Digital Drive Train Services. Enabling an increase in productivity and safety

Transcription

1 Digital Drive Train Services Enabling an increase in productivity and safety Unrestricted Siemens AG 2018

2 Siemens drives the Digital Enterprise for Process Industries VIRTUAL WORLD Cloud platform and operating system Integrated Engineering (2D/3D) & commissioning Asset Performance Management Data analytics Digital Twin & Simulation REAL WORLD Recipe, feedstock quality, Process & plant documentation Real Plant Secure Connectivity Integrated Operations & Services Digitally enhanced products Maintenance Process & Engineering & 1 Product design 2 Operation plant design 3 commissioning 4 5 Services

3 Digital Drive Train Services Start into the digital future Remote Services Condition Monitoring Services Improvement and Optimization Services Shorten unplanned downtime by enhancing troubleshooting activities Minimize planned and unplanned downtimes by optimizing maintenance activities Optimize the asset performance by managing assets based on performance KPIs Drive Train Analytics Energy Performance Contracting (Energy Analytics as option) Remote Support (incl. On-Call Service) Remote Diagnostics / Mobile Diagnostics / + Corrective Preventive/Predictive Proactive

4 Remote Services > Remote Support Fast downtime recovery by support via remote access connection Solution Siemens is offering Remote Support as add-on for on-call service contracts for converters Based on customer request, a remote connection can be established to the customer's system, enabling data analysis, error detection and in several cases also direct troubleshooting crsp Remote Support

5 Remote Services > Remote Support Key benefits Shorten unplanned downtimes by faster access to expert analysis and thus faster converter troubleshooting Reduced maintenance intervention cost by less and faster on site services and a high rate of firsttime-fix High data security by state of the art security standards (ISO & CERT certified) and full customer control

6 Remote Services > Remote Support Use-Case Fault in switchgear Customer installation Switchgear Transformer SINAMICS GM150 SIMOTICS HV compact Gear unit Compressor Operation Converter trip Drive train failing during operation with various error messages Real case w/o Remote Support Duration: 48 hours 1 Response time (detection) No guaranteed reaction time Root-cause w/o access to data (analysis) Advice customer via phone how to collect data, no direct access to drive train data Field Service troubleshooting (correction) Onsite analysis by expert required to find problem Problem solved Scenario with Remote Support Duration: 4 hours 1 Downtime saved Response time (detection) Expert response in 1 hour at weekend Guarantee d reaction time Root-cause with access to data (analysis) Remote access to all data and trace functions No Field Service needed, found out via remote trace function that converter is ok Customer troubleshooting (correction) Assistance for the customer No waiting time for Field Service, direct break fix at switch gear by customer Problem solved 44 hours saved 1 1 Specific use-case, exact time depending on e.g. contact time/availability of spares Unplanned downtime

7 Remote Services > Drive Train Analytics Fast downtime recovery with cloud-based alert and direct support Solution As part of Drive Train Analytics Siemens offers a new type of on-call service for converters Based on an automated alert a Siemens Expert contacts the customer to inform about the detected error and remotely supports the customer with direct troubleshooting Drive Train Analytics (DTA)

8 Remote Services > Drive Train Analytics Key Benefits Shorten unplanned downtimes by direct expert contact and cloud-based data availability enabling faster troubleshooting Reduced human intervention by due to continuous remote monitoring of critical assets Cloud-based analytics enabling real time fleet transparency with continuously improving data analysis

9 Remote Services > Drive Train Analytics Use-Case Fault in outside wiring and inside fiber-optical connection Customer installation Switchgear SINAMICS PERFECT HARMONY GH180 SIMOTICS HV compact FAN Operation Scenario w/o DTA Converter trip Drive train failing during operation Response time (detection) Root-cause w/o access to data (analysis) Field Service troubleshooting (correction) Duration: 12.5 hours 1 No guaranteed reaction time Advice customer via phone how to collect data, no direct access to drive train data Onsite analysis by expert required to find problem Proble m solved Real case with DTA Duration: 1.5 hours 1 Downtime saved Response time and root-cause with direct access to data (detection and analysis) System informs Siemens about failures and storage provides previous and current drive data including fault log and event log Siemens gets informed at the same time as customer and found out via historical data that customer can fix the problem by himself 1 Specific use-case, exact time depending on e.g. contact time/availability of spares Customer troubleshooting (correction) Assistance for the customer No waiting time for Field Service, immediate break fix started by customer Proble m solved 11 hours saved 1 Unplanned downtime

10 Condition Monitoring Services > Drive Train Analytics Cloud-based condition monitoring of the drive train to minimize downtimes Solution Analysis of converters, motors and gear units in one single system Continuous monitoring of all components to ensure transparency of the condition and health status of the equipment Automated alerting mechanism for various errors, foreseeing predictable failures Real-time status transparency based on dashboards and automated reports Drive Train Analytics (DTA) Automated reports Customer dashboard Automated alerts Expert Reports

11 Condition Monitoring Services > Drive Train Analytics Key Benefits Early error identification with continuous monitoring incl. automated reports for minimized unplanned downtimes Automated alert notification enables specific failure prevention measures Cloud-based analytics enabling real time fleet transparency with continuously improving data analysis and reduced human intervention

12 Condition Monitoring Services > Drive Train Analytics Use-Case Detection of weak points in the winding insulation Customer installation Operation MV motor Mill Winding failure Winding failure due to deterioration of insulation caused by aging Real case w/o DTA Operation Planned maintenance Response time (detection) Root-cause w/o any kind of data (analysis) Onsite inspection (analysis) Repair Center repair (correction) Duration: 3 months 1 No guaranteed reaction time Advice customer via phone what failure it could be Detection of winding failure In-house repair necessary, winding had to be replaced completely Proble m solved Scenario with DTA Duration: 5 days 1 (planned shut down) Downtime saved Operation with Drive Train Analytics (analysis) Automated reports and expert diagnostics Siemens detected at early stage a weak point in the winding insulation by Partial Discharge measurement via Drive Train Analytics Detection of weak points in the winding insulation 1 Specific use-case, exact time depending on e.g. contact time/availability of spares Planned maintenance (correction) Simple winding repair, repair with the right spare parts Simple winding repair before the winding is irreparably damaged Operation 3 months saved 1 Planned downtime Regular operation Unplanned downtime

13 Drive Train Analytics > Drive System Analyzer Web-based tool for visualization of all relevant status information 1. Fleet overview Fleet overview: Connected assets, incl. asset name, asset state and connection status Asset data overview: Asset specific KPIs, such as operation hours, specific temperature points 2. Asset data overview Asset health condition overview: Asset specific alert and fault notification records, incl. most frequent and longest duration alerts 3. Asset health condition overview One single tool for measurement and monitoring (also 3rd party)

14 Drive Train Analytics > Automated report Receive automatically generated status reports each month Monthly report on health condition of the respective asset Most relevant KPIs and events visualized in detailed charts for the respective timeframe Standardized report structure for each asset type (e.g. converter)

15 Data Science is multi-disciplinary Domain Knowhow + Algorithms + Data = Value Machine Learning Supervised Unsupervised Reinforcement Teach the machine relationship between data and context Labels Regression / Classification Find hidden structure in data No labels Clustering Algorithm learns to react to an environment Observe / Act / Reward Reward system D A T A

16 Prescriptive analytics builds upon data not magic Prescriptive Actions Failure- /Lifetime Prediction Failure- /Lifetime Prediction Failure Detection/ Root Cause Failure Detection/ Root Cause Failure Detection/ Root Cause Anomaly Detection Anomaly Detection Anomaly Detection Anomaly Detection Transparency Transparency Transparency Transparency Transparency Increasing complexity & business value

17 Thank You! Brad Maurice Vertical Manager Mining Siemens Limited Digital Factory and Process Automation Phone: siemens.com