Monitoring Asset Health and Maximo. Trevor Johnstone, Matrikon April 16, 2009

Transcription

1 Monitoring Asset Health and Maximo Trevor Johnstone, Matrikon April 16, 2009

2 Agenda Introduction Asset Management & CBM Integration Starting Point Asset Monitoring & Integration with Maximo: Meridian Energy Other examples of Monitoring Asset Health 2

3 Company Overview Global Presence 17 offices 17 partner companies Leading clients around the world 3

4 The Industries We Serve Mining 6 of 8 Top Mining Companies Petrochemical 5 of 7 Largest Refining Operations Oil & Gas 4 of 6 Top Oil & Gas Companies Power 3 of 6 Leading Power & Utilities Companies Forestry 5 of 8 Top Pulp & Paper Operations Alcan, Anglo Coal, Barrick Gold, Bema Gold, BHP Billiton, CE Zinc, Falconbridge, Iluka, PhelpsDodge, Rio Tinto, Suncor, Syncrude, Xstrata Bayer Material Science, BOC, Braskem, Chevron, Dow, Ecopetrol, Marathon, NOVA Chemicals, Sasol, Shell, Tesoro BP, ConocoPhillips, Chevron, CNRL, Enbridge, Encana, ExxonMobil, Husky, Keyera, Nexen, OXY, Santos, Saudi Aramco, Total, StatOil, Wintershall Ameren, BCTC, ConEdison, Constellation, DTE, Dynegy, Entergy, Meridian, NRG, Ontario Power, PG&E, RWE, Southern, TransAlta Abitibi, Ainsworth, Boise Cascade, Canfor, Georgia- Pacific, Kimberly- Clark, Louisiana- Pacific, MeadWestvaco, Weyerhaeuser 4

5 Matrikon Suite Best-In-Class Technology Visualize & Propagate Analyze Suite Aggregate & Contextualize Collect Integrated thin client applications accessed through your browser 5

6 Which customers are interested in Asset Effectiveness? They all are 6

7 The Progression of Asset Management Strategies CURRENT SITUATION HOLISTIC PASSIVE Maintenance relegated to lower levels in Organisation. Assets not critical, downtime, lost production or capacity not important. REACTIVE Break-fix strategy. Potential for significant asset downtime and lost capacity. Usually involves non-mission critical and simple Assets One step ahead of breakdowns. Usually involves mission critical, complex and high capacity assets. Complete maintenance work and inspections before failures occur. PREVENTATIVE Anticipate problems before they occur. Prevent breakdowns and maximises plant capacity by real-time monitoring of asset condition indicators including vibration, quality degradation, and run time and compares to asset reference models. PREDICTIVE Applies all concepts to the appropriate assets to optimise, improve and evolve asset performance THE FUTURE Source: Aberdeen Group 7

8 Asset Management Solutions Maintenance Work Management Preventive Maintenance Work Planning & Sch. Work Execution Maintenance Work Management Reliability (M) Condition Monitoring Condition (C) Condition Monitoring Threshold Monitoring Tracking Measured Data Advanced Statistical Analysis Industry monitoring solutions Work Management Reliability Condition (B) Monitoring RCM, FMEA/FMECA Criticality Analysis Operating KPI s, OEE, Downtime 8

9 The Matrikon Operational Excellence Model Tests DCS PI Asset Data Analyse Notify Take Action Integrated Solutions 9

10 Integration Starting Point Usage-based Preventative Maintenance Send Meter Readings Direct Work Order generation based on conditions Actual usage/uptime calculations sent to CMMS MIMOSA-compliant Open Standards communication Maximo 4,5,6 & 7 10

11 Integration with Real-Time Data Built-in Real-Time Connectivity Trend Archive Web Report Control CMMS/ERP Scale Radio UNIX Ethernet Windows Serial Database RTU Analyzer DCS PLC 11

12 OSA-CBM Standard Interface 12

13 The need to close the ACTION GAP and the ANALYSIS GAP Measurement & Storage ANALYSIS GAP Effective data analysis and diagnosis is not keeping pace with data measurement and storage investment Analysis and Diagnostic Resources per site ACTION GAP Ever reducing resources per facility have difficulty keeping pace with the diagnostic results and legislative requirements 13

14 The 3 Cornerstones to closing the GAP People Technology Processes Technology Select Standard Technology that builds upon existing strategies across the enterprise People Change Management is a key consideration when providing users with new tools and methods Processes Apply Best Practices to generate intuitive, user oriented work flows 14

15 Proven Solution: Meridian Energy Meridian Energy Plant Asset Management (PAM) Advanced condition monitoring for New Zealand s largest power utility: 30% of NZ capacity Includes Transmission Substations & Generation Assets Award-winning CBM built in partnership with Matrikon Key Goals for Meridian 1. Transparency of Equipment Health 2. Equipment Diagnostics Recommendations Time to Failure / Time to Risk Limit 3. Repeatable, objective, accurate analysis 4. Monitor effectiveness of maintenance program 15

16 Transformer 16

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18 How Does PAM Work? PAM has a developed a set of asset-based software models using agreed performance characteristics & targets Uses the offline condition monitoring information from CMMS (Maximo) & online data from historian (PI) Interprets whether these are within the parameters of performance requirements Utilizes a web-based dashboard to provide an overview of asset health If a potential issue arises, submit a Work Order to the CMMS Provides trending & reporting tools to examine how assets are performing & ageing over time, and capture this rate of change 18

19 Solution Architecture: Logical Layout 19

20 383DTF 383D TF 383DTF

21 383DTF 21

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23 CMMS Write-back 23

24 Indicates a PAM work order Additional PAM fields which are populated once analysis is run. 24

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26 Change status 26

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28 Route the work order 28

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32 Limits (from the IEEE standards) used within CK for transformer monitoring. 32

33 Data map used for PI tags Data map for a specific transformer 33

34 Asset Health Index Region Health Area Health Substation Health Asset Health Oil Health Elec Health Other Health Asset health Group health weighted avg Oil Test 1 Oil Test Oil Test N Elec Test 1 Elec Test Elec Test N Other Test 1 Other Test Other Test N Condition Index for each test: 1-4 Analytics Engine HISTORIAN EAM GIS OTHER Online & Offline data sources Asset Health Index algorithms are configurable 34

35 Benefits To Date Functionality Dashboard enables customised view of one, some, or all of the assets in the system Data entry easier and more accurate Improvements Test results are entered in a timely manner no lost data Improved maintenance planning capability both tactical and strategic Weaknesses in Job Plans highlighted and corrected Gaps in our historical data highlighted and corrected Understanding Asset Condition Very Early warning of changes Increased visibility of ALL assets as they are added to the system Asset monitoring programme is much more robust Improved understanding of the condition of assets Confidence in the maintenance being carried out Engineers and Plant Managers can see the most important issues without spending time searching for unknown problems 35

36 Other Online CBM Examples 36

37 GE Energy Case Study: Transformer Monitoring Predicted 5 days Before Trip! Failure Fault Occurred and Transformer Tripped Process Out of Control 5.2 Days Online data provides early event detection of transformer failure 37

38 Early-Event (Anomaly) Visualisation 38

39 Solution: Mobile Equipment Monitor Equipment Status Electronic Control Central Monitoring Structure & Suspension Hoist Hydraulics Speed & Weight Customers Developed with sponsorship from FMI Equipment manufacturer P&H In talks with several major mining companies Power Train Electrical System Cooling System Tire Pressure Break Temperature Hydraulic System Matrikon Suite Components Alarm Manager Operational Insight Equipment Condition Monitor Monitors mining equipment in real-time, enabling the prediction and prevention of failures and increased equipment effectiveness & asset life Additional Matrikon Components Data Loggers 39

40 Case Study: P&H Mining Equipment Shovel Owners: Real-time proactive maintenance of critical assets P&H Mining: Feed vast amounts of reliability data back to Maintenance & Engineering P&H Mining providing global value-added CBM service for all their shovels 40

41 Wind Asset Monitoring Solution 41

42 Wind Asset Monitoring Solution 42

43 Wind Asset Monitoring Solution 43

44 Wind Asset Monitoring Solution 44

45 Wind Asset Monitoring Solution 45

46 Wind Asset Monitoring Solution 46

47 Wind Asset Monitoring Solution 47

48 Wind Asset Monitoring Solution 48

49 Matrikon View of Asset Monitoring in order for an Asset Health Monitoring solution to deliver on and sustain the business objectives, Application needs to be Trusted Integrated into consistent workflow Maintained Business Processes need to be: Documented Effective Consistent Understood Architecture needs to be: Open (and standards-based wherever standards exist). Reliable Scalable Secure 49

50 Questions? Trevor Johnstone 50