USERS CONFERENCE Copyright 2016 OSIsoft, LLC

Transcription

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2 Loram Knows How to Keep Things Moving Presented by Eric Manninen Principal Electrical Engineer

3 Agenda Overview 1. Loram Company Overview 2. Machine Design System Layout 3. Business Drivers for Information Enabled Solution 4. OSI PI Server Solution Implementation 5. Loram s VantagePoint Portal Demonstration 6. Questions for Presenter? 3

4 Loram - Company Overview Office Headquarters are located in Hamel, MN Employs over 1000 people Builds Leased and OEM Machine Equipment Outstanding Safety Record Provides Railway Maintenance Services to Major Commercial Railroads and Passenger Rail Markets across North America and the World through: Rail Grinders RailVacs Ditchers RailTrains Track Lifters Track Undercutters Rail Inspection Vehicles Shoulder Ballast Cleaners 4

5 Loram Representative Machine Types RailVac Light-Rail Grinder Shoulder Ballast Cleaner Rail Grinder For more information, visit us at: 5

6 Loram Rail Grinder Video Demonstration 6

7 Physical Layout of typical Rail Grinder Machine Typical Length of 800 feet (244 m) 43 Liter Diesel Engine Generator Set 4920 KW Power Generated on Machine Power Bus draws up to 4000 Amps HP Grind Motors Travels up to 70 miles/hour (113 km/h) Operates at 20 miles/hour (32 km/h) 10,300 Gallons of Diesel Fuel stored 50,000 Gallons of Water stored on Machine for Fire Suppression System 26,400 feet (8047 m) of total wire used 7

8 Loram s Business Challenges: Pre-Machine OSIsoft PI Server Implementation Machine Operators Crew is not technically trained with Automation skill-set Troubleshooting information from crew is not reliably Accurate Mean Time to Repair Diagnosis of component failure was a slow multiple day process Failure analysis was not real-time capable Historical Data Logging Legacy datalogs only stored locally on machine for 30 days Datalogs must be manually removed and sent to engineering Format is not easily readable, customizable, or searchable Machine Diagnostic Logs Manual hand-written logs off Chart recorders, Metering, and Gauges Predictive Maintenance was not able to be implemented Reliability Data and Remote Diagnostics are limited Most downtime situations require a remote site visit by field service personnel 8

9 Engineering and Controls: Information System Requirements Engineering Long-Term Corrective action planning for component failures Diagnosis of historical component product life Real-time Failure analysis of current system Key Performance Indicator Data Electronic Historical Datalogs provide machine performance data remotely Data that is easily accessible, sortable, and searchable in a variety of reports A system that can handle multiple months worth of local storage before upload Historical Trending verification of Machine Runtime Performance to Design Controls Controller Tag Data Reporting Electronic Historical Datalogs provide sequence of event data remotely Data is easily accessible, sortable, and searchable in a variety of reports Determination of root cause analysis of complex machine control faults Diagnostics reports determine operator, code, or machine component issues 9

10 Operations and Field Service: Information System Requirements Operations Collection of Reliability Data and Remote Monitoring Electronic Datalogs of totalizer data on engine run hours, historical generator loads, and other important KPIs. Predictive maintenance using remote diagnostics (MTTF) Historical Machine Efficiency available for comparison study Real-time feedback using Ad-Hoc tag reporting on current machine issues Field Service Collection of Reliability Data and Remote Monitoring Machine Location tracking for travel and component replacement scheduling Real-time Failure analysis through Web Portal Remote Diagnosis time reduction from 1 or 2 days to hours improving MTTR Remote Real-time Failure analysis to replace field service travel Predictive Maintenance improvement to reduce downtime, save expensive component failure, and decrease field service call volume needs 10

11 Loram s Historical Data Collection and Reporting Solution In-Rack Historian: FactoryTalk Historian ME module collects data multiple Rockwell PLCs. Store and Forward: Collected Data is Uploaded to OSIsoft PI Server when cellular data network becomes available. Historical Database: OSIsoft PI Server holds the data for long-term storage and historical reporting usage. Reporting Server: FactoryTalk Vantage Point stores standard reports as well as AdHoc created queries in the field. Mobile Clients: Microsoft s Surface has a VantagePoint client application and can view webbased dashboards. HistME 11

12 Putting it all Together: Reporting Solution Implementation Controls Set Point and KPI Trends Machine Diagnostic Dashboards OSIsoft PI Server FT VP Server Engineering Report Users Field Service Machine Runtime Data Totalizers AdHoc Trouble- Shooting Reports Operations HistME FT Hist. ME Train Car Each User Group uses their Web Client Interface to View their Unique Reporting Tool-Set 12

13 History and Progress of this Historian Solution GPS Dashboard Map for Machine Reporting and Tracking in

14 This unique GPS enabled google maps interface allows tracking of machine progress at a glance and drill-down to machine reports Since implementing the first machine historian in 2011, more informationenabled machines have been retro-fitted or started up with this solution and new machine types plan to upgrade. RG402-01/19/2012 RG403-02/27/2013 RG406-03/03/2013 RG405-04/04/2013 RG404-04/20/2013 RG401-06/11/2013 RG408-11/15/2013 RG410-05/05/2014 RG409 - Planned RG411-08/01/2014 RG412-07/09/2015 RG414 - Future 14

15 Web Dashboard and Reporting Demonstration Loram s VantagePoint Web Portal Home Page Each Machine has a set of pre-built reports based on troubleshooting experience 15

16 Loram s Machine Reporting Dashboard Machine Selection Machine Overview Grind Diagnostics Power Generation Traction Data Dust Collection Hydraulic System 16

17 Machine Efficiency Data Reports Proactive Improvement Tracking and Comparison 17

18 Framing Historical Data into Event-based Reports provides Warranty / Legal Protection 18

19 Report Tracking Ambient Machine Temperatures can Correlate Potential Heat-related Component Failure 19

20 AdHoc Report created to Troubleshoot Machine and Solve Field Issue Remotely 20

21 OSIsoft PI System: Live operational data was a reality at Loram COMPANY and GOAL Loram is North America s leading supplier of Railroad maintenance services and machines, and wanted to improve machine diagnostics and reporting. Company Logo Picture / Image CHALLENGE Machine operational data was only available on the machine and required a multiday retrieval. Machines are remote Machines are constantly moving Machine troubleshooting required on-site technician SOLUTION Using PI System and Rockwell Automation solutions to automate data collection and displays Uses PI Server as the data collection server Allows KPI reporting, machine metrics and remote troubleshooting RESULTS Loram increased ability to diagnose problems and improved operation through use of live data. Developed metrics to improve performance of machines Decreased troubleshooting time dramatically reducing costs Improved engineered solutions with real data and reporting 21

22 Contact Information Eric Manninen Principal Electrical Engineer Loram Maintenance of Way For more information, visit us at: 22

23 Questions Please wait for the microphone before asking your questions Please remember to Complete the Online Survey for this session State your name & company search OSISOFT in the app store 23

24 Thank You

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