INT-04 How do you spell IntelaTrac?

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INT-04 How do you spell IntelaTrac? Presented by: David Dollar, Sr. product Manager October 15, 2013 social.invensys.

2 INT-04 How do you spell IntelaTrac? Presented by: David Dollar, Sr. product Manager October 15, 2013 / #SoftwareRevolution /InvensysVideos /Wonderware /Wonderware IntelaTrac User Community 2013 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.

Agenda History of IntelaTrac Primary Use Cases IntelaTrac Application Components Value and Return on Investment Q/A An overview of IntelaTrac, the primary use cases customers deploy, and a tour of

3 Agenda History of IntelaTrac Primary Use Cases IntelaTrac Application Components Value and Return on Investment Q/A An overview of IntelaTrac, the primary use cases customers deploy, and a tour of the application components and users who execute/manage/ maintain them. Included are examples of how field operations and inspections may be managed today within your facility and how, using IntelaTrac and mobile computers, you can enhance the reliability of your operations and attain key business objectives. Slide 3

4 A brief History of IntelaTrac Began as SafeTrac Controls in 1995 Name changed to SAT Corporation and IntelaTrac Version 1.0 in 1998 Worked with clients beginning in 2001 to document return on investment (ROI) and best practices Version 3.2 and advanced scheduling released in 2008 SAT purchased by Invensys Wonderware in 2008 Groundbreaking Version 4.0 released in 2010 IntelaTrac Extensibility SDK released in 2011 Version 4.2 and Administration enhancements complete a major overhaul of IntelaTrac in 2012 Version 4.3 and Dynamic Asset Assignment released in 2013 Slide 4

5 Agenda History of IntelaTrac Primary Use Cases IntelaTrac Application Components Value and Return on Investment Q/A Slide 5

6 Industry Challenges Example of Challenges in Process Industries: Over 50% of maintenance cost are directly related to improper operation of equipment. 89% of all components fail randomly. These failures are most often caused by neglecting the basic care of equipment. Secondary equipment failures and production slowdowns are 8-10 times more costly than primary equipment failures. These failures are often caused by Reassembly Errors, Part Defects, Installation Errors, and Improper Operation. The front line workforce has the opportunity to radically improve plant reliability and operational profitability. Relying just on Maintenance does not allow us to drastically reduce failures. Slide 6

7 IntelaTrac s Mobile Platform Addresses Industry challenges Field Worker Rounds Field Worker Training Process Data Logbook Product Changeover Alarms & Events Manual Maintenance Lock Out / Tag Out Slide 7 Startup Procedures Compliance

8 IntelaTrac Uses Operations rounds Maintenance and I & E inspections HSE safety and environmental rounds Learning mobile learning on-the-job Projects/Turnarounds status / details Quality Assurance time stamped lab sample Calibration Inspections Security and Accountability Slide 8

9 Operator Rounds Operator rounds generally focus on the visual inspection of plant assets, however they are also used to facilitate data collection of temperatures, pressures, flow rates, vibration levels, water chemistry, spills and leaks, and other safety and operating condition data. Operator Rounds are typically scheduled based on shifts but they may also be scheduled based on a rotating crew assignment. Operator Rounds may be scheduled by the Shift, Day of Week, Week of Month, Month, etc. Most companies implementation of Operator Rounds is paper based Slide 9

Paper based Operator Round Examples Prim Frac/Dil Stm Process & Equipment Evaluation Sheet -1 DAY

) Range/Limit WHICH RUNNING A/B 2:00 7:00 / / 14:00 19:00 / / Date: OPERATOR SEAL LEAK

TURBINE RESERVOIR RESERVOIR H2O OUT LINKAGE NOISE, OIL LEVELS WATER TEMP PROPERLY VIBRATION > 50%

MOTOR HTR ON DISC PRESS 170-190 PSIG PUMP, MOTOR OIL LEVEL >50% SEAL LEAK E-1624 STEAM TEMP READ

RUNNING DISC PRESS 80-110 PSIG OIL LEVEL >50% SEAL LEAK J-1603 A/B HFO PUMPS IF RUNNING DISC

Comments & Notes Slide 10 IN AUTO JA-1629 B LFO PUMP NOISE, DISC VIBRATION IF PRESS TEMP (FEEL )

DISC PRESS 110-130 PSIG J-1612 A/B PRIMARY HWB PUMPS OPERATOR WHICH RUNNING A/B OIL LEVEL > 50%

10 Paper based Operator Round Examples Prim Frac/Dil Stm Process & Equipment Evaluation Sheet -1 DAY SHIFT NIGHT SHIFT J-1614 A/B E-1 REFLUX PUMPS DISC NOISE, PRESS VIBRATION PSIG TEMP (FEEL ) Range/Limit WHICH RUNNING A/B 2:00 7:00 / / 14:00 19:00 / / Date: OPERATOR SEAL LEAK Range/Limit 2:00 7:00 14:00 19:00 WHICH RUNNING A/B SPEED RPM READ SEAL LEAK PUMP, GOV, COOLING TURBINE RESERVOIR RESERVOIR H2O OUT LINKAGE NOISE, OIL LEVELS WATER TEMP PROPERLY VIBRATION > 50% FREE < 105 ºF LATCHED TEMP (FEEL ) DISC PRESS PSIG JA-1629 A LFO PUMP STANDBY IN AUTO AND MOTOR HTR ON DISC PRESS PSIG PUMP, MOTOR OIL LEVEL >50% SEAL LEAK E-1624 STEAM TEMP READ DISC PRESS > 50 PSIG READ NOISE, AMPS VIBRATION < 170 AMPS TEMP (FEEL ) JA-1629 C LFO PUMP IF RUNNING DISC PRESS PSIG OIL LEVEL >50% SEAL LEAK J-1603 A/B HFO PUMPS IF RUNNING DISC PRESS PSIG OIL LEVEL >50% SEAL LEAK NOISE, VIBRATION TEMP (FEEL ) 7:00 14:00 19:00 Comments & Notes Slide 10 IN AUTO JA-1629 B LFO PUMP NOISE, DISC VIBRATION IF PRESS TEMP (FEEL ) RUNNING PSIG / / / / Range/Limit 2:00 J-1620 B E-1604 FEED PUMP J-1620 A E-1604 FEED PUMP DISC PRESS PSIG J-1612 A/B PRIMARY HWB PUMPS OPERATOR WHICH RUNNING A/B OIL LEVEL > 50% SEAL LEAK SEAL FLUSH ON JA-1671 A/B COND PUMPS NOISE, VIBRATION WHICH TEMP (FEEL ) RUNNING A/B / / / / / / DISC PRESS > 50 PSIG

11 In Between? A Real Example Data collected on paper Calculations completed in the field with a programmable pocket calculator Timely calculation results required to make real time adjustments to the test procedure Slide 11

Slide 12 Data collection alone does not improve work processes Paper does not help promote Best Practices Collected data tends to only

12 Problems with Paper based Operator Rounds Paper is Static Difficult to get the data into a system where it can be trended or acted upon Difficult to respond to audits Hard to detect errors Hard to change Difficult to report against Data is late No or little accountability Slide 12 Data collection alone does not improve work processes Paper does not help promote Best Practices Collected data tends to only be available to individual operators if they search for it. Inaccuracies not recorded or corrected Relies on the experience of individuals

IntelaTrac Captures Stranded Data Typically 40-60% of assets in a plant are non-instrumented Boiler Variable Source Of Data Temps DCS Pressure DCS Safety valves IntelaTrac Burner Tilts IntelaTrac Air

13 IntelaTrac Captures Stranded Data Typically 40-60% of assets in a plant are non-instrumented Boiler Variable Source Of Data Temps DCS Pressure DCS Safety valves IntelaTrac Burner Tilts IntelaTrac Air Heaters Variable Source Of Data Air Diff DCS Rotation DCS Blow pressure IntelaTrac Steam Traps IntelaTrac Power Generation Process Draft Fans Variable Source Of Data Position DCS Viv position DCS Lube oil status IntelaTrac IntelaTrac pump/motor Turbine Variable Source Of Data Status DCS Pressures DCS Oil Pumps IntelaTrac Valves IntelaTrac Condenser Variable Source Of Data Back pressure DCS Extraction DCS GEA System IntelaTrac Leaks IntelaTrac Slide 13 Feed Pumps Variable Source Of Data Bearings DCS Temp/Pressure DCS Vibration IntelaTrac Lube oil IntelaTrac Generator Variable Source Of Data Vibration DCS Lube oil DCS Buss Duct IntelaTrac Booster Pumps IntelaTrac Transformer Variable Source Of Data Temperatures DCS Excitation DCS Trans Oil IntelaTrac Fans/coolers IntelaTrac

14 Top 5 Reasons for Mechanical Failure 1. Design of asset for the application 2. How asset is operated 3. Quality of the repair on the asset 4. How the asset is maintained IntelaTrac Directly Addresses These Issues 5. Asset wears out / end of life IntelaTrac Indirectly Addresses These Issues Slide 14

IntelaTrac Rotating Equipment Best Practices Field Worker Round Design Centrifugal pump,

and the surveillance technique used in our IntelaTrac Best Practices solutions.

It is critical for success that Field Workers also receive the training required to be able

15 IntelaTrac Rotating Equipment Best Practices Field Worker Round Design Centrifugal pump, seal and driver defect awareness is raised through identification of typical failure modes and the surveillance technique used in our IntelaTrac Best Practices solutions. Deficiencies are detected and communicated, allowing prompt action to be taken. It is critical for success that Field Workers also receive the training required to be able to properly identify and mitigate any deficiencies. INT-21 IntelaTrac for Lubrication Routes Slide 15 Wed 2:30 Cortez D

Incorporating Equipment Operational Awareness Centrifugal pump surveillance examples In addition to inspecting the seal during Field Worker rounds, the following minimum conditions should be observed

16 Incorporating Equipment Operational Awareness Centrifugal pump surveillance examples In addition to inspecting the seal during Field Worker rounds, the following minimum conditions should be observed and if found mitigated immediately before damage occurs and or reported for mitigation. Are the oil sight glasses clean? Is the oil full up to the proper level? Is the discharge pressure within range? Is the pump base plate clean? Is the mechanical seal leaking? If so, which of the 3 basic locations? Is the oil clean? Are any pipe supports loose? Is the pump vibrating or making unusual noise? Is the seal flush system working properly? The pump suction valve must always be 100% open during operation. INT-23 Operator Rotating Equipment Training Slide 16 Thurs. 8:00 Thurs. 9:15 Cortez D

17 Agenda History of IntelaTrac Primary Use Cases IntelaTrac Application Components Value and Return on Investment Q/A Slide 17

18 IntelaTrac System Architecture 1 8 Slide 18

19 IntelaTrac Software Components IMC IntelaTrac Management Center Single point of login to the IntelaTrac desktop applications Procedure Configuration & Scheduling Review & Reporting Administration Documentation & Help Links Slide 19

20 System Configuration INT TSS-01 IntelaTrac Best Practices and Troubleshooting Slide 20 Tues 4:15P Coronado C CD

21 Crew and Shift Configuration Slide 21

22 Task Definition Workflow Example IntelaTrac Can Directly Impact These Areas Slide 22

23 Building Content Review Of Operating Unit Review considers reliability based inspections for Operations, Maintenance and Inspections for all equipment in the Unit. Unit operational needs are defined. HSE Compliance requirements are defined as per local and governmental regulations as well as site specific permitting. Getting all Departments involved in the review process ensures high value inspections are being completed by all parties. Factors Considered When Creating The Field Worker Rounds How much time will be allotted for the Field Worker to perform the inspections? Does every task asked have a limit associated with it? If not, is there a valid reason to still ask the question? Are the rounds built in a logical geographic pattern that eliminates the need for RFID or Bar Code scanning? Slide 23

24 Building Content contd. Factors Considered When Creating The Field Worker Rounds Continued Are the action messages focused advise detailed enough for a new Field Worker? Do any of the tasks require the Field Worker to create an unsafe situation? What additional training is going to be required for the Field Worker to perform these tasks in an optimal manner? Are the rounds built in a way to ensure data can easily be extracted for reporting? Procedure Review Once the rounds are built they need to be reviewed and tested before releasing to the end user. After the initial rollout and a brief stabilization period the rounds should be reviewed again so limits can be adjusted, tasks added or taken away, additional training can be provided, etc. Slide 24

25 Procedure Builder Base Configuration List of Bases displayed based on the individual user s permissions Procedure Categories assist in organization Default Views - Advanced Filter Procedure Revision History Slide 25

26 Procedure Builder - Configuration Drag & Drop from the Toolbox Procedure Items -basic building blocks Integrations to External Systems Peripheral Integration Conditions define follow-up Actions Single and Multiple Actions Decisions for Advanced Workflow INT-TSS-02 IntelaTrac Advanced Options Wed 9:15 Coronado C INT-13 Advanced Expression Editor Training Thurs 8AM Cortez C Slide 26

27 Procedure Scheduling Calendar view of scheduled procedures Look Ahead (Current or Future Scheduled) Look Behind (Completed, Overdue or Missed) Drag & Drop Scheduling Slide 27

28 Mobile Rounds & Procedures Ease of Execution Operator is presented with a list of Tasks Using Defined Pick Lists Device / Virtual Keyboard Peripheral Devices History Includes Notes Tabular Slide 28

29 Mobile - Focused Advice and Escalations Take Action! Message Text can be calculated Could be delivered from an external system at run time Slide 29

30 Mobile- Attached Documents Attached Documents provide a method to include additional information (usually reference material), in the form of a PDF, graphic, or spreadsheet, with a Procedure. Slide 30

31 Images on the Mobile Mobile IntelaTrac users can attach images to Task Notes The Note and Image are stored together The user can add additional Notes and Images Image Markup is supported in Version 4.3 Slide 31

32 Auditor Plus Review and Approval 17 Pre-Configured Reports Completed / In Progress Scheduled vs. Completed Exception Mobile Log Entry Reports Administrative Filters Customizable / Extensible Column Display & Naming Cell Coloring based on data New reports can be added Export to Spreadsheet Slide 32

33 Procedure Details View 33 Slide 33

34 Web Reports Creating Data Visibility through Scheduled and Ad Hoc Web Based Reporting. INT-18 Reporting Capabilities for IntelaTrac Slide 34 Wed 9:15 Cortez D

35 Agenda History of IntelaTrac Primary Use Cases IntelaTrac Application Components Value and Return on Investment Q/A Slide 35

Key Performance Indicators (KPI) & Return on

36 Key Performance Indicators (KPI) & Return on Investment (ROI) Identifying Key Performance Indicators (KPIs) and ensuring your Return On Investment (ROI) are critical for any project executed at your plant. Now the questions are: What do I track? How do I track it? Slide 36

37 KPI Examples Daily KPIs Daily KPIs should be tracked for round completion percentages, approval percentages, and exceedences reported. ROI KPIs Equipment Failure saves. Work Orders written based off of IntelaTrac findings Work order cost reductions Post-IntelaTrac versus Pre-IntelaTrac. ENV Compliance F&S Compliance Reliability Based KPIs Unit Utilization Pre/Post IntelaTrac Equipment MTBF Slide 37

38 KPI Defect Identification: Seal Issues Custom Reports built off of IntelaTrac Data Slide 38

39 Earlier Detection Of Defects Leads To ROI KPI s Reduced Equipment Repair Costs Tracking Success through mining data from other systems INT-15 Gaining Management Buy-In and Post Implementation Assessment Slide 39 Tue 4:15 Cortez D

40 Detect Defects Not Failures Slide 40

41 Questions & Answers Contact Information: David Dollar (office) (mobile) 2013 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.

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INT-16 Assigning Asset at Runtime

Slide 1 INT-16 Assigning Asset at Runtime Presented by: David Dollar, Sr. Product Manager October 16, 2013 social.invensys.com @InvensysOpsMgmt / #SoftwareRevolution /InvensysVideos /Wonderware /Group/Wonderware