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.
Sl ©
Invensys proprietary &
Overview
 Introductions
 What is Condition Manager?
 The Niche
 The Solution
 Value Proposition
 Case Study:- VECTREN Power
Slide
3
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
Slide 11
The Layers
Operations
Maintenance
(asset utilization)
(asset availability)
ERP
Plant Business
Control
MES
Focus at the Business Level
Driving economicPerformance
performance measurementsEnterprise
and
Supply Chain Management
Asset
improvements from all plant resources.
Management
Convergence
Production Management
Industrial
Energy
Management
Alarm
Management
Logic
Control
Slide 12
Industry
Unit 1
Solution
Plant Operational Control
Plant Asset
Focus
Industryaround
Industryequipment sets or groups
Management
Unit
2 asset
Unit availability
n
Driving
and asset utilization
Solution
Solution to achieve local optimum.
measurements
System Condition
Security
Monitoring
Analysis
Operations
Operation
Asset Management
Management
Dashboards
Focus around field device/equipment
Pump
Valve
Instrument
Condition Condition
Condition
Process Driving Loop
asset availability and asset utilization
Tracking
Management
Controlmeasurements
Loop
and improvementsTracking
in component
assets. Tracking
Loop
Analysis
Other Device
Condition
Tracking
Think of CM in 3 Simple Stages
Collect – Data Sources include, intelligent field devices,
historians, asset performance models, and OPC diagnostic
sources
Analyze – Single to multi-variable rules based engine, simple
and complex expressions, advanced statistical control
(WER), thresh-holds, etc…
Act – Automatic generation of Work Orders, Work Requests,
Equipment Activity Records, E-Mails, MS BizTalk
workflows,etc…,
Slide 13
Condition Based Maintenance Approach
Asset
Register
Slide 14
Configuration
Engine
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 one 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
–
Ability to integrate a condition based maintenance strategy
–
Windows look and feel
–
With the wide range of users – Janitors, mechanics, supervisors, little skills
development was required.
Slide 19
Condition Based Maintenance - BEFORE
Over 15,000 separate equipment readings archived in Honeywell PHD
data historians at two power plants.
Hours
RPM’s
Temperature
Data
Historian
Slide 20
Condition Based Maintenance - AFTER
Page
E-mail
Readings
Work Request
Work Order
Data
Historian
Slide 21
Condition Manager
How has CM Changed Vectren’s Overall
Business?

Users given autonomy to determine

because PM work done by
entities, monitoring points, details
need and not by schedule.
and outputs.


No regulatory or safety compliance

Fewer outages.
issues.

Improved responsiveness
Work requests automatically
created.

Slide 22
to bad situations.
Pages or e-mails sent on all
triggering events.

Time and money saved
Statistics passed to Avantis.

“Automated eyeballs” do
work formerly done by
engineers allowing them to
do other work.
Types of Equipment Monitored
Slide 23

Motors: hours, temperature, RPM’s

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
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, Inc.