IOT Valve Monitoring The digital revolution

Transcription

1 IOT Valve Monitoring The digital revolution

2 Our product portfolio offers a wide range of variations Meeting customer needs in all industries Flow Level Positioners Process Protection Accessories Electromagnetic Ultrasonic In-line & Clamp-on Coriolis Vortex Point Radar and Guided wave radar Ultrasonic Temperature Rail Field Head Sensors Pressure Weighing Controllers Recorders Software SITRANS Library SIMATIC PDM Page 2

3 Challenges in the process industry? Page 3

4 Challenges in the process industry? Plant runtime > 30 years Page 4

5 Challenges in the process industry? Availability Page 5

6 Challenges in the process industry? Investment protection Page 6

7 Our answer Digitalization Data flow Networking Transparency Intelligence Page 7

8 And the field devices? A Page 8

9 Defective And the field devices? can cause massive disruptions A Page 9

10 SIMATIC PDM MS monitors the status of intelligent field devices SIMATIC Process Device Manager Proven tool for managing intelligent field devices Page 10

11 One station monitors up to 500 intelligent field devices A Page 11

12 SIMATIC PDM MS For use in small plants or relevant to specific plant sections up to 500 field devices up to 1000 field devices up to field devices Page 12

13 SIMATIC PDM MS is simple Supports the most used communication types Page 13

14 SIMATIC PDM MS is capable of even more Cyclical retrieval of device data Page 14

15 Data SIMATIC flow in PDM the MS cloud is capable for of even more EAM, Cyclical CM, retrieval Service, of all Maintenance data Page 15

16 Uniform XML data interface Page 16

17 The Siemens Vision: A cloud based, vendor independent Asset Performance Suite User MindApps 3 rd Party Process Industry Apps Data analysis Asset diagnosis Health monitoring Predictive maintenance Services and Applications (own, Siemens, OEMs,...) MindApp Fleetmanager Build your own Dashboard OEM App Analytics App Asset and Process Performance Suite Valve Monitoring DCS Health Monitoring Pump Monitoring Control Performance Analytics Drive Train Analytics Event Analytics Specific applications for certain asset groups Harmonized Look & Feel Covers assets from multiple manufacturers IIoT platform (cloud) MindSphere Secure data storage Worldwide access to all plants and locations Plants worldwide Data acquisition via field sensors and plant network Page 17

18 Take advantage by the wealth of your plant data to increase plant uptime and lower operating costs Control valves are important for the operation and safety of every chemical plant. Unexpected valve failures can lead to plant downtimes, process upsets and safety risks Unnecessary maintenance leads to high operating costs The solution: Valve Monitoring from Siemens Provides comprehensive information on the health of your control valves Supports optimized maintenance of your valve fleet Page 18

19 Valve Monitoring Application Customer advantages Increase plant uptime by avoiding spontaneous valve failures + Customer advantages Recognize anomalies and wear in time for planned maintenance slots + + Reduce maintenance cost through predictive maintenance Increase Plant Availability Reduction of Maintenance and Operation Cost Minimize wear and reduce operating cost through optimized positioner settings + Enabling company-wide use of expert know-how Increase transparency on valve and positioner quality + Recognize and analyze quality and measures across installed base + Page 19

20 Valve Monitoring System Integration with PCS 7 V1 of App as an On-premise installation On-premise installation PCS 7 (or S7 400) DCS Health Check Valve Monitoring Pump Monitoring Drive Train Analytics OS PDM MS serves as edge device collects all diagn. data generates XML files XML file Firewall AS cyclic transfer e.g. 1x / day Field Bus or HART Valve positioner diagnostic data via routing through AS cyclic upread, e.g. 1x / day Requirements in the plant PCS 7 data base export to PDM MS Selection of the valves to be monitored (recommendation: all) PDM MS (micro IPC with software) for up to 500 valves Communication link from PDM MS to App PC Page 20 Requirements in the evaluation center PC (or VM ware) to run the App incl. environment Browser (Chrome) access to the App

21 Hardware of the PDM MS: The Siemens Industrial PC Microbox IPC427C PDM MS serves as edge device collects all diagn. data generates XML files Link to the Siemens pages on IPC427C: click here Page 21

22 Valve Monitoring System Integration V1 of App as an On-premise installation On-premise installation DCS DCS Health Check Valve Monitoring Pump Monitoring Drive Train Analytics Operator Station PDM MS serves as edge device collects all diagn. data generates XML files XML file Firewall Controller cyclic transfer e.g. 1x / day Field Bus or HART Valve positioner diagnostic data cyclic upread, e.g. 1x / day Requirements in the plant Selection of the valves to be monitored (recommendation: all) list of tags, positioner types, EDDs, field bus addresses Connection to field bus resp. HART multiplexer PDM MS (micro IPC with software) for up to 500 valves Communication link from PDM MS to App PC Page 22 Requirements in the evaluation center PC (or VM ware) to run the App incl. environment Browser (Chrome) access to the App

23 Valve Monitoring Options with later versions of App Choice between On-premise and Mindsphere installation additional option: Mindsphere DCS Asset Performance Suite Valve Monitoring Pump Monitoring Drive Train Analytics DCS Health Check Operator Station PDM MS serves as edge device collects all diagn. data generates XML files XML file Firewalls, DMZ, etc. Controller cyclic transfer e.g. 1x / day Field Bus or HART Valve positioner diagnostic data cyclic upread, e.g. 1x / day Requirements in the plant Selection of the valves to be monitored (recommendation: all) list of tags, positioner types, EDDs, field bus addresses Connection to field bus resp. HART multiplexer PDM MS (micro PC with software) for up to 500 valves Communication link from PDM MS to Mindsphere Page 23 Requirements in the evaluation center Mindsphere environment to run the App Browser (Chrome) access to the App

24 Valve Monitoring Features Display and analysis of KPIs, flagging of anomalies Valve Health Status & History Calculation and analysis of KPIs such as Total travel Number of direction changes Change of end positions Slip stick, Control deviation Electronics temperature... Diagnostics Generation of maintenance messages if limits are reached in anomalies are detected Service Recommendations today as an optional service automatically after gaining more data Page 24

25 Valve Monitoring Features Show valve details including Valve detailed information KPI comparison User comments Log of events incl. comments and maintenance events and notices Tracking of peculiar valves in Watchlist Tracking of maintenance actions Page 25

26 Valve Monitoring Features Maintenance Support Estimation of a recommended maintenance date per valve Extrapolation of several Wear KPIs and comparison with set limit Derivation of recommended maintenance date predicted wear date Page 26

27 Valve Monitoring Features Maintenance Support Generation of optimized valve maintenance plans Automatic generation of maintenance plans, i.e. lists of valves due for maintenance based on a (externally) specified maintenance schedule and the predicted wear date of each valve Continuous updates of plans through near-real-time maintenance data Individual modification of maintenance plans via drag and drop possible Freezing of plans, locking of valve to a certain plan Transfer of maintenance information to superordinate Maintenance System (e.g. Siemens COMOS MRO or SAP PM or IBM Maximo) Page 27

28 Summary: Supporting the potential of Asset Performance Optimization and Predictive Maintenance through the Valve Monitoring App Today, the valuable data from valve positioners are rarely used the assessment and optimization of valve setings is often neglected valves are typically maintained in fixed intervals unnecessary cost or used until failure risk Customer Value through the Valve Monitoring App Increase of Plant Availability Reduction of Maintenance Cost Enabling company-wide use of expert know-how Page 28