Productie Proces Automatiseringsdag PPA Intelligente In en On-line Analytische instrumentatie

Transcription

1 Productie Proces Automatiseringsdag PPA Intelligente In en On-line Analytische instrumentatie

2 Wastewater Treatment Plant Parameter: ph Oxygen Conductivity Agenda: Intelligent Sensors Automatic Validation

3 Analytical Process Data Control Optimize Processes Quality of Product Yield of Process Efficiency Total Cost Hot Spots Skilled Operators Complexity of analyzers Liability of analyzers Time 3

4 Intelligent Sensor Management Maintenance installation configuration calibrations Live Time of Sensor trouble shooting replacement ISM is METTLER TOLEDO s solution for easy loop maintenance 4

5 Proactive vs. Reactive Maintenance Today, about 65 % of manufacturing plants worldwide replace defective equipment only then, when it does not work anymore: Process lines have to be stopped Replacement parts must be organized quickly Process lines have to be restarted Result: manufacturing time is lost, more resources have to be mobilized, planning becomes difficult Reactive maintenance is very frequent, even if it is the less efficient way to perform maintenance 5

6 Time-Based vs. On-demand Maintenance When they choose for proactive maintenance, manufacturing plants often perform their maintenance on a fixed-interval basis: Intervals are set by trial-and-error The majority of maintenance checks turn out to be unnecessary Expenses for Maintenance & Repair are high There is a real possibility of failure between intervals Time-based, proactive reduces the risk of process downtime and sensor failure to a reasonable level, but at high costs 6

7 Predictive Maintenance is Proactive With predictive maintenance, action is only required when the intelligent field loop pro-actively requests service: Probability of failure remain low Expenses for Maintenance & Repair are low Less downtimes with lower maintenance costs: the perfect solution from the customer s point of view Predictive maintenance is an industry trend ISM Evolution loops can fully support this trend 7

8 Plug & Measure for Easy Installation Pre-calibrated sensors can be replaced in minutes, with the upside of an lab-quality calibration calibrations trouble shooting replacement installation configuration calibrations trouble shooting replacement 8

9 New Maintenance Concept with ISM In the field In the maintenance shop / lab Swap sensors for regular maintenance and calibration ph DO ph DO ph Use sensors pre-calibrated by isense for fast and easy replacement in the field 9

10 isense TM System Overview 10

11 isense TM Asset Suite isense is a key extension to the ISM Portfolio isense boosts the benefits of ISM Easy pre-calibration in the lab Unique sensor performance visualization isense allows true sensors asset management Self-generated Pdf protocols Database of all sensor actions 11

12 Comprehensive Database All sensor operations are recorded in the SQL database and can be exported for further trend analysis Full sensor history (right-click for PDF) Track where the sensor is used Deactivate Sensor permanently 12 Extensive sensor asset base management becomes possible with isense

13 Advanced Diagnostic Tool The sensor wear monitor is a trend indicator for the ageing of the sensor installation configuration calibrations trouble shooting replacement 13

14 Sensor Wear: How it Works Wear factor Temperature / C ph Conditions like SIP, CIP or High ph, high Temperature are weighted and recorded to compute the sensor wear 14

15 Adaptive Calibration Timer calibrations installation configuration trouble shooting replacement 15 The Adaptive Calibration Timer allows to perform true Predictive Maintenance

16 Enhanced Diagnostics Information New sensor Used Sensor 16

17 Contactless Data Transfer Fist Generation ISM based, enhanced Contactless connector ph and DO to start No ISM, some diagnostics Contactless connector ph and DO 17

18 Memosens Next Generation Media Release 26 November 2008 agree on cooperation for inductive connector systems 18

19 Vertical Information Flow Conventional Bus System Bus System ISM Sensors Field level Process Control level 12,3 ma 171,4 mv TAG: LIC PV: 8.32 ph SV: 25.3 C Slope: 58.2mV/pH s/n: Sensor: InPro4800 S. Wear: 16 % Next cal in: 47 days Bus communication and ISM technology, together a strong team 19

20 Integration of Digital Communication MES Level (Manufacturing Execution System - Level) Operation (HMI) Concentrate and Forward Information Control and Engineering level Maintenance level Field level Sensor level 20

21 Digital Roadmap Vision 2007 Near Future Future Vision PD A Intelligent loop K8S K8S K8S ph DO ph ph DO Digital Sensor Digital Transmitter Cable less Mobile Service tool Diagnostics & Service 21

22 Wastewater Treatment Plant Parameter: ph Oxygen Conductivity Agenda: Intelligent Sensors Automatic Validation

23 Wastewater Treatment Plant

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30 System Components DCS

31 Automatic Cleaning In-line Chemical Cleaning Retractable Sensor Housings

32 Ceramic Retractable Housing

33 Control Data

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35 Control Data

36 Control Data of both cleaning procedures

37 Productie Proces Automatiseringsdag PPA Intelligente In en On-line Analytische instrumentatie