Professional Documents
Culture Documents
Presenters
Augie DiGiovanni
VP, PlantWeb Services
Agenda
Subject
PlantWeb Services offers DESIGNa structured approach to implementing PlantWeb technology during FEEDs or in existing facilities
Topics
Why Plant Asset Management (PAM) Designing a PAM Program Customer Case Studies PAM Program Data integrated with CMMS
Agenda
Subject
PlantWeb Services offers DESIGNa structured approach to implementing PlantWeb technology during FEEDs or in existing facilities
Topics
Why Plant Asset Management (PAM) Designing a PAM Program Customer Case Studies PAM Program Data integrated with CMMS
Agenda
Subject
PlantWeb Services offers DESIGNa structured approach to implementing PlantWeb technology during FEEDs or in existing facilities
Topics
Why Plant Asset Management (PAM) Designing a PAM Program Customer Case Studies PAM Program Data integrated with CMMS
Limited manpower Budgetary restraints Too busy reacting to machine problems to be proactive / strategic Lack of management understanding of maintenance strategies Level of maintenance employee training Not sure how to justify improved best maintenance practices
45 38 27 22 21 20
Other 4%
Instruments 20%
Agenda
Subject
PlantWeb Services offers DESIGNa structured approach to implementing PlantWeb technology during FEEDs or in existing facilities
Topics
Why Plant Asset Management (PAM) Designing a PAM Program Customer Case Studies PAM Program Data integrated with CMMS
DeltaV
TM
Asset Management
Condition-based maintenance Increased reliability Increased availability Reduced costs Transmitter Diagnostics Device health Plugged sensing lines Control Valve Diagnostics Sensor failure, etc. Device health Travel deviation Packing Machinery Diagnostics friction, etc. Motor-pump health Vibration Cavitation, etc
Transmitter Diagnostics Device health Plugged sensing lines Control Valve Diagnostics Sensor failure, etc. Device health Travel deviation Packing Machinery Diagnostics friction, etc. Motor-pump health Vibration Cavitation, etc
Transmitter Diagnostics Device health Plugged sensing lines Control Valve Diagnostics Sensor failure, etc. Device health Travel deviation Packing Machinery Diagnostics friction, etc. Motor-pump health Vibration Cavitation, etc
Transmitter Diagnostics Device health Plugged sensing lines Control Valve Diagnostics Sensor failure, etc. Device health Travel deviation Packing Machinery Diagnostics friction, etc. Motor-pump health Vibration Cavitation, etc
Plant Efficiency
Plant performance optimization Predictive diagnostics services Monitoring and analysis services
Tr Start up ad itio na l
Start up
Turnaround execution
Repair services
Time
SMART MEASUREMENT
SMART SAFETY
SMART MEASUREMENT
PlantWeb Services
Business Objective Identification Gap Analysis (vs. industry / site) Site Assessment & Benchmark Goals / KPI
Structured implementation approach INSTALL - Setup / Training IMPLEMENT - Alerts / Procedures INCORPORATE CMMS / KPI
Skills Assessment Skill Development Plan Product / Technology Courses Industry certification
1. ID business objectives / LOA 2. Assess site | Gaps | Benchmark 3. ID Goals / KPIs or PAM Spec.
4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3 8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integration
1. Review arch / components 2. Install & license software 3. Confirm device communication 4. Create initial database 5. Setup alert monitor 6. INSTALL any SNAP-ONs 7. Review basic functions 8. Review formal training / mentor 9. Backup database 10. End User Signoff
3. Establish 1-3 goals / KPIs 4. Evaluate work flow 5. Validate priority of assets 6. Written Procedures 7. Optimize alerts & AMS Suite 8. Review New 9. Path Forward / Project Report Procedures1
Map into Maintenance Strategy Blueprint matrix MTBF / MTBM and Planning / Scheduling 3 based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work
1 2
Business objectives
Plant Manager Availability Uptime Fuel Costs Efficiencies Performance Targets Labor costs Rank of Facility Sales Demand Operations Throughput Daily output targets Unplanned issues Equipment problems Alarm Management Safe Operation Maintenance Work Order priority % PM Completion Availability to Run Safety Work Order Backlog Planning & Scheduling PM Cost by Asset
1. ID business objectives / LOA 2. Assess site | Gaps | Benchmark 3. ID Goals / KPIs or PAM Spec.
4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3 8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integration
Now, what is the Maintenance Strategy (PAM Plant Asset Management) that enables me to achieve these business objectives? How do I rationalize investments in predictive intelligence?
Map into Maintenance Strategy Blueprint matrix MTBF / MTBM 3 Based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work
1 2
1. ID business objectives / LOA 2. Assess site | Gaps | Benchmark 3. ID Goals / KPIs or PAM Spec.
4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3 8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integration
Map into Maintenance Strategy Blueprint matrix MTBF / MTBM 3 Based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work
1 2
1. ID business objectives / LOA 2. Assess site | Gaps | Benchmark 3. ID Goals / KPIs or PAM Spec.
8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integration
Map into Maintenance Strategy Blueprint matrix MTBF / MTBM 3 Based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work
1 2
New Facilities
4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3
1. ID business objectives / LOA 2. Assess site | Gaps | Benchmark 3. ID Goals / KPIs or PAM Spec. 4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3 8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integration
Validate Tasks
1. ID business objectives / LOA 2. Assess site | Gaps | Benchmark 3. ID Goals / KPIs or PAM Spec.
4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3 8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integration
Map into Maintenance Strategy Blueprint matrix MTBF / MTBM 3 Based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work
1 2
Identified how Maintenance work is Discovered Initiated Planned Scheduled Performed Closed out Contingencies
Work Process Work Initiation Work Approval and Prioritization PreExecution Resolution NO Can Work Proceed? PreExecution YES Work Execution Work Close Out & Audit
Planning Required?
YES
Planning
NO
Scheduling YES
Shutdown Scheduling
Work Process
1. ID business objectives / LOA 2. Assess site | Gaps | Benchmark 3. ID Goals / KPIs or PAM Spec.
4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3 8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integration
Roles and
Map into Maintenance Strategy Blueprint matrix MTBF / MTBM 3 Based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work
1 2
1. ID business objectives / LOA 2. Assess site | Gaps | Benchmark 3. ID Goals / KPIs or PAM Spec.
4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3 8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integration
Map into Maintenance Strategy Blueprint matrix MTBF / MTBM 3 based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work
1 2
Agenda
Subject
PlantWeb Services offers DESIGNa structured approach to implementing PlantWeb technology during FEEDs or in existing facilities
Topics
Why Plant Asset Management (PAM) Designing a PAM Program Customer Case Studies PAM Program Data integrated with CMMS
Reactive tasks 70% of monthly work orders Lack of sufficient maintenance task documentation Asset Priority on 30,000 assets Develop Maintenance Tasks on 10,000 most critical assets
Created 3,000 new tasks
Gap Analysis drove evaluation of I&V maintenance Task Optimization Discover / create consistent documentation on 2,000 assets
Provide OEM data sheets / instruction manuals
Develop Maintenance Tasks / Procedures Provide specific procedures for I&V rebuilds or calibrations; provide specific procedures for Smart Device Alerts and diagnostics Map CMMS Integration Build new procedures into EMPAC AMS Device Manager - Consolidate 10 offline copies into single networked license, set up alarms
Training program reinforce new procedures / re-train personnel
Maintenance Strategy Blueprint Revise PM intervals, understand opportunities to outsource, develop roadmap for upgrades, inventory optimization Training program developed specifically for installed base of Instruments and Valves Use AMS Device Manager for better control of feedstock Provide new maintenance procedures, transfer into CMMS
PlantWeb Services
DESIGN IMPLEMENT INCORPORATE
Agenda
Subject
PlantWeb Services offers DESIGNa structured approach to implementing PlantWeb technology during FEEDs or in existing facilities
Topics
Why Plant Asset Management (PAM) Designing a PAM Program Customer Case Studies PAM Program Data integrated with CMMS
Aggregates information across plant assets Provides management summaries from underlying AMS Suite applications and other data sources Links predictive diagnostics with Maintenance Planning and other enterprise systems Integrates PlantWeb Services data with asset information
Asset prioritization Work planning & scheduling Diagnostic technologies used
PlantWeb technology
Bearing Faults Gear Faults Belt Wear Mounting
Mechanical
Boiler Sooting Turbine Blade Wear Capacity Reductions Increased Energy Use Hourly Cost Increase
Process
Heat Exchanger Fouling Cumulative Cost Increase Maintenance Effectiveness Pump Efficiency Dropping Equipment Efficiency Drop
Travel Deviation Drive Signal Supply Pressure Valve Signature Cycle Counter Step Response Dynamic Error Band
Glass Electrode Failure pH Electrode Aging Ref Electrode Coating Ref Electrode Failure Ref Electrode Poisoning
Configuration Warning Process Condition Sensor Failure RTD Drift Electronics Failure RTD Life Estimation
Electronics Failure Sensor Failure Process Condition Reverse Flow Empty Pipe Calibration Error Configuration Warning Sensor Failure Electronics Failure Configuration Warning Process Condition Plugged Impulse Lines
Managing HART and Ff devices Managing and detecting faults on rotating / mechanical machinery Monitoring the efficiency of large pieces of process equipment
AMS Suite brings together information from assets across your plant
Electrical Asset Management Documentation Systems Corrosion Monitoring Inventory Control Systems CMMS Work Order History
Many systems have information pertinent to plant assets. AMS Asset Portal consolidates this information.
Agenda
Subject
PlantWeb Services offers DESIGNa structured approach to implementing PlantWeb technology during FEEDs or in existing facilities
Topics
Why Plant Asset Management (PAM) Designing a PAM Program Customer Case Studies PAM Program Data integrated with CMMS
PlantWeb Services ensures effective deployment of your AMS Suite DESIGN structured approach for FEEDs / New Projects / Existing Facilities
Execute prior to technology deployment 1. Business Objectives / Goals
Gap Analysis on existing facilities / programs Maintenance Strategy Blueprint matrix
Identifies asset criticality (priority) and task periodicity (what to do when)
2. Formalized Design
Technology Deployment
Detectable failure modes / criticality drives technology investments Includes utilization of PlantWeb to execute ~80% planned work
Develop Maintenance Strategy Blueprint for top 25% CMMS Integration (procedures attached to Indus Passport) Phase 1: (2) Paper Machines - 13 week project
Asset Priority: 2,781 assets; Task Optimize: 1,193 assets Reduced Man-hour effort 69.1% (17,079 down to 5,272) Asset Priority on 2,851 assets; Task Optimize 870 assets Reduced Man-hour effort 70.6% (16,832 down to 4,949) Asset Priority: 2,516 assets; Task Optimize: 754 assets
Results
Summary
Work Shop Topics
Simply purchasing PlantWeb technology does not get it done. Must incorporate technology into your daily processes. Lowest-Cost Maintenance should be part of the FEED PlantWeb Services offers DESIGN
A structured approach to implementing PlantWeb technology Applies to FEEDs or existing facilities that want to formalize a Maintenance Strategy Addresses integration with CMMS (new planned Work Order generation)
Benefit
Allows you to easily make it part of the design requirement
Ensures PlantWeb technology is implemented properly
Feedback? Questions?