OpEx Advantages + Asset Optimization

Transcription

1 Dominik Brand Manager FOUNDATION Fieldbus Endress+Hauser Process Solutions AG. Slide 1

2 CapEx / OpEx savings and life cycle phases Operation Design Installation FAT,SAT, Commissioning Maintenance Renewal CAPEX Savings OPEX Savings Use of an open standard technology Reduction in cost for wiring, barrier, marshalling rack and Junction box Reduction in cost for control system - I/O interface Reduction in cost for power supply unit and number of cabinets Reduction in control room size Engineering and documentation Use of an open standard technology Increased information for better operation, accuracy of measurement & control Enhancement in control function and the performance Improved throughput On-line diagnosis enables true preventive maintenance Improved trouble shooting Fast commissioning, lower start-up costs Slide 2

3 Increase Plant Availability Slide 3

4 Where are the OpEx savings? Operation and Production Costs Additional production time by: Improved maintenance for: Fewer process upsets High availability Easier and faster incremental expansion Improved throughput by: Improved quality and productivity Improved Alert capabilities for better operation Improved accuracy of measurement and control Data access for Business Intelligence Slide 4

5 Where are the OpEx savings? Maintenance Costs Right time or proactive maintenance to: Reduce unnecessary trip to plant Avoid failure instead of solve failure Reduce time to repair Root cause identification and elimination Reduce inventory cost Infrastructure with: Centralized maintenance Centralized tooling and data management Slide 5

6 Operation and Production Costs Slide 6

7 Control In the Field Performance Benefits CIF provides superior reaction to deterministic disturbance in the process Possible to synchronize data sampling and control Possible to reduces Latency effect in the control chain CIF provides enhanced process integrity Slide 7

8 Reduced Variability 62 Process Output (%) Slide 8 Time (s)

9 Tighter Loop Control Control Limit Digital Analog Pneumatic Manual Slide 9 For fast process application: Improvements in response time of between 10% and 30 % Improvements in disturbance rejection of up to 20% Digital Analog Pneumatic Manual

10 Migrate CIF progressively. maximizing ROA! DCS Advanced Control M A X Ethernet A S S E T S FF - H1 Field Controller Hybrid CIF Pure CIF U T I L I Z A T I O N Slide 10

11 Maintenance Costs Slide 11

12 Potential for improvements Potential for Predictive Maintenance with Pressure Transmitters 35% 30% 25% 35% 28% Shell Global Solutions 20% 15% 20% 10% 5% 0% Routine check No Problem Calibration shift 6% 6% 4% Zero Off Plugged lines Failed Slide 12 63% of instrument maintenance labor results in no action taken -> waste of resources

13 Potential for improvements Maintenance today: 63% of work orders generated for transmitters are unnecessary either no problem or problem with other equipment 75% of control valves removed from process lines did not require removal 50% of instrument tech s time is spent on paperwork Slide 13

14 Equipment Monitoring in the Plant Process Condition Monitoring Devices Functions Sub-processes Other key performance indicators Quality F t LC FC F f FC Machine Condition Monitoring Condition Monitoring Runnability Monitoring Oil lubrication Monitoring Field Device Condition Monitoring Field Devices on different field buses Slide 14 It is all about Diagnostic Information!

15 Role Based Diagnostics Process Control Engineering Station Plant operators Asset Management Maintenance Station Plant maintenance engineering Control Network H1 Slide 15 1

16 Maintenance Urgency Wear Reserve Slide 16

17 Maintenance Urgency Wear Reserve Alarm Warning Prediction of time Before affecting the process Wear reserve Slide 17

18 Additional Key Improvements Centralized Tooling and Configuration data Easy back-up of the configuration data Easy audit trail and data management Easy update and migration of the Tooling Basis and fundament for real Asset Management Better Calibration Management Improved Management of the Installed Basis Slide 20

19 Asset Optimization Control Network Asset Management Software uses fieldbus for Asset Optimization Solutions ❸ ❷ ❶ Digital Communication from Sensor to Asset Management inductive signal transmission inductive energy transmission Slide 21

20 Asset Optimization Asset Data Access Control Network Parameter access via fieldbus for both Transmitter and Sensor to enable: Configuration Diagnostic Slide 22

21 Asset Optimization Calibration Mngt. Control Network Manage complete life cycle of a sensor Trace the calibration and adjustment history Customized calibration protocols are generated automatically Slide 23

22 Asset Optimization Link to CMMS Level portal Control Network CMMS Internet ❸ ❷ ❶ Slide 24

23 Business Intelligence - Managing Data Slide 25

24 Questions? Slide 26