Eduardo Lima, Jornadas Técnicas 2015 Conveyor Fit Utilizing all your potential. ABB Group May 18, 2015 Slide 1

Transcription

1 Eduardo Lima, Jornadas Técnicas 2015 Conveyor Fit Utilizing all your potential May 18, 2015 Slide 1

2 Conveyor Fit Asset Management Monitor the operating condition during the lifetime of the equipment, increasing the plant availability, reducing maintenance costs and avoiding unscheduled downtime. Automation assets Instruments, Valves, Drives,... (devices with embedded logic) Controllers, switches, servers, computer stations. Production assets (*) Rotating equipment (pumps, motors, compressors, turbines) Process/Logistic equipment (crushers, conveyors, trucks, trains, boilers, screens, etc) Electrical equipment (transformers, switch-breakers, substations) 18 de maio de 2015 Slide 2 Move the traditional wide used time-based maintenance to the real-time condition based maintenance, through automatic data acquisition and analysis (using DCS data. e.g. 800xA). **Source ARC Advisory Group Report Plant Asset Management

3 Conveyor Fit Improve maintenance execution A survey (1) revealed the following data: Reduction of Maintenance of Effort by 50% Change in the distribution of the types of maintenance: Traditional World Class Reactive 50% 15% Preventive Time 35% 30% Preventive Condition 15% 55% (1) Thomas Marketing Information Center, Dec Percentage Reactive Maintenance Preventive Maintenance Time Based Preventive Maintenance Condition Based Traditional Situation Conveyor Fit Situation Practices Description Typical World Class Asset Management Powered by Conveyor Fit Reactive run till it breaks ~55% <10% Fast detection, diagnosis and fault repair Preventative on the schedule ~31% 25%-35% From schedule based to runtime based maintenance Predictive only when required ~12% 45%-55% Asses condition information of plant assets and integrated maintenance workflow Proactive eliminate root-causes ~2 Rest Analyze behavior of all critical assets May 18, 2015 Slide 3

4 Asset Management Pillars Asset Management Intelligent devices Vibration and temperature monitoring (on-line & off-line) Process/ logistic/ mine equipment Electrical equipment IT assets (servers, controllers, switches, computer stations, etc Performance loop control management May 18, 2015 Slide 4

5 Condition Monitoring two main work processes Field Equipment Management Mainly targeting maintenance as part of daily operation Short decision cycles Tightly linked to or integrated in control system Examples include: Mecanical faults with equipment Sensor failures Electrical faults Detectors Emerging equipment fault Alert and investigate Fault detected by monitor Alert plant operators of emerging fault (Alarm/Event) Initiate investigation Inspect equipment Perform diagnostics using available tools Consult with Subject matter experts Diagnose Decide and implement Generate work orders Perform maintenance Process Equipment Management Diagnostics supporting longterm maintenance planning and management Longer decision cycles Linked to corporate maintenance management systems Examples include: Reduced efficiency of pump and compressor strings Fouling in heat exchangers Reduced separator efficiency etc Performance degradation Identify Automatic identification of degraded performance Assessment of criticalty Suggested actions Notification to relevant personell Detailed evaluation of root cause Detailed assessment of criticality Update identification models and suggestes actions Diagnose Decide and implement Update maintenance plan Issue work orders Knowledge transfer

6 Conveyor Fit Data Flow Data Gathering Logic structure system definition Fieldbus Protocol (FF, Profibus, Hart, ) ma Hand-held devices Manually entered data Image data and other protocols Dynamic OEE Process variable Equipment variable Environmental variable Equipment faceplate data Administration variable Decision Rules Technological platform Data integration CMMS Integration IBM Maximo Ellipse Oracle EAM Output Active Work Orders Basic Features Work Orders History Equipment Status Scheduling Spare Parts Availability Reports 18 de maio de 2015 Slide 6

7 800xA - The Power of Integration Key areas for Asset Optimization Engineering, Maintenance and Operator Workplaces Configuration, monitoring and root cause analysis tools Device integration technologies HART, Wireless HART, FF, Profibus, Profinet, IEC61850, SNMP/SNMP Trap, OPC Understanding condition monitoring of connected devices and equipment Instrumentation, HV/MV/LV electro systems, vibrations, IT and process equipment Enterprise integration Real time data connected to CMMS AM SDK Custom built Asset Monitors May 18, 2015 Slide 7

8 Conveyor Fit Features Asset Monitor and Asset Viewer Asset Monitor provides automatic detection and reporting (using soft alarms) according to AM algorith Asset Reporter Displays composite severity of all AM on the object and links to more detailed condition information Asset Viewer Displays the Asset Tree with current asset severity indications

9 CMMS integration One maintenance workflow throughout the entire plant 1. Problem detetcted by real-time condition monitoring 2. Is workorder already scheduled? 3. Submit fault order to CMMS 4. Workorder automatically added and scheduled in CMMS 5. Corrective action taken. Operations notified. True predictive maintenance Cross plant collaboration Operations - Maintenance Reduced time to repair Automatic object synchronization Secure network connection

10 Reports, messaging and web access Share and access conveyor maintenance data Asset condition reports identifies asset with high failure rate and supports proactive maintenance strategies and masseging for remote alarm notification. Internet Explorer access to all asset diagnostic data via web server

11 Conveyor Fit Machinery Monitoring Machinery and vibration monitoring two purposes Protection Predictive maintenance Different equipment and industries has different needs Interfaces to 3:rd party monitoring systems ABB WiMon 100 Wireless Condition Monitoring ABB MCM800 Machinery Condition Monitoring Sensors wired to control system I/O May 18, 2015 Slide 11

12 Conveyor Fit Power Train Transformer, Circuit Breakers, IED Overload assistance Increased availability Condition assessment Improved maintenance planning Real time data Remote access via web interface ABB / Group PA / Control Systems May 18, 2015 Slide 12

13 Conveyor Fit Purpose Deliver valuable information about the tendency (or fast detection) to failure of the conveying systems, enabling a reliable maintenance time-window for a planned action and providing a condition based approach. Also, provide enough time for maintenance and operation to act in order to take control of the equipment wear (e.g. reducing conveyor load) and maintenance planning (e.g. having enough time to prepare the materials and resources for the equipment repair) Conveyor Fit monitor the following failures modes: Belt Longitudinal Cracks Belt Misalignment Belt Thickness / Wearing Belt Damage Belt Excessive Temperature Belt Speed and Slip May 18, 2015 Slide 13

14 Asset Optimization Services Application e.g. Conveyor Belts Temperature Misalignment & Longitudinal Crack Reports Alarms Messaging Early Alarms Speed & Slip Belt Damage Belt Thickness & Wearing Manufacturer or third party additional solution ABB May 18, 2015 Slide 14

15 Conveyor Fit Interface AssetVista May 18, 2015 Slide 15

16 Conveyor Fit Interface AssetVista May 18, 2015 Slide 16

17 CPMS Conveyor Fit HMI Interface May 18, 2015 Slide 17

18 Conveyor Fit HMI Interface May 18, 2015 Slide 18

21 Conveyor Fit Service Port Interface May 18, 2015 Slide 21

22 Conveyor Fit Service Port Interface May 18, 2015 Slide 22

23 Conveyor Fit Periodic Reporting and On-line Analysis Description Condition Comments Conveyor Inspection Critical Action required Belt Misalignment Good No action required Belt Damage Good No action required Belt Thickness Critical Action required Belt Speed and Slippage Good Need to be monitored Temperature Good No action required May 18, 2015 Slide 23

24 Conveyor Fit Periodic Reporting and On-line Analysis Delivering periodic reports about the conveyor health and on-time alarms for critical problems. Description Condition Comments Conveyor Inspection Critical Action required Belt Misalignment Good No action required Belt Damage Good No action required Belt Thickness Critical Action required Belt Speed and Slippage Good Need to be monitored Temperature Good No action required May 18, 2015 Slide 24

25 Conveyor Fit Conclusions and Benefits The use of Conveyor Fit module provides the proper platform for asset management, enabling: assets tracking; full view dashboard; messaging services; remote prediction and diagnostic services. After the start-up ABB will be able to deliver: a customized and periodic diagnosis report with predictive focus, aiming to be an auxiliary support for the on-site customer s Maintenance Engineering team. with on-line connection to the closest CPMS Regional Center, it will be possible to access the system remotely in case of troubleshooting or even deliver a 24hs continuous monitoring service. it will be also possible to connect CPMS directly to the maintenance systems in order to open automatic work orders, generate reports (e.g. SAP/PM, IBM/Maximo,..) May 18, 2015 Slide 25

26 Asset Optimization Services Contacts Eduardo Botelho de maio de 2015 Slide 26

27 May 18, 2015 Slide 27

28 Conveyor Fit 1/7 Retomadora 09RC001

29 Conveyor Fit 2/7 Atividades realizadas na Torre 04 (Sala de Automação e Polias de acionamentos da U00-09TP003): 1. Colocação dos paineis ABB na sala de Automação. 2. Montagem e fixação da JB 01 próxima ao Motor Montagem e fixação da JB 02 próxima aos Motores 01 e Montagem da Infraestrutura de eletrodutos na região do Motor Montagem da Infraestrutura de eletrodutos entre JB01 e JB Lançamento dos multicabos 8X3X1mm² shieldado entre Sala de Automação e JB 01 e entre JB 01 e JB Lançamento de 6 cabos 3X1mm² entre JB 01 e JB Montagem das réguas de bornes nas JB S 01 e Fabricação dos suportes dos instrumentos. 10. Fixação do Suporte dos sensores de desgaste na Polia do Motor Lançamento do cabo 8X3X1mm² JB 02 até os sensores de desgaste.

30 Conveyor Fit 3/7 JB 01 Fixada próx. Motor 03 Paineis ABB na Sala de Automação JB 02 Fixada próx. Motores 01 e 02 Multicabos 8X3X1mm² lançados

31 Conveyor Fit 4/7 Paineis, infraestrutura e lançamento de cabos. Local da JB 01 Sala da Automação Lançamento dos multicabos 8X3X1 Eletroduto entre JB 01 e JB 02 JB s 01 Suportes dos instrumentos Placas de bornes das JB s 01 e 02

32 Conveyor Fit 5/7 2) Capa de proteção dos sensores 1) Barra com os suportes dos sensores 3) Capa montada na barra 4) Montagem completa do suporte com a grade de proteção.

33 Conveyor Fit 6/7 Montagem painel PNI (Remota IP-67 MURR) Painel PNI para conexão dos sensores de desalinhamento da Torre 01 e Torre 03. Eletrodutos abaixo da 09TP003 para interligação ao PNI.

34 Conveyor Infraestrutura Fit e lançamento 7/7 de cabos. Montagem dos eletrodutos e lançamento dos cabos para os quatro sensores de desalinhamento da Torre 01 e Torre 03.