Keeping Assets Healthy PI System s Role in Asset Maintenance Presented by Gopal GopalKrishnan, P.E. Keith Pierce
CBM Prescriptive Guidance http://pages.osisoft.com/cbmwebinarondemand.html 2
Terms & Definitions Condition Based Maintenance Condition Monitoring http://pages.osisoft.com/cbmwebinarondemand.html 3
Condition Monitoring is an Effective Maintenance Strategy 4
CBM means different things to different people Incipient Failure Detection Condition Monitoring Condition Assessment CBM Preventive Maintenance 5
Operations Data + Events History Maintenance Data + Events History PI System Maximo Mincom Asset Suite Passport 6
Operations vs. Maintenance Data Pressure Flow Temperature Level Vibration Oil analysis Motor current Thermography 7
PI System s role in Maintenance 8
The 6 Steps of CBM with the PI System 1. Connect to relevant sources 2. Collect and archive data 3. Assign context (asset based) 4. Execute condition monitoring logic PI Interfaces PI Asset Framework PI Data Archive PI AF Analytics PVS & PI Coresight PI Notifications PI System Access 5. Visualize real-time conditions 6. Alert & notify Collect Manage & Enhance Deliver 9
To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 10
To Do List - Advanced Asset health score Work management integration it is not hard SAP PM, Maximo, Oracle Make it easy for Maintenance to see Operations (PI System) data 11
To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 12
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To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 14
Incipient Failure Detection Potential Failure Functional Failure Source: ECG 15
Filter clogging, Heat exchanger fouling Filter differential pressure over 3 months 16
Air heater tubes plugging, Oxygen analyzer drift Air heater tube plugging at a coal power plant over 450 days Oxygen analyzer (dual sensor) drift 17
Motor vibration alert calculations 18
To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 19
Notify asset owner include links to displays http://dfpicoresight/coresight/#/pbdisplays/10073 20
Linked PI System display from Notifications 21
Boiler feed pump motor vibration is increasing 22
To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 23
Report across asset events 24
To Do List - Advanced Asset health score Work management integration it is not hard SAP PM, Maximo, Oracle Make it easy for Maintenance to see Operations (PI System) data 25
CBM data sources (T&D example) PI System Distribution SCADA Transmission SCADA PI HDW Doble Electrical results Breaker Tests Diagnostic data External ESOC PI Transformer loads Delta-X MV90 Weekly substation inspection Hydran Gas equipment results CMMS order history Asset registry updates Transformer oil analysis 26
Asset health score http://videostar.osisoft.com/regional_seminars/2009/boston/video/rs2009_boston_cbm_pseg_gopal_rothweiler.wmv 27
Asset health score - details 28
Asset health score - template 29
Asset health score roll up calculations 30
To Do List - Advanced Asset health score Work management integration it is not hard SAP PM, Maximo, Oracle Make it easy for Maintenance to see Operations (PI System) data 31
PI System to CMMS data flow PI server PI Alerts Integration Framework Data or WorkOrder trigger CMMS Measurements Process Analysis Condition Assessment Meter or WO Acknowledgment GAUGE CHARACERTISTIC CONTINUOUS OPERATING PARAMETERS Running or Idle Pressure Temperature Rpm Vibration Oil level Portal Meter or WO Acknowledgment Integrated view of Operations and Maintenance WORK ORDER CRON TASK Mincom Asset Suite Passport EQUIPMENT 32
Send runhours from PI to SAP counter 33
Template for SAP integration 34
To Do List - Advanced Asset health score Work management integration it is not hard SAP PM, Maximo, Oracle Make it easy for Maintenance to see Operations (PI System) data 35
Linked PI System display from Maximo http://pisb:8079/coresight/#/displays/adhoc?dataitems=\\myaf\mafdb\11300&starttime=*-30d&endtime=*
http://pisb:8079/coresight/#/displays/adhoc?dataitems=\\myaf\mafdb\11300&starttime=*-30d&endtime=*
Shared Asset Names
Maximo asset hierarchy in Asset Framework Maximo equipment list Maximo locations
Shared Asset Names Search for pump in Maximo Search for pump in PI ProcessBook
Shared Asset Names Maximo Work Orders for pump 11430 in PI Web Parts
Maximo assets via PI Builder
To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 43
gopal@osisoft.com Solution Architect OSIsoft, LLC kpierce@osisoft.com Solution Architect OSIsoft, LLC 4 6
Questions Please wait for the microphone before asking your questions Please don t forget to Complete the Online Survey for this session State your name & company http://eventmobi.com/emeauc15 47
Thank You