
© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are
proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their
respective owners.
Overview
• Introduction
• What is Condition Manager?
• The Niche
• The Solution
• Value Proposition
• Case Study: VECTREN Power
Slide 3
Condition Management Challenges
• Moving From Re-active to Pro-active Operations
• Maximize Reliability and Availability, Balanced with
Utilization while managing complexity
• Managing the huge number of devices and assets
from many different suppliers
• Building and maintaining operations expertise as
workforce ages
• Provide Collaboration environment for Operations
and Maintenance
Slide 4
The Opportunity
• Reduce unplanned outages
• What is the cost of one hour of downtime?
• 5% average production loss per annum due to unscheduled downtime
• Reduce downtime
• More timely and effective responses to issues
• More effective shutdown/turnaround
• Reduce unnecessary preventive maintenance
• 30 to 50% of preventive maintenance is unnecessary
• Can represent 10 to 20% of total maintenance cost
Source: ARC
Slide 5
What is the Invensys Condition Manager
Solution?
An easy-to-use,
rules-based
asset condition manager
that intelligently and
automatically raises
alerts to actual or
potential problems.
Slide 6
Condition Manager
• Allows organizations to move beyond simple
calendar based maintenance
• Proactive condition-based maintenance
• Empowers operators by providing the ability to
track maintenance activity associated with an asset
• Increases asset availability by reducing unplanned
downtime
Slide 7
Well Connected
Aggregates real-time data from leading plant floor
systems
• Plant Historians
• Modeling Engines
• Field Device Monitoring solutions
• Standard OPC client interface simplifies integration with other
advanced monitoring technology
Slide 8
Solid Foundation
• Employs MSMQ and Web Services for exchanging data with
the Enterprise Asset Management system
• Option to send BizTalk alerts when conditions are triggered
Slide 9
Value Proposition
The CM
Slide 10
Improved Asset Availability
and Reliability
• Ensures necessary availability
to support production goals
• Avoids unplanned outages
through early detection and
improved planning
• Delivers availability at the
lowest possible cost
• Extends equipment life
• Improves resource utilization
Key Messages
• Unique, intelligent real-time condition management solution
that collects and analyzes real-time diagnostics from all plant
production assets
• Provides early failure detection to increase asset availability,
reduce costs and avoid unnecessary maintenance and
downtime
• Supports continuous improvement through integrated
workflow management driving appropriate action to improve
overall asset performance
• Provides operations, engineering, and maintenance with easy
access to current asset information for better decision making
to help optimize asset contribution over its full lifecycle
Slide 11
The Layers
Operations
Maintenance
(asset utilization)
(asset availability)
ERP
Plant BusinessMES
Control
Focus at the Business Level
Driving economic performance measurements and
Supply Chain Management
Enterprise Asset
improvements
from all plant resources.
Performance
Management
Production Management
Industrial
Energy
Management
Alarm
Management
Logic Control
Slide 12
Convergence
Plant Operational Control
Plant Asset
Industry
Focus Industry
around equipment sets or groups Management
UnitDriving
2
Unit n
asset availability and asset utilization
Solution
Solution to achieve local optimum.
measurements
System Condition
Security
Monitoring
Analysis
Operations
Operation
Management
Dashboards
Asset Management
Focus around field device/equipment
Instrument
Pump
Valve
Condition
Condition
Condition
Loop
Driving
asset availability and asset utilization
Process
measurements
and improvementsTracking
in componentTracking
assets.
Tracking
Management
Control Loop
Industry
Unit 1
Solution
Loop
Analysis
Other Device
Condition
Tracking
Think of CM in 3 Simple Stages
1. Collect – Data Sources include intelligent field devices,
historians, asset performance models, and OPC diagnostic
sources
2. Analyze – Single to multi-variable rules based engine,
simple and complex expressions, advanced statistical
process control (WER), thresholds, etc…
3. Act – Automatic generation of Work Orders, Work
Requests, Equipment Activity Records, E-Mails, MS BizTalk,
Workflows, etc…
Slide 13
Condition-Based Maintenance Approach
Asset Configuration
Engine
Register
Slide 14
CM Configurator
• The CM Configurator is used to associate Real Time Points,
Models and Intelligent Devices with Avantis Entities for the
purpose of generating maintenance events.
• This is accomplished with drag 'n’ drop ease of use.
Runtime Hours
Starts & Stops
Device Status
Device
Parameters
Slide 15
Avantis Entity
Condition Manager Components
Inspect:
Configuration Environment
Maintain: Asset Registry
The Maintenance View
Slide 16
One
Integrated
Business
Process
Repair: Operations \ Event View
Understand the Starting Point
Culture
– Willing and ready to change
– Recognize the issues
Business Processes
– Current, optimized
– Built on best practices and benchmarks?
– Measurement Systems in place
Corporate Knowledge
– Available, Accessible
Technology Base
Slide 18
Case Study
● Vectren Corporation (NYSE:VVC), is a progressive energy-holding company
headquartered in Evansville, Indiana
● Delivers gas and/or electricity to more than 1 million utility customers in Indiana and Ohio
Challenge
–
Streamline Maintenance work and Equipment processes
–
Drive down the cost of unplanned work
Reasons for choosing Avantis
Slide 19
–
Ability to integrate a condition based maintenance strategy
–
Windows look and feel
–
With the wide range of users – Janitors, mechanics, supervisors, skills development
was required
Condition-Based Maintenance - BEFORE
Over 15,000 separate equipment readings archived in
Honeywell PhD data historians at two power plants.
Hours
RPMs
Temperature
Data
Historian
Slide 20
Condition-Based Maintenance - AFTER
Page
E-mail
Readings
Work Request
Data
Historian
Slide 21
Work Order
Condition Manager
How has CM Changed
Vectren’s Overall Business?
● Users given autonomy to determine
entities, monitoring points, details
PM work done by need and not
and outputs
by schedule
● No regulatory or safety compliance
issues
● Pages or e-mails sent on all
triggering events
● Work requests automatically created
● Statistics passed to Avantis
Slide 22
● Time and money saved because
● Fewer outages
● Improved responsiveness to bad
situations
● “Automated eyeballs” do work
formerly done by engineers
allowing them to do other work
Types of Equipment Monitored
● Motors: hours, temperature, RPMs
● Pumps: amps, hours
● Fans: temperature, vibrations
● Filters: hours
● Air compressors: hours,
temperature
● Monitors: PPM, pH
● Generators: temperature
● Air blowers: hours
● Turbines: vibrations
● Storage tanks: gallons
Slide 23
Voice of the customer: Vectren
“Automated Eyeballs. Instead of wasting an engineer’s time
reviewing charts, that engineer is freed-up to do other tasks.”
“If you are creative, you can have CM create a Work Request well
ahead of anyone noticing the change.”
“CM is a tool that provides a very cost effective way to optimize
PM programs. Through its creative application we have improved
reliability and avoided costly emergencies.”
“The PM functionality alone provides enough savings to pay for
the CM implementation.”
“The value added proposition is in the early detection of change,
well ahead of any problem. Forewarned is forearmed. You can
plan, schedule and in some cases budget for the problem. You own
the problem, instead of the problem owning your operation.”
Slide 24
Questions?
Slide 25
Copyright 2009 ExperTune,