Keeping Assets Healthy PI System s Role in Asset Maintenance

Transcription

1 Keeping Assets Healthy PI System s Role in Asset Maintenance Presented by Gopal GopalKrishnan, P.E. Keith Pierce

2 CBM Prescriptive Guidance 2

3 Terms & Definitions Condition Based Maintenance Condition Monitoring 3

4 Condition Monitoring is an Effective Maintenance Strategy 4

5 CBM means different things to different people Incipient Failure Detection Condition Monitoring Condition Assessment CBM Preventive Maintenance 5

6 Operations Data + Events History Maintenance Data + Events History PI System Maximo Mincom Asset Suite Passport 6

7 Operations vs. Maintenance Pressure Flow Temperature Level Vibration Oil analysis Motor current Thermography 7

8 PI System s role in Maintenance 8

9 The 6 Steps of CBM with the PI System 1. Connect to relevant sources 2. Collect and archive data 3. Assign context (asset based) 4. Execute condition monitoring logic PI Interfaces PI Asset Framework PI Data Archive PI AF Analytics PVS & PI Coresight PI Notifications PI System Access 5. Visualize real-time conditions 6. Alert & notify Collect Manage & Enhance Deliver 9

10 To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 10

11 To Do List - Advanced Asset health score Work management integration it is not hard SAP PM, Maximo, Oracle Make it easy for Maintenance to see Operations (PI System) data 11

12 To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 12

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14 To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 14

15 Incipient Failure Detection Potential Failure Functional Failure Source: ECG 15

16 Filter clogging, Heat exchanger fouling Filter differential pressure over 3 months 16

17 Air heater tubes plugging, Oxygen analyzer drift Air heater tube plugging at a coal power plant over 450 days Oxygen analyzer (dual sensor) drift 17

18 Motor vibration alert calculations 18

19 To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 19

20 Notify asset owner include links to displays 20

21 Linked PI System display from Notifications 21

22 Boiler feed pump motor vibration is increasing 22

23 To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 23

24 Report across asset events 24

25 To Do List - Advanced Asset health score Work management integration it is not hard SAP PM, Maximo, Oracle Make it easy for Maintenance to see Operations (PI System) data 25

26 CBM data sources (T&D example) PI System Distribution SCADA Transmission SCADA PI HDW Doble Electrical results Breaker Tests Diagnostic data External ESOC PI Transformer loads Delta-X MV90 Weekly substation inspection Hydran Gas equipment results CMMS order history Asset registry updates Transformer oil analysis 26

27 Asset health score 27

28 Asset health score - details 28

29 Asset health score - template 29

30 Asset health score roll up calculations 30

31 To Do List - Advanced Asset health score Work management integration it is not hard SAP PM, Maximo, Oracle Make it easy for Maintenance to see Operations (PI System) data 31

32 PI System to CMMS data flow PI server PI Alerts Integration Framework Data or WorkOrder trigger CMMS Measurements Process Analysis Condition Assessment Meter or WO Acknowledgment GAUGE CHARACERTISTIC CONTINUOUS OPERATING PARAMETERS Running or Idle Pressure Temperature Rpm Vibration Oil level Portal Meter or WO Acknowledgment Integrated view of Operations and Maintenance WORK ORDER CRON TASK Mincom Asset Suite Passport EQUIPMENT 32

33 Send runhours from PI to SAP counter 33

34 Template for SAP integration 34

35 To Do List - Advanced Asset health score Work management integration it is not hard SAP PM, Maximo, Oracle Make it easy for Maintenance to see Operations (PI System) data 35

36 Linked PI System display from Maximo

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38 Shared Asset Names

39 Maximo asset hierarchy in Asset Framework Maximo equipment list Maximo locations

40 Shared Asset Names Search for pump in Maximo Search for pump in PI ProcessBook

41 Shared Asset Names Maximo Work Orders for pump in PI Web Parts

42 Maximo assets via PI Builder

43 To Do List - Basic Create a watch list early warning system Equipment usage run hours, tons processed, start/stop cycles Equipment condition alerts filter clogged, heat-exchanger fouled, motor vibration high Notify the asset owner with links to details Create a report across asset and production events 43

44 CBM related talks at this conference Leveraging the PI System's Mobile Device Access and Visualization Capabilities to Enable CBM for Distribution Assets Manila Electric Company Industry Day Power and T&D - 11:20 AM 11:50 AM Achieving Enterprise-wide Operational Intelligence using the PI Server's Asset Framework SunCoke Energy Industry Day - Metals and Mining 3:40 PM 4:10 PM Leveraging the Enterprise Agreement to Maximize Value from the PI System Infrastructure One Solution at a Time Evergreen Packaging Industry Day Paper and Pulp - 11:20 AM 11:50 AM 44

45 CBM Pod Tues: 12:30-5:30 Wed: 9:00-7:00 Thurs: 9:00-5:45 Fri: 9:00-noon 45

46 Solution Architect OSIsoft, LLC Solution Architect OSIsoft, LLC 4 6

47 Questions Please wait for the microphone before asking your questions State your name & company 47

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