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?
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?
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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?. . .
