Jack van der horst September 22/23, Asset optimization and management

Transcription

1 Jack van der horst September 22/23, 2008 Asset optimization and management

2 Introduction to Asset Management The integration of asset management into operator environment can enhance process uptime while reducing maintance cost.

3 Agenda What is Asset Management? Why implement an Asset Management Strategy? How to implement an Asset Optimizer? System 800xA Asset Optimization Scope of Supply Real World Implementation Examples CLAM MNS is

4 Why Implement an Asset Management Strategy? Minimize downtime & unscheduled shutdowns Improve Overall Equipment Effectiveness (OEE) Enable predictive maintenance strategies Maximize the effectiveness of maintenance activities Capture and use workforce knowledge

5 Asset Management: The Opportunity Profit Loss Design limit Operating target Break Even (BEP) Throughput Plant upset Lost opportunity Partial shut-down Maximize Plant Uptime Startup Shut-down 1. Keep the assets available for production 2. Prevent plant upsets 3. Run assets at design limits Time

6 Asset Management: Maintenance Practices Reactive Fix on failure Preventative Maintain on a schedule Predictive Maintain when conditions detected Created by Oil & Gas Industry Reliability Centered Throughput Startup Plant upset Partial shut-down Apply the appropriate technique based upon the role of the asset, safety, and criticality Lost opportunity Shut-down Time

7 Asset Management: Reactive Maintenance Fix on Failure Expensive when considering productivity impacts unplanned downtime secondary failures overtime costs Leads to fire fighting mentality Throughput Lost opportunity Plant upset Partial shut-down Startup Shut-down Time

8 Asset Management: Preventative Maintenance Maintain on a schedule basis Throughput 12%-18% savings over Reactive Maintenance Avoid catastrophic failures Extend life of assets Wastes Resources by performing maintenance that may not yet be required Risk of inducing failures while maintaining a healthy asset Often requires more maintenance staff Lost opportunity Plant upset Partial shut-down Startup Shut-down Time

9 Asset Management: Predictive Maintenance Maintain on Condition Throughput 30%-40% savings over Reactive Maintenance 8%-12% savings over Preventative Maintenance Extend life of assets Preemptive Safer require investment in condition monitoring equipment Lost opportunity Plant upset Partial shut-down Startup Shut-down Time

10 Asset Management: Reliability Centered Maintenance Unscheduled Maintenance (Hours) Over $20 Billion USD, or almost 5% of total North American production is lost each year due to unscheduled downtime. ARC Insights Preventive Run-to-failure Proactive Predictive SOURCE: World-Class Reliability Benchmarking, ABB Reliability Services

11 AM Technology Benchmarking 7 Step Process Asset Management Readiness Assessment Equipment Criticality Analysis Asset Monitor Value Estimation Asset Management Strategy Reporting Service and Technology Solutions Implementation Continuous Improvement

12 Application Oriented Approach Focus on specific problem areas IT Asset Monitoring Remote Diagnostic Systems Smart Instruments Heat Exchangers Rotating Equipment Control Loop Performance Control System Equipment Key Performance Indicators Start small and grow big into a Plant Wide Asset Optimizer

13 System 800xA Architecture One common platform for all software products

14 Typical 2 Hour Maintenance Repair 2 Hours Identification 6-12 Minutes Verification Minutes Administration Minutes Repair Minutes With Integration this can become } Minutes 48

15 Connectivity Object Mapping Links single or multiple SAP/PM Equipment records to an 800xA Aspect/Object SAP PM Equipment

16 CMMS Data Views Active work orders Work order history Equipment status Preventive maintenance Fault report submitter Portal Views Streamlines the Maintenance Workflow Reduces Paperwork Increases overall equipment effectiveness

17 CMMS Connectivity - Fault Report Submittal

18 The Complete 800xA Asset Optimization Solution Asset Monitors User Defined Asset Monitors (Basic, Custom) Heat Exchanger Asset Monitors IT Asset Monitoring System Status Asset Monitor 800xA System Health Asset monitors for field instrumentation Control Loop Asset Monitor (CLAM) Interfaces & Communications CMMS Integration (SAP, Maximo, IFS) SMS & Messaging AO Applications DLI Vibration Monitoring Integration AMS Integration Harmony System Health (CNAM) Loop Performance Manager (LPM) Device Management System (DMS) Calibration Integration Real Time Production Intelligence (RTPI) Data Logger for MV Drives Optimax Boiler Efficiency Reliability Dashboard

19 Real World Implementation Examples Semiconductor Plant Equipment Performance Pharmaceutical Facility Early Warning Paging System Pulp & Paper Mill ABB Equipment Health Vale Inco Labrador, CA Rotating Equipment

20 Semiconductor Plant Equipment Performance Issues Critical Assets: Reactors and Refrigeration Units

21 Pharmaceutical Plant Batch Processing Process Control Paging System Execute 7 Step AM Benchmarking Process (next step)

22 Pulp & Paper Mills: Remote Services Pilot Sites ABB Equipment Remote Service QCS Remote Diagnostic Service Harmony DCS Network Remote Diagnostic Service Process Control Next Steps Control Loop Asset Monitoring Loop Performance Management

23 Full Service Site with DLI Integration Lower Maintenance Cost Focused OEE uptime agreements Condition Based Maintenance Motors and pumps DLI Vibration Thermal Imaging Pressure & Flow Run-Time Hours Reliability Dashboard Visualize Total Plant Health Maintenance Engr Plant Mgmt Vale Inco Company

24 System 800xA Asset Optimization Complete asset optimization for: automation devices plant infrastructure plant equipment production processes Asset Monitoring and Reporting DMS Calibration Integration CMMS connectivity Remote access via web technology Real-time monitoring of asset health Reporting and analysis visualization tools Single application view CMMS Connectivity

25 Asset Monitoring and Reporting The ABB Advantage Oops! BAD! OK! Scheduled Monitoring of Asset Health Status Smart and detailed Condition reporting Message distribution Electronic Record based fault report submitting

26 Currently Available Asset Monitors Standard Asset Monitors System Status Calibration Status Vibration Monitoring KPI Performance QCS Sensors and Scanners Smart Field Devices (HART, FF, Profibus) PC Networking and Monitoring Process Equipment

27 Maintenance Workplace Organizes and arranges asset information for maintenance personnel Asset Group alarm bands Asset Structure Maintenance personnel filters Selected asset available aspects Selected aspect viewing area

28 Remote Alerts to Key Plant Personnel 800xA Messenger Driven from Alarm/Event Lists Pagers, , and SMS/GSM devices Assign messages to specific individuals or groups LCV-101 Out of Service Message handler allows specification of source and destination Message scheduling

29 Asset Viewer Asset Tree provides quick identification of maintenance conditions Most severe problems are propagated up the tree Asset Monitors identify severity of asset performance degradation

30 Asset Reporter Asset Reporter is a detailed view of all asset monitor conditions for a given asset Condition details are available by rightclicking on the item of interest

31 Asset Reports Asset Reports Comprehensive information to aid in every day decision making AO standard reports include: Asset Condition History Calibration Overview reports Running Time reports Counter Check reports

32 System 800xA Optimizing plant asset availability and performance CLAM Control Loop Asset Monitor

33 For the Operator Can I still operate? How shall I operate? What must I do? Can I trust the measured values? For whom? Asset - Information For the Maintenance Manager What kind of demands / requirements does the plant currently have? What must be overhauled/repaired? For the Operations Manager What is the cost of Production? How does my spareparts inventory look? How can I optimize my output?

34 Typical Maintenance Workflow Asset Monitor Ooops! OK! Alarming The Asset Monitor is the key to maintenance workflow Show status and alarms Message distribution

35 Device Management and AO (CLAM) Device Type Managers (DTM s) and The Control Loop Asset Monitor (CLAM) DTM: Diagnostics: Valve Dead band Test (Stiction) Multipoint Step Test Dynamic Loop Test Valve Analysis Test Control Valve PID Identify: (CLAM) Control Loop Performance Indicates hysteresis and stiction Oscillatory performance DTM: Diagnostics: Valve Degradation Analysis Emergency Shut Down Simulation (Partial Stroke Test) DTM: Diagnostics: Freeze detection Deviation Limit Input failure Safety Shut off valve Flow Transmitter Process Logical Co-existence of Device Management and Asset Optimization in a Control System 1. Display DTM diagnostics and alarm 2. Display and alarm based on P&ID performance

36 Control Loop Asset Monitor (CLAM) Monitor any control loop Based on three control loop variables SP (Set Point) PV (Process Variable) CO (Control Output) Using a patented algorithm Part of a Valve Diagnostic Implementation

37 Control Loop Asset Monitor (CLAM) CLAM only helps for control valves in a control loop (since CLAM is for control loops) CLAM works on control loop measurements i.e. the assessment of actual valve behavior is very rough CLAM can: detect valves exhibiting stiction leading to self-sustained oscillations (stiction in non-oscillatory loops will not be identified) assess if the valve is over- or undersized i.e.; is it mostly working <10% or >90% of the valve opening? assess if the valve changes direction 'often' assess if the valve exhibits 'excessive action' As all these values are collected, they can of course be processed and further visualized, but this is not part of CLAM currently. In LPM, where the same functionality runs, a bit more visualization is feasible since there is a database storing all indices computed.

38 CLAM - Asset Monitor View Control Loop Asset Monitor

39 Asset Monitoring and Reporting Continuous Condition Monitoring for all kinds of Plant Assets in one system with root cause detection capabilities reported into a single User Interface. Brings diagnostics information from field devices into alarm list in a unified way Adds information for faster and precise fault detection to reduce downtime Same functionality for all assets reduces amount of different procedures Provides workplace and views for maintenance centric workflow

40 MNS is New Sensor Technology Integrated in outgoing contact bar - Current - Voltage - Temperature Maintenance relevant information and data

41 MNS is Motor Starter Starter types MControl MControl Function loaded as software depending on requirements. DOL REV-DOL DOL with RCU REV-DOL with RCU Star / Delta 2 Speed Actuator

42 MControl Communication Extension

43 Switchgear and Smart Relay Life Cycle Current transformer Voltage Unit (for MCU 2) Switchgear > 25 Years Electronic Protection Relay 5 10 Years MCU 1 / 2 Base plate (w Terminals)

44 Protection Control Information Standard Motor Protection Thermal Overload Blocked / Stall Phase Loss Underload / No Load plus Advanced Functions in MNS is Condition Monitoring of MCC Asset Management selectable protection and control functions selectable measurement values plus Extended Functions Thermal Overload EEx-e Phase Unbalance Underload cosphi Earth Fault Motor Temperature (PTC) Undervoltage, Autom. Re-Start, Staggered Start

45 MNS is Fully Integrated and Scalable Scalable functions and application with MNS is Standard motor application with MNS INSUM switchgear solution Intelligent motor protection and control Integrated bus communication Conventionally connected motor starter through Remote I/O

46 MNS is System Architecture

47 MStart Supervision MControl is monitoring connected MStart device After power up of MControl it is reading configuration information from connected MStart module. If this information does not match with the configured information then MControl will go into Power Module Supervision trip status. If information is matching MStart is ready for operation. If MStart module is inserted while MControl is already running the same procedure as above described is applicable.

48 MNS is and DCS Operator Workplace or Electrical Workstation Engineering Workplace or Maintenance Workplace Control Network DCS Process Controller DCS Connectivity Server MNS is OPC Server Ethernet TCP/IP OPC Server for MNS is open data interface dedicated information flow Process control through standard interfaces Information flow: open and directed

49 MNS is in DCS Operation Operation Faceplates Faceplates Advanced Conventional Extended Information Motor Control Operation Workplace Operation and Control Process Monitoring Electrical Workplace Switchgear Monitoring Parametering Alarm Logs, Trends, History Switchgear Asset Management

50 Possible solutions Process optimization Analyzing the asset state and operational process to evaluate life cycle impact Predictive maintenance (condition based) Motor Thermal Load Motor Thermal Load Time Important to analyze the right information Time

51 Possible solutions Better device management Analyzing failure, advising maintenance activities and appropriate CMMS integration Reactive maintenance (reduced time to repair to a minimum) Asset monitors (provide additional information) 800xA Asset Optimization (Maintenance tool) MNS is Condition monitoring (analyzing data)

52 MNS is Switchgear Condition Monitoring Switchgear Condition Communication Interface (MLink) Communication error Protection and Control (MControl) Location error Communication error Power Module (MStart) False type of module (cause: wrong MStart type for motor) Phase Loss (cause: blown fuse) Feedback fault (cause: contactor welded) Contact temperature monitoring (cause: bad power cable connection)

53 MNS is Asset Monitors beyond Switchgears Motor or Process Component Monitoring Electrical (Thermal) Load too high over a long period of time (cause: mechanical stress on motor or machine) Motor Temperature too high (cause: electrical fault in motor) Mechanical Underload warning (cause: mechanical fault on motor or machine) Vibration alarm (detected by additional components) Operational Motor Operation Hours exceeded (cause: end of maintenance period reached)

54 MNS is Asset Management with 800xA MCC Asset Monitors 800xA Maintenance Workplace Asset Monitor Asset Monitor Asset Monitor Asset Condition Document

55 MNS is and Asset Management Improve Reactive Maintenance Response Times Quicker detection of failures by online asset monitoring Investigation of equipment health without need to enter the field Support Preventative Maintenance Shift to consumption based maintenance via reporting of runtime and usage Facilitating Predictive Maintenance Monitor and act upon diagnostic conditions directly from devices Eliminate maintenance cost of devices that do not need attention

56 MNS is and Asset Management Support RCM maintenance techniques Incorporate severity based on asset role and criticality Root Cause reporting via device specific asset monitors Reduced Time to Repair Diagnostics aids, Recommended actions readily available Documentation and Standard Operating Procedures one click away Streamlined maintenance workflow Integrated maintenance procedure and CMMS No manual data entry errors, paper work reduction

57 800xA Maintenance Workplace

58 800xA Maintenance Workplace

59 800xA CMMS Interface (Maximo or SAP)

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