Day 2 1400 Digitized O&M Field Work

Digitized O&M Field Work
Ang Beng Chong
Senior Manager
Service Operations
Yokogawa Engineering Asia Pte Ltd
5th July 2007
TECHNOLOGY INNOVATIONS FAIR

& USERS CONFERENCE – 4th-5th July 2007
Purpose of Inspection
Equipment must be inspected periodically to assure it

is working all the time.
Nobody wants sudden shutdown/Surprise.
Object of data inspection
– Visual data
• Equipment wear and tear
• Corrosion
• Manual gauge readings
– Audio
• Noise (rotating equipment)
Data not connected to
DCS must be collected
manually

1
General Patrol Inspection model
After equipment is installed . . . . . . Inspection staff perform periodic inspection
To maintain equipment operability to record data & operating condition/status
Paper
Very time
Keep the record
monthly without 1. Manually input patrol
consuming process
data analysis or inspected data into
summary Excel spread sheet
2. Keep the record in
paper
For monthly
reporting, Inspection point Unit Condition Value
Pressure kg/cm2 OK 5.00
summarize the data
Temperature oC OK 120.00
collected for
Level mmH2O HIGH 1500.00
trending and Status RUN
reporting using MS- Current Amp ABNORM 15.00
Excel functions Valve %Open % 75.00

What is the main concern ?

2
IPPAT Plus PatrolMate
PDA Based Patrol Inspection System

Functions Overview
Each inspection point
select from list to is capable of
input data and displaying a trend
status graph of the last 8
readings
Sync
View Data and
mark items
under repair.
Inspect items for
repair. Report on job
completion
Display the collected field data as a report or graph
11
Routine Patrol Plant 2
10.5
Inspector Inspector 96 Start 28/Oct/2005 10:58 AM
Approved by Inspector 99 End 28/Oct/2005 11:05 AM
10
Upper Lower Standard Inspection

Inspection point Unit Condition Value
limit limit value date/ time 9.5
P2 U1 Eqm A Pr ess ure kg/cm2 100.00 50.00 75.00 ABNORM 1.00 10:59:36 AM
P2 U1 Eqm A Temperature oC 0.00 30.00 100.00 ABNORM 120.00 10:59:37 AM
9
P2 U1 Eqm A Level mmH2O 2000.00 200.00 1000.00 HIGH 1500.00 10:59:37 AM
P2 U1 Eqm A Status 0 0.00 0.00 0.00 RUN 10:59:44 AM
P2 U1 Eqm A Cur rent Amp 20.00 0.00 15.00 ABNORM 15.00 10:59:38 AM 8.5
P2 U1 Eqm A Valve %Open % 100.00 10.00 90.00 1/4 75.00 10:59:39 AM
P2 U1 Eqm B Pressure kg/cm2 100.00 50.00 75.00 OK 60.00 11:00:05 AM 8
P2 U1 Eqm B Temper ature oC 0.00 30.00 100.00 OK 100.00 11:00:12 AM
P2 U1 Eqm B Lev el mmH2O 2000.00 200.00 1000.00 OK 1200.00 11:00:15 AM
7.5
P2 U1 Eqm B Status
P2 U1 Eqm B Current
P2 U1 Eqm B Valve %Open
0
Amp
%
0.00
20.00
100.00
0.00
0.00
10.00
0.00 RUN
15.00 OK
90.00 Open
15.00
85.90
11:00:23 AM
11:00:27 AM
11:00:33 AM 7
With ID Tag installed,
P2 U1 Eqm C Pressure
P2 U1 Eqm C Temper ature
P2 U1 Eqm C Lev el
kg/cm2
oC
mmH2O
100.00
0.00
2000.00
50.00
30.00
200.00
75.00 OK
100.00 OK
1000.00 OK
75.00
35.00
1234.00
11:00:51 AM
11:05:01 AM
11:05:01 AM
6.5 user can scan the ID
P2 U1 Eqm C Status
P2 U1 Eqm C Current
P2 U1 Eqm C Valve %Open
0
Amp
%
0.00
20.00
100.00
0.00
0.00
10.00
0.00 OFF
15.00 ERRATC
90.00 Open
15.00
88.70
11:01:07 AM
11:05:12 AM
11:01:24 AM
6
User can key in remarks Tag to narrow down
with handwriting pad the target
for each instrument instrument before
data input
3
Paperless / Effective work
Inspector no need to bring paper

check sheet anymore.
Easy to transfer data to PC.
Save unproductive time in

- writing report
- Filing report
- Checking reports
when things go wrong
No unreadable hand-writing
Standard inspection procedure
Standardized comments

Optional Hardware to support different needs
2 different model for different

needs.
Model “IT-10”
- Ruggedized hardware
- Industry PDA
- IP54
- Drop durable 1.0m to concrete
Model “i.Roc 620”

- Ruggedized hardware
- Explosion Proof
- 2G EEx ia IIC T4 (Zone 1)
- IP65 (Brief immersion)
- Drop durable 1.0m to concrete
Model IT-10
Model i.Roc 620

4
RFID Tag to guide patrol inspection
With the RFID tag, inspector can

immediately identify the point of
inspection.
Reduce human errors

Strong Time Stamping
With the RFID tag used, it is able

to produce work with proper
time stamped.
Data is collected accurately
Data is collected on time
Data is collected consistently
Time to read RFID:

2006.10.25 14:23:05
Time to register data:

2006.10.25 14:25:27

5
Time Stamping
Building/Area Building/Area
Block A Block B
?
3rd Floor
2nd Floor
3rd Floor
1st Floor
2nd Floor
1st Floor RFID TAG
No accountability! Powerful Timestamp

Cannot verify Inspector Record every time of data
have been there entry and RFID tag reading

8-Point Trend to check previous data
PatrolMate has its intelligence to

assist inspector at site
Provides 8 point trend for all

inspection points
To help inspector to further

predict the life span of the
equipment checked and then
report to the superior accordingly.
Maximum to store up to 50,000

inspection points per PDA

6
RFID tag on any surface
RFID can be pasted on

- Any hazardous environment
- Any metal surface
Can be tightened with screws
Not affected by dust coverage
Unique number (No replication)

Possible ID Tag Locations
ON ON ON ON
E 101
OFF OFF OFF OFF
Vessel
ON ON ON ON
OFF OFF OFF OFF
Panel
Transmitter
Similar
Gauge
Pump Valves

7
Easy Report Generation
Generate a report within few

seconds with just 3 clicks.
Generated report is in familiar

format – Microsoft Excel
Report can be then converted for

other purpose
Can be converted to trend graph
Easy to customized
Trend graph

11
Select “Print”

8
22
Select your format “Sample”


9
Value in PatrolMate – Overall
Paperless
Automated PDA to sync to computer server
Inspection Better Record Keeping
Reduce Errors Less manual work

Less human error
Assure Accuracy Assure data availability and reliability
Improve Reduce unproductive work

Shorten learning
learning curve for new staff
Productivity Less routine, more decision activities
Improve More system centered

Less people centered
Cost Effectiveness

Case Study
Pulau Seraya Power Station in Jurong Island

10
Air-Con systems in the power station :
Air-Con
Split Air-Con
Units Cooling
Air-Con Towers
Ducting
Air-Con Chiller
Systems

Old Method of Recording & Filing system :
Checklist
Records kept in files. Filing

cabinets
- Alarm status not highlighted.

- Paper becomes soggy & torn.
- Use up large quantity of paper, files &
cabinet space.

11
New IPPAT Paperless System :
ISO 9001 Certifications

Paperless IPPAT System
Environmentally Friendly for ISO 14001

Highlighted ALARM STATUS with IPPAT

12
Trend Charts and Graphs

Paperless & Cost Savings
Portable Hard Disk

13
Benefits gained for the operation
Highlight alarm status immediately.

Allow immediate Trending & Printout of Trend Charts
& Graphs.
Allow adoption of Preventive & Predictive
Maintenance strategies.
Paperless; 1 portable hard disk compared to piles of
files & many filing cabinets.
Cost Savings in paper, files and cabinets.
Save space or free up filing cabinet space for more
important documents.

Thank you for your attention

14

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Digitized O&M Field Work

Ang Beng Chong

5th July 2007

TECHNOLOGY INNOVATIONS FAIR

Equipment must be inspected periodically to assure it

TECHNOLOGY INNOVATIONS FAIR

TECHNOLOGY INNOVATIONS FAIR

What is the main concern ?

TECHNOLOGY INNOVATIONS FAIR

PDA Based Patrol Inspection System

Upper Lower Standard Inspection

Inspector no need to bring paper

Easy to transfer data to PC.

Save unproductive time in

Standard inspection procedure

TECHNOLOGY INNOVATIONS FAIR

Optional Hardware to support different needs

2 different model for different

Model “i.Roc 620”

TECHNOLOGY INNOVATIONS FAIR

With the RFID tag, inspector can

Reduce human errors

TECHNOLOGY INNOVATIONS FAIR

Strong Time Stamping

With the RFID tag used, it is able

Data is collected accurately

Data is collected on time

Data is collected consistently

Time to read RFID:

Time to register data:

TECHNOLOGY INNOVATIONS FAIR

1st Floor RFID TAG

No accountability! Powerful Timestamp

TECHNOLOGY INNOVATIONS FAIR

8-Point Trend to check previous data

PatrolMate has its intelligence to

Provides 8 point trend for all

To help inspector to further

Maximum to store up to 50,000

TECHNOLOGY INNOVATIONS FAIR

RFID can be pasted on

Can be tightened with screws

Not affected by dust coverage

Unique number (No replication)

TECHNOLOGY INNOVATIONS FAIR

Possible ID Tag Locations

TECHNOLOGY INNOVATIONS FAIR

Generate a report within few

Generated report is in familiar

Report can be then converted for

Can be converted to trend graph

TECHNOLOGY INNOVATIONS FAIR

Easy Report Generation

TECHNOLOGY INNOVATIONS FAIR

TECHNOLOGY INNOVATIONS FAIR

Easy Report Generation

TECHNOLOGY INNOVATIONS FAIR

Reduce Errors Less manual work

Improve Reduce unproductive work

Improve More system centered

TECHNOLOGY INNOVATIONS FAIR

Pulau Seraya Power Station in Jurong Island

TECHNOLOGY INNOVATIONS FAIR

Day 2 1400 Digitized O&M Field Work

Day 2 1400 Digitized O&M Field Work