Products Solutions Services. Endress+Hauser. Engineering in Food & Beverage

Transcription

1 Products Solutions Services Endress+Hauser Engineering in Food & Beverage Slide 1 / 28

2 Agenda Introduction, Endress+Hauser at a Glance Fit for Purpose instruments Follow the signal Asset Management Why and how? Energy management Follow the signal Example UHT Slide 2 / 28

3 Our structure Holding company in Reinach, Switzerland 19 production facilities in 11 countries Sales centers and representatives in more than 100 countries Regional sales support centers Slide 3 / 28

4 Endress+Hauser at a glance 2014 Our world We provide sensors, instruments, components and systems for tasks in the field of Level measurement Flow measurement Pressure measurement Temperature measurement Analytics and sampling Data management Device communication and integration

5 Engineering Services Consultancy Engineering in Food & Beverage Field of activity key focus ERP BPI (Business Process Integration) Middelware ERP Integration Maintenance management Asset information (AIM) Device information (DIM) Calibration CM Inventory (IMS) Tank Terminal Management (TTM) Energy monitoring/ management Analyse Infrastructure Instrumentation & (Level Flow Pressure Temperature Analysis) Slide 5 / 28

6 Diagnostics Value / Asset information Engineering in Food & Beverage Follow the Signal User System Data Signal : Quality Assurance/Metrology : CMS (Calibration) : Not real time (week/month) : 4-20mA, Fieldbus (digital) User System Data Signal : Operator : DCS, PLC/SCADA : Real time (second) : 4-20mA, Fieldbus (digital) Driver : Quality Driver : Process, Accuracy Quality Management Process Management User System Data Signal : Process Manager : MES, EMS (Energy) : Not real time (hour/day) : 4-20mA, Fieldbus (digital) User System Data Signal : Safety : SiS (Safety) : Real time (second) : 4-20mA, Fieldbus (SiS, PROFIsafe) Driver : Efficiency Driver : Safety, Reliability Energy Management am&t Safety Management CMMS System CMS DCS EMS ERP MES PAM PLC SCADA Acquisition SiS : Computerized Maintenance Management : Calibration Management System : Distributed Control System : Energy Monitoring System : Enterprise Resource Planning : Manufacturing Execution System : Plant Asset Management : Programmable Logic Controller : Supervisory Control And Data Slide 6 / 28 : Safety Instrumented System User : Engineering / Maintenance Systems : PAM, CMMS (Asset) Data : Not real time (hour) Signal : Status (digital) Driver : Reliability, Availability Asset and Ronald Life Cycle de Mngt. Vries User : Logistics System : ERP (Material Management) Data : Not real time (hour/day) Signal : 4-20mA, Fieldbus (digital) Driver : Delivery, Flexibility Inventory Management TankVision

7 Triangle approach Platform Demand Installation Instruments Slide 7 / 28

8 Shorten time to production, Ensure & improve asset performance during operation Maintenance management Performance Monitoring, Maintenance Analysis Inspection and monitoring of assets Spare part management Maintenance/Calibration Planning & Scheduling Calibration management Device Configuration Management Asset Information Management Documentation management Slide 8 / 28

9 Enable Continuous Improvement VISION, MISSION & STRAGTEGY As Is Audit CONCEPT DEVELOPMENT IMPLEMENTATIO N EXECUTION IMPROVEMENT High level Objectives AS IS Audit Install Base Audit Standardization of Activities SOP & WI Clear assignments Checklists Inspection Calibrations Business processes Consistent Data Adequate Administration Right Level of detail, tagnumber level Timeliness Planning Within Specification Out of specification Certification Time consumption Breakdown Continuous Improvements Analyses of Data Breakdown Overview Calibration Data Objective: Optimum Availability Focused Maintenance Effective result Efficient execution Vision, Mission and Strategy What is necessary to achieve to support the Vision, Mission and Business Strategy Criticality of Tags Current Level of maintenance Migration plan MPE Value Existing Systems Slide 9 / 28

10 Solutions packages and services mix Your business process philosophy defines the mix Your Business Process Maintenance Management Your Business Process philosophy Outsourcing Maintenance Management. Insource Maintenance Management E+H offering mix is based on your strategy mix/operating point The mix is determined via Consulting Maintenance Management Services. Maintenance Management Solution Packages Service Agreements for Maintenance Management Solution Packages for Maintenance Management Slide 10 / 28

11 Information assurance Dynamic hyperlink / Web Services W@M Enterprise Flow Pressure Level Temperature Analysis Endress+Hauser Product center Serial number Order code Manuals Certificates Purchase info Events: Production info Calibration info Repair info Serial# CER Endress+Hauser Sales center Maintenance reports Calibration reports Service reports Repair reports Inspection reports within maintenance or calibration contracts Slide 11 Slide 11 / 28

12 Self-Monitoring and diagnosis of field devices OK Device is operating normally 1. Maintenance required (M = maintenance) 2. Check function (C = check) 3. Off-spec (S) 4. Failure (F = failure) Slide 12 / 28

13 Example: Temperature diagnostic functions Sensor drift detection If the measured values of the two sensors deviate by a preset value, a warning signal is given to the PLC. Ambient temperature monitoring The temperature of the electronics is controlled constantly. Monitoring of the sensor limits The physical measuring range of the connected sensor was exceeded/under-cut. Open circuit or short-circuit Failure of the sensor cables is recognized on RTD's and TC's. Short-circuit detection on RTD's. Sensor backup In case of a sensor failure the trans-mitter automatically switches to the second sensor and sends a warning signal to the PLC. Cable-corrosion-detection Corrosion control on the sensor cables of an RTD 4-wire or TC sensor. Simulation active Slide 13 / 28

14 Reference Topology Plant Asset Management Life Cycle Management Portal (CER) Control Workstation HMI Maintenance Workstation Device configuration & Asset Information Internet replication * see note below Profinet Ethernet TCP/IP Profibus DP Intelligent Ethernet/ PROFIBUS gateway Fieldcare central Device configuration & Device Performance Monitoring (Namur 107 compliant) ET-200iSP/M: RIO PROFIBUS DP/HART HART-PASSTHROUGH DP PA Profibus PA *Note: Before Device Performance Monitoring (DPM Namur 107) can be implemented it s important to check if the PLC hardware is compatible. Level Pressure Temperature Flow W@M Enterprise (Asset information) REV. DESCRIPTION DATE BY CUSTOMER Cargill Krakatau 0 PAM LCM KBL PROJECT PAM LCM SIZE FSCM NO DWG NO A4 SCALE 1:1 SHEET 1 OF 1 REV 0 Slide 14 / 28

15 Business Process Integration SAP-PM Service results from: - Customer (CMMS) - E+H (CompuCal) Any System Integration Update Middleware Middleware Work order data CompuCal KPI update In dashboard Calibration Management Calibration Work order Asset update for audit trail Integration Middleware Calibration executed & Managed W@M Portal/Enterprise Instrument specific Central Asset information Beamex MC5 Automated Field Calibration CompuCal Mobile Manual Field Calibration Slide 15 / 28

16 How is the plant condition and how is it supported when it needs attention? SAP-PM Service results from: - Customer (CMMS) Device Performance Monitoring OPC UA Middleware Send notification to Service supplier W@M Portal/Enterprise Update status in Asset Logbook Store data in historian E+H SMP via Netviewer Inspection executed & Managed Instrument specific Central Asset information Slide 16 / 28 Beamex MC5 Automated Field Calibration OSI Pi Data Historian Workflow

17 Project Approach projects: Overview and process CAPEX Savings OPEX Savings Project Evaluation Inventarisation Concept Implementation Data Analysis Optimization Continuous improvement 1 day 1 day 1-2 weeks 1-2 months years Scope and budget definition On site analysis of the installed base. Final report and presentation. User Requirement specifications Functional Design Specifications Detailed and modular offer based on the PAM concept. Components delivery and installation. Installation of software. Inclusion of existing instrument data. Commissioning. Project management. Analysis and interpretation of the collected data and identification of areas for potential savings CMMS W@M Suggestions how to do maintenance on demand to improve efficiency. Device performance Monitoring KPI Develop and implement continuous improvements and thereby increase efficiency Project plan. Training. (life cycle management) Service. Folie 17 Slide 17 / 28

18 Products Solutions Services Energy Management Slide 18 / 28

19 Diagnostics Value / Asset information Engineering in Food & Beverage Follow the Signal User System Data Signal : Quality Assurance/Metrology : CMS (Calibration) : Not real time (week/month) : 4-20mA, Fieldbus (digital) User System Data Signal : Operator : DCS, PLC/SCADA : Real time (second) : 4-20mA, Fieldbus (digital) Driver : Quality Driver : Process, Accuracy Quality Management Process Management User System Data Signal : Process Manager : MES, EMS (Energy) : Not real time (hour/day) : 4-20mA, Fieldbus (digital) User System Data Signal : Safety : SiS (Safety) : Real time (second) : 4-20mA, Fieldbus (SiS, PROFIsafe) Driver : Efficiency Driver : Safety, Reliability Energy Management am&t Safety Management CMMS System CMS DCS EMS ERP MES PAM PLC SCADA Acquisition SiS : Computerized Maintenance Management : Calibration Management System : Distributed Control System : Energy Monitoring System : Enterprise Resource Planning : Manufacturing Execution System : Plant Asset Management : Programmable Logic Controller : Supervisory Control And Data Slide 19 / 28 : Safety Instrumented System User : Engineering / Maintenance Systems : PAM, CMMS (Asset) Data : Not real time (hour) Signal : Status (digital) Driver : Reliability, Availability Asset and Ronald Life Cycle de Mngt. Vries User : Logistics System : ERP (Material Management) Data : Not real time (hour/day) Signal : 4-20mA, Fieldbus (digital) Driver : Delivery, Flexibility Inventory Management TankVision

20 Triangle approach Platform Demand Installation Instruments Slide 20 / 28

21 Motivation for Energy Management Reasons why energy Management is a current topic in companies Sustainabilit y responsible independent awareness of values eco-friendly Reducing energy costs (Save money, KPI) Legal and political possibilities (e.g. tax exemptions, subsidies eq SDE+, EIA & MIA) Improve company image / Marketing / Public relations Sustainability management Strategy for Energy and Environment Management system certification (EMAS, DIN EN 16001, ISO 50001, DIN ISO 14001) Competitive advantages (Cost price) Produce and sell Green products and services Improvement/ optimization of production processes Slide 21 / 28

22 Engineering in Food & Beverage Energy Trends Product Carbon Footprint Will be very important for each and every product DIN ISO International standard for energy management Data Integration Flexible integration of energy relevant data into other systems Sustainability 50% of end-consumers require sustainable products Cost Savings To gain advantages against competitors and be more efficient Energy Solutions Rising Energy Prices Green Image Create sustainable company image by advertising of companies green activities Big Data Large amounts of data that will be analyzed and used for forecasting and identifying improvements Slide 22 / 28

23 Potential Savings Research has shown that realistic savings of 5%-15% are achievable Slide 23 / 28

24 Topology of an full scale EMS Slide 24 / 28

25 UHT-Temperature curves of product and sensor T [ C] Standard control limits Exceedance of maximum temperature loss of quality, waste of energy! Improvement of control accuracy! higher safety lower costs QuickSens control limits Slow control loop: Product temperature Temperature signal competitor insert with standard technology Fast control loop: Product temperature Temperature signal Dropping below minimum temperature microbiological risks! t [s] Slide 25 / 28

26 UHT - Temperature curves of product and sensor T [ C] Shorter response time of insert leads to: Faster control loop, narrower control band Higher measurement and control accuracy Higher food safety, optimum quality, energy/cost savings Average product temperature standard sensor Slow control loop: Product temperature Temperature signal competitor insert with standard technology Fast control loop: Product temperature Temperature signal Lower average temperature Average product temperature standard sensor t [s] Slide 26 / 28

27 UHT - Example calculation for possible cost savings 1 UHT treatment module Runtime: 5,000 hours per year Higher control accuracy by usage of fast response time technology Example: decrease of average product temperature by 2 C through narrower control bandwidth and faster temperature detection. 2 C lower average temperature means 30 kg less steam per hour! Average costs for 1 kg steam = kg/h x 5,000 h/year x 0.08 /kg steam = = ,- /year Benefits: Cost savings of ,- /year and at the same time higher food safety! Slide 27 / 28

28 Products Solutions Services Any questions? Slide 28 / 28