Enterprise Asset Maintenance Optimization

Transcription

1 Cognizant Utilities Solution Overview Enterprise Asset Maintenance Optimization Executive Summary In large enterprises, reducing costs related to asset maintenance, repair and ultimate replacement is among senior management s top concerns. Downtime in any network, manufacturing or computer system ultimately results not only in high repair costs, but in customer dissatisfaction and reduced revenue. To combat this, we have developed an optimized way to model assets and their associated business events, which are structured and mapped in SAP. Traditionally, the power utilities industry has faced numerous obstacles to achieving 100% reliability. One key reason is the difficulty in predicting the mean time between failures (MTBF) of transmission and distribution equipment. Most utilities follow manufacturer recommendations for preventive maintenance using a calendar-based approach for repairing or replacing equipment. But there is an ongoing need to develop and implement a plan to allow utilities companies to change maintenance practices from reactive to proactive. While many utilities have implemented SAP s plant maintenance (PM) module in their infrastructure to improve maintenance processes, most didn t to do so proactively. Merely implementing PM is not sufficient for a true proactive approach. Electric delivery asset management departments across the industry developed a maintenance management system that used a proactive condition-based maintenance approach to help predict equipment failures before they occurred. The primary assets of concern include transformers, phase-angle regulators, high-voltage regulators, load tap changers (LTCs) and breakers. These maintenance systems, which are built on an OSIsoft platform, use several modules, including: The PI system for archiving operational data. A module database for sorting real-time data, aliases, parameters and process specs into groups for use in programs and displays, coupled with PI ACE/Performance Equation. Process Book, a graphics package for creating dynamic, interactive displays of data. RLINK (a business process engine between operational and enterprise levels) for interfacing to the SAP PM module for generating work orders and notifications. Using this software, more people across the enterprise are privy to asset conditions and thus can make better decisions and respond quickly to problems. With more people analyzing the data, utility company systems can ensure that maintenance information is much more accurate and reliable now than before the software s implementation. However, after many years some utilities companies experienced critical challenges in maintaining the RLINK and new features enabled in OSIsoft/SAP infrastructure. As a result: Maintenance has become more complex in adapting to changes. cognizant utilities solution overview november 2012

2 Dependency of PI point has increased the cost of tag usages. Traceability of failures is a challenge. Performance degrades as message volumes increase. The need has arisen to have a solution that is asset based rather than tag based. (Most global energy companies use an historical/ time series database to Energy utilities (and an array of manufacturing and process enterprises) continuously seek ways to improve business performance yet lack intuitive ways to manage complex events from the plant and distribution network. capture real-time asset information, based on sensors, and store these measures in tags.) To overcome these challenges, we have developed a solution we call Asset Maintenance Center (AMC), which monitors processes and synchronizes assets, translates operational events to enterprise events and records the responses from the enterprise. 1 Insights derived from these measures, events frames and enterprise actions are the core ingredients for real-time performance of the asset network. Business Needs Energy utilities (and an array of manufacturing and process enterprises) continuously seek ways to improve business performance yet lack intuitive ways to manage complex events from the plant and distribution network. To maintain the availability of the assets and drive organizational productivity, senior leaders, principal engineers, network operators and production supervisors need real-time access to information across enterprise systems. This provides the insights needed to inform decisions made throughout the enterprise network. Essential elements include: Real-time status of all resources and work centers. Alarms and alerts that provide real-time resource status information. Ability to view a range of resources and to switch resources in the case of breakdowns. Real-time visibility into all maintenance orders across the entire network, anytime and anywhere. Ability to create measurement readings and counter readings for job safety and environmental protection. Ability to create warning and instruction notifications. Ability to perform reliability management. Integrated Enterprise Maintenance Our enterprise Asset Maintenance Center (AMC) platform for OSIsoft and SAP software monitors network assets via configurable business rules that automatically process, translate and intuitively manage enterprise data workflow, bi-directionally, into an event frame model using SAP enterprise services (which is SAP s SOA, built on top of NetWeaver). The AMC records all responses on work orders, measurements documents and notifications from individuals using SAP TM across the enterprise. Doing so enables the AMC to monitor various comparative KPIs on asset health performance and field level responses. Cognizant s Solution Our solution redefines asset events from a traditional point-based approach to an event-frame model. This paradigm shift would associate event frames with an asset model. An event frame records important process or business events and helps users find the related real-time data. Specifically, the model provides a service-based trigger mechanism to implement asset rules based on the asset types. SAP has exposed the catalog of asset management services and processing services as per the SOA model. So, based on operational data we invoke the appropriate enterprise services and the response of all the tracked services. This handshake between systems gives the solution a truly agile approach where it is loosely coupled. Our AMC functions as a vital component for receiving the business events. It conveys actionable events to the enterprise systems based on dynamic rules. These rules, which can be adjusted by users with a configuration management interface, are based on the asset category and history of the asset performance. The solution is built on OSIsoft s PI Event Frames to store, search, view and compare the time ranges of data by name or other attributes. Each asset attribute is monitored by associating the service deployed to execute the asset performance conditions and trigger actions. Event Frames workflow is generated and recorded for every prudent condition. Our intuitive service components process utilities solution overview 2

3 Benefits of AMC AMC Console Best practices and expertise from OSISoft and SAP focusing on energy and processes industries. OSISoft Business Process Engine SAP Standards-based interfaces for wider compatibility and modular deployment. Built with service-based model, process optimization with event frames and service notification. Figure 1 all relevant events and actionable events in appropriate enterprise systems. To complete this workflow, the system also monitors and processes responses in a multithreaded, indigenously built workflow engine that processes messages from the request queue and stores the responses with the corresponding requests in the queue. There is also a comprehensive, configurable dashboard view of the asset health conditions. Benefits Move to an asset-based approach from a tag-based model, thus simplifying the view of assets and also saving the utility the cost of unnecessary dependence on nontrivial tags. Use of the OSIsoft PI Notification and Event Frames model. Benefits of the PI approach are that the system monitors the process, notifies operations when key events occur and communicates results all based on userdefined business rules. Event Frames helps by recording important process or business events and enabling users to find the related realtime data. Enterprise (SAP) collaboration happens through an SOA-based approach. This makes application interoperability easier, enabling extensibility and lowering the costs of operation. Creates maintenance documents, notifications and work orders in a more predictive approach, using business rules. Reduces the maintenance cost by repairing compared to replacement. Provides event insight analytics in asset comparison using event overlays. Event Overlay Trend Events Temperature (degree celsius) :00 11:00 12:00 13:00 14:00 15:00 16:00 17: Moisture (PPMu) MOIST_NWK94 TEMP_NWK44 TEMP_NWK32 TEMP_NWK88 7/19/2012 Using this Event Frame concept the asset event patterns could be compared against similar asset categories which is called an event overlay. Figure 2 utilities solution overview 3

4 Fault Management: Type, Status and Resolution Dashboard Figure 3 Fault Management: Type, Status and Resolution Dashboard Princeton\LTC2001 MDoo ID Notification ID Work Order ID M N W LTC Motors Amps WMS ef- Stop LTC Positions able and olsvisualanalytics Plot Load Watts 60 Top Oil DegC LTC Oil DegC Bottom Oil DegC Oil Temperatures (C) Plot /4/ :17:05 AM 10/4/2012 6:17:05 AM Figure 4 Fault Management: Type, Status and Resolution Dashboard Figure 5 utilities solution overview 4 10 Cooling Fan Amps Stage 3 Load (MWatts)

5 Enterprise asset synchronization: Asset hierarchy is maintained in the operational systems based on how the asset category, measurement points and other associated attributes are grouped. The industry currently loads various eenterprise Asset information into these systems as a batch, with some manual mechanism. Our solution simplifies the process by automating this synchronization using SAP Enterprise Asset Management Services and OSIsoft Asset Framework to resolve these challenges and improve efficiency. Tracks the operational health of the functional location or equipment against enterprise conditions. Drills down to the equipment level and the corresponding availability status. Correlates the various measurement points with similar equipment category. Software Specifications Microsoft NET Framework 4.0.SQL server 2008 R2 Version. Enterprise Library 5.0. SAP Enterprise Services Explorer. 1.1 for Microsoft.NET. OSIsoft PI Server PI AF Server 2010 R3 Version PI Notifications. PI Event Frame. SAP SAP ECC SAP PM. SAP Net Weaver 7.3. Enterprise Services Repository. SAP PI 7.3. Footnote 1 AMC is a proof of concept that demonstrates how distribution network engineers and enterprise executives can monitor and optimize asset performance and process events in real time to their enterprise systems, bidirectionally. References S.A. Snowden and B.R. Upadhyaya, Automated Diagnosis of Motor-Operated Valves, Maintenance and Reliability Conference Proceedings, May A.L.G. Carneiro, A.A Da Silva and B.R. Upadhyaya, Development of an Integrated Condition Monitoring System for Motor-Operated Valves for Brazilian Nuclear Power Plants, Maintenance and Reliability Conference, Gatlinburg TN, May J. Hines and R. Seibert, Technical Review of On-Line Monitoring Techniques for Performance Assessment, Vol. I, S. Wegerich, SmartSignal Corp., Condition-Based Monitoring Using Nonparametric Similarity Based Modeling, Japanese Maintenology Society Meeting, J. Hines and D. Wrest, Signal Validation Using an Adaptive Neural Fuzzy Inference System, Nuclear Technology, 1997, pp Auto Associative Model Input Variable Selection for Process Modeling, April 2004, Virginia Beach, VA. On-Line Monitoring Robustness Measures and Comparison, September 2004, Halden, Norway. J. Hines, A. Usynin, MSET Performance Optimization through Regularization, Nuclear Engineering and Technology 2005, 38(2): S. Wegerich, R. Singer, J. Herzog, and A. Wilks, Challenges Facing Equipment Condition Monitoring Systems, Maintenance and Reliability Conference Proceedings, May 8-10, utilities solution overview 5

6 About Cognizant Cognizant (NASDAQ: CTSH) is a leading provider of information technology, consulting, and business process outsourcing services, dedicated to helping the world s leading companies build stronger businesses. Headquartered in Teaneck, New Jersey (U.S.), Cognizant combines a passion for client satisfaction, technology innovation, deep industry and business process expertise, and a global, collaborative workforce that embodies the future of work. With over 50 delivery centers worldwide and approximately 145,200 employees as of June 30, 2012, Cognizant is a member of the NASDAQ-100, the S&P 500, the Forbes Global 2000, and the Fortune 500 and is ranked among the top performing and fastest growing companies in the world. Visit us online at or follow us on Twitter: Cognizant. World Headquarters 500 Frank W. Burr Blvd. Teaneck, NJ USA Phone: Fax: Toll Free: inquiry@cognizant.com European Headquarters 1 Kingdom Street Paddington Central London W2 6BD Phone: +44 (0) Fax: +44 (0) infouk@cognizant.com India Operations Headquarters #5/535, Old Mahabalipuram Road Okkiyam Pettai, Thoraipakkam Chennai, India Phone: +91 (0) Fax: +91 (0) inquiryindia@cognizant.com Copyright 2012, Cognizant. All rights reserved. No part of this document may be reproduced, stored in a retrieval system, transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the express written permission from Cognizant. The information contained herein is subject to change without notice. All other trademarks mentioned herein are the property of their respective owners.