Asset Optimization

Asset Optimization
Gertjan Edelijn
Business Development Manager
BU Asset Optimization
Change is the process by which
the future invades our lives
Alvin Toffler
Company Confidential
February 22, 2012
Slide 2
2
Enterprise Asset
Management
Het gehele en optimale beheer
van fysieke activa om waarde te
maximaliseren
Asset Management
Het veiligstellen van ‘future
business’ en het managen van
‘complexe’ en ‘kritische’ Assets
Het in een systematisch proces
ontwikkelen van een slimme
operating omgeving
Company Confidential
February 22, 2012
Slide 4
Meerdere disciplines aan elkaar
gekoppeld
Meer diagnostische mogelijkheden
Samenwerken om gezamenlijke
doelen te bereiken.
Aktueel
BEHOEFTE
– Verbeterde (Plant)Reliability, Effectief en Efficient
maintenance, Effectief MOC, Opleidingstijd verkorten,
Optimaliseren werkinstructies, Kennisbehoud….
VRAAG
– Hoe verbinden we alle verschillende disciplines
‘Beheersbaar’ met elkaar ?
• zodat men in de uitvoering effectief kan samenwerken
• Informatie geborgd blijft binnen de organisatie
Company Confidential
February 22, 2012
Slide 5
Wat is de oplossing??
Is technologie de
oplossing?
Het verhogen van
expertise?
Positieve impact
door veranderen van
werkprocessen?
?
?
?
Company Confidential
February 22, 2012
Slide 6
Is Reliability de basis?
Reliability
• Unplanned Shutdowns
• Capacity Utilization
• Maintenance Index
Financial
Efficiency &
Throughput
Safety &
Environment
• Return on Capital
Employed (ROCE)
• Income & Margin
• Capital
• Throughput
• Energy Intensity
• OpEx
• Plant Availability
• Incidents
• Spills / Emissions /
Discharges
• Fines / Penalties
Personnel
• Human
Productivity
• Training
• Critical Skills
• Knowledge
Retention
Machinery Events:
Controllable, Predictable or Unpredictable
Controllable
Predictable
Unpredictable
Equipment Health
100%
Performance Monitoring
Predictive Diagnostics
0%
Time
Predictive Diagnostics and Performance Monitoring
provide the advanced warning necessary for business
decisions
Effective online machinery monitoring addresses all three
situations
Emerson Confidential - ©2010 Emerson Process Management
Machinery
Protection
Reliability methodiek
DESIGN
ASSET MANAGEMENT PROGRAM
Assessment
&
Design
Asset
Prioritization
Asset
Maintenance
Task Optimization
Asset
Maintenance
Blueprint
CONTINUOUS
IMPROVEMENT
IMPLEMENTATION
Technology
Deployment
Expertise
Optimization
Work
Processes
Optimization
CONTINUOUS
IMPROVEMENT
MANAGEMENT
Performance
Measurement
& Analysis
CONTINUOUS
IMPROVEMENT
Improvement
Planning
Welke onderhoudstrategie voor welke
equipment & assets?
Asset Prioritization / ACR
■ Herkennen van kritische systemen en assets
■ Afstemmen van onderhoud & business objectieven
■ Gebruik bestaande informatie om de onderhoudstrategie te
optimaliseren
Asset Optimization Focus:
Process information is
core to plant health and
used to evaluate optimum
maintenance strategies
PRO
ACT I
VE
PRED
ICTIV
E
PREV
E
REAC
NTIVE
TIVE
Process information is used
to evaluate equipment
health and maintenance is
planned.
Maintenance done on a
time-based schedule
Maintenance done only
when equipment breaks
Hoe verhogen we uw Reliability?
Voorspellende intelligentie
– betrouwbaarheid te verhogen.
– betere output en lagere kosten.
– makkelijker en veiliger te besturen
en te onderhouden.
Software detects
vibration & provides
lube oil analysis to
detect premature
wear—helping
prevent
mechanical failure.
Predictieve mogelijkheden voor MEER
informatie
Meer- en slimmere instrumenten
Verspreid over meer Assets
Geven meer informatie
De huidige transmitters
hebben meer power dan de 1e
DCS controller.
De predictieve paraplu
Emerson
’s Asset Optimization
Emerson’s
Technology and Services
ROI for Periodic data collection
ROI for Automatic data collection
Machinery Applications at Typical Plant
Compressors
Turbines
Generators
Online Solutions for
critical machinery
5%
Critical
Fans Pumps Motors Gears
25%
Essential
Transmitters
30%
Important
20%
Secondary
20%
Non-Essent
ial
Emerson Confidential - ©2010 Emerson Process Management
Portable instrument
Run to fail
Online Machinery Monitoring
Protection, Prediction, Performance Monitoring
Operations
Maintenance
Performance Monitoring
• Maximise production
• Reduce energy used
• Minimise emissions
Predictive Diagnostics
• Maximise availability
• Increase dependability
• Reduce maintenance costs
Machinery Protection
• Avoid catastrophic failures
• Increase safety
• Satisfy insurers
Emerson Confidential - ©2010 Emerson Process Management
Machinery Protection
CSI 6500 for Turbomachinery
API 670 Compliant Protection Full
turbine supervisory instrumentation
Full
FullTSI
TSI
• Case Expansion
• Case Expansion
• •Differential
Expansion
Differential Expansion
• •Eccentricity
Eccentricity
• •Thrust
position
Thrust position
• Relative Vibration
• Relative Vibration
• •Temperature
Temperature
• •Speed
Speed
• Zero speed
• Zero speed
• Absolute Vibration
• Absolute Vibration
Dual,
Dual,Redundant
Redundant24
24VDC
VDC
Power
Power
TSI = Turbine Supervisory Instrumentation
Emerson Confidential - ©2010 Emerson Process Management
Predictive Diagnostics
CSI 6500 Machinery Health Monitor
API 670 Compliant Protection
Full turbine supervisory instrumentation
Predictive Monitoring
Field based intelligence
Control
Controlsystem
systemstyle
style
field-based
predictive
field-based predictive
processor
processor
PeakVue
PeakVuefor
forrolling
rolling
element
and
gearboxes
element and gearboxes
Full
Fullintegration
integrationtotothe
the
AMS
Suite
AMS Suite
Emerson Confidential - ©2010 Emerson Process Management
Predictive Diagnostics
CSI 6500 Machinery Health Monitor
API 670 Compliant Protection
Full turbine supervisory instrumentation
Predictive Monitoring
Transient Analysis
Field based intelligence
For Turbomachinery
Transient
Transientanalysis
analysisfor
for
turbomachinery
turbomachinery
100+
100+hour
hourtransient
transient
data
recording
data recording
Live
LiveView
ViewMode
Mode
Replay
ReplayMode
Mode
recorded
recordeddata
data
ofof
Emerson Confidential - ©2010 Emerson Process Management
CSI 9420 Wireless Vibration Monitoring
Mount transmitter
away from machine
Application
)
Typical: 3m or 10m
• Works on any equipment
• Not application specific
)
300 feet / 100 meters
CSI 9420
1420
Wireless Vibration Transmitter
• Measurement processing
• Radio communication
• Power Module
Smart Wireless Gateway
Outputs
Outputs (scalar
(scalarvalues)
values)
1.
1.
Overall
Overall Vibration
Vibration
2.
2.
PeakVue™
PeakVue™Vibration
Vibration
Range:
Range:
Comment:
Comment:
Units:
G’s
Units:
G’sPeak
Peak
1,000
Hz
–
20,000
1,000 Hz – 20,000 Hz
Hz
Quantify
Quantifyearly
earlybearing
bearing&& gearbox
gearboxdefects
defects
3.
3.
Temperature
Temperature
-30
-30 to
to +250
+250 FF // -34
-34 to
to+120
+120 CC
When
sensor
with
embedded
When sensor with embedded temperature
temperatureused
used
Units:
Units:
Range:
Range:
Comment:
Comment:
Range:
Range:
Comment:
Comment:
)
Velocity
Velocity(in/sec
(in/secor
ormm/sec)
mm/sec)
22 Hz
Hz–– 1000
1000 Hz
Hz(per
(perISO
ISO 10816
10816 standard).
standard).
Identifies
problems
like
imbalance
Identifies problems like imbalance and
and looseness
looseness
Emerson Confidential - ©2010 Emerson Process Management
De Emerson Oplossing
PlantWeb® Digital Plant Architecture Empowers
with Predictive Intelligence
PlantWeb improves plant efficiency by > 2%
– Improves plant production
– Lowers conversion costs
Asset Optimization Maximizes
PlantWeb Operational Benefits
Quantified business results are primarily
improved asset and plant availability, reduced
maintenance costs, and reduced utilities costs
Het vergaren van informatie is niet het
probleem
…
probleem…
Analyseren van informatie
en deze toepassen voor
business besluitvorming is
de uitdaging
De uitdaging van MEER informatie
Asset Performance Management
Geintegreerde asset informatie
Leveren van business intelligentie
Continu verbeteren van business
intelligentie
Integrated Solution
Asset Performance Management
A Closed Circuit
Enterprise Asset
Management (EAM)
Asset Performance
Management (APM)
Predictive Asset
Management
Herkent u dit Scenario?. . .