Rajesh Kaza. Leadership Seminar. Technology to Enhance Operations and Maintenance Synergy

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1 Rajesh Kaza Leadership Seminar Technology to Enhance Operations and Maintenance Synergy

2 Good Intentions Goal: Meet Production Targets 2

3 Team Objectives Maintenance Goal: Meet Production Targets 3

4 Team Objectives Goal: Meet Production Targets Operations 4

5 The Reality Goal: Meet Production Targets Operations Maintenance 5

6 Another Ineffective Relationship Customer: Operations Supplier: Maintenance A customer-supplier relationship between operations and maintenance undermines equipment reliability improvements. Idhammar, Torbjörn. "Is Maintenance a Supplier or Partner?" Idcon.com. ICON, INC. Web. 30 Apr < 6

7 Why have a partnership? Challenging business conditions Cost cutting Lower production Widely variable production schedules Demanding delivery schedules 7

8 Why have a partnership? Operators are knowledgeable about the equipment operating characteristics and circumstances surrounding many of the failure modes, and have an acute understanding of the failure consequences. This experience equips operations to play a key role in the development, execution and sustainability of maintenance and reliability strategies. By linking operator knowledge into a maintenance strategy.operators will feel ownership of the solution, which is a pivotal factor in program sustainability. Casto, Paul R. Creating a New Partner with Reliability Centered Operations." Uptime April-May 2010:

9 Honeywell Field Advisor Support site initiatives related to: Maintenance Excellence Operator Driven Reliability (ODR) Asset Basic Care etc. Execution and tracking of field tasks Operate within limits Reporting 9

10 Typical Field Advisor Architecture Application Server Database Server Mobile Computers Firewall CMMS EAM Historians Level 3/4 Network USB Cradled Mobile Computer Desktop Clients 10

11 Field Advisor Benefits Paper based data records are difficult to analyze and track Extend equipment life and avoid secondary damage by catching impending failure earlier Ensure field operators adhere to best practices when performing their tasks Train new field operators quickly and ensure they achieve the required competency level Appropriate actions can be taken when critical limits are exceeded for an asset Ensure the sharing of data across teams concerned with asset health Maintenance, operations and reliability 11

12 Field Advisor Value 20% - 80% (50% average) reduction in Unplanned Downtime 50-70% reduction in process safety incidents Mechanical availability improved from 93 to 98% Doubled completion of operator care activities Improved Mean Time Between Failure For example, bad oil in pumps reduced from 30% to 5% of pumps Reduced maintenance costs (secondary damage and emergency work) Payback in 6 to 12 months 12

13 Benefits of ODR Actual Site Feedback upon Implementation Key Performance Indicators Key Factors Tasks to be Performed Expected(%) Improvement Production Efficiency, Incidence Avoidance & Abnormal Situation Management 1. Structured round execution minimizes the error and improves safety 2. Production Saves due to equipment failure can be improved 3. Improved decision support with focused advise to operators and shift level exception reporting 1. Standardization of field work flow activities with regards to operations and basic equipment care 2. Standardization & consistency in field rounds and implementation of best practices 3. Field rounds to comply to HSE activities 4. Improved decision support by implementing field messages, shift level reporting and periodic web reporting 0.5-1% People Excellence 1. Platform for deploying best practices and standard work practices 2. Achieving 100% Procedure Use Compliance 3. Improve Training Effectiveness 4. Moving towards green initiative drive due to reduction of paper work 1. Electronic paperwork will allow to transfer accurate data to all stake holder in time. 2. Quick root cause analysis by can be performed 3. All field operations rounds executed through ODR 5% of productivity 13

14 Benefits of ODR Actual Site Feedback upon Implementation Key Performance Indicators Key Factors Tasks to be Performed Expected (%) Improvement Maintenance Cost Reduction 1. Reduction in emergency work orders 2. lower maintenance costs due to early detection 3. Equipment basic care will now be owned by operations like leaks,basic checks etc 4. With Consistent sustained data collection, reduction in no of exception seen in the field thus increasing the MTBF 5. Proactive preventive maintenance 1. Operators will also own basic care of the equipment and provide first level alerting 2. Additional basic equipment health related parameter checking through operator rounds 3. Decision support in the field and reporting to maintenance via proper reports 1-2% of maintenance budget Safety 1. Conduct regulatory safety checks 2. Conduct scheudled Safety valve surveys, fire extinguisher, safety shower surveys etc. 3. Lockout/ tagout any environment checks, HSE, Compliance audits 1. Extend to other departments like safety and maintenance inspections Increased Workforce productivity 1. Electronic paperwork, 2. More value added data collection 3. Improved data quality and trail for audits 4. Execute best practices for any field checks 1. Detailed periodic data collection in shorter time span leaving more time to carry out value added activities in the field like physical inspections etc 5-10 % of productivity gains 14

15 OneWireless EHM Complete solution for monitoring rotating equipment Turbines, compressors, pumps, fans, blowers, motors, etc. Wired performance in the wireless world 15

16 OneWireless EHM Critical Assets (1% or less) Vital Assets (2 to 5%) Typically not spared Balance of Plant Assets (30 to 70%) Typically spared Continuously Monitored Wired Protection Systems $100K per asset Continuously Monitored Wired Condition Monitoring Systems $20K per asset Hourly Monitoring $6K to 8K per asset Weekly to Quarterly Portable Condition Monitoring $1.8K to 5.4K per asset (3 years) 16

17 Typical OneWireless EHM Architecture Aptitude Analyst Asset Manager Experion Station (DCS) OneWireless Data Collection Dally Vibration (acceleration) Temperature (0-5/4-20mA) Speed (tachometer) Load (4-20mA) Pressure (4-20mA) Wireless SP Wi-Fi Low power Short range Multi-hop mesh Hybrid star mesh topology Capacity for over 30K sensors Analysis Dynamic Data Trending/Charting Band Alarms Assessment Correlation of vib, process and round data for health assessment Notifications CMMS Integration Operations Overall Vib. Asset Mgr Alerts 17

18 XYR 6000 Hardware supports simple, user configured diagnostics that can be continuously sent to operations for action HSM Hopewell Problem Material build up on a fan can cause failure (2 Days) Solution $50K production and repair expense Extensive damage within 8 hours Operations can prevent this damage by flushing this fan (remotely) if notified early enough Configure an automatic diagnostic on XYR 6000 module Send diagnostic to operations once a minute Send alert when diagnostic reaches limit 18

19 Asset Manager Monitor and analyze complex assets 19

20 Asset Manager Dashboard Enhanced monitoring Performance, Corrosion, Vibration Health Index Simple PV-like trend 20

21 21 Technology can enable partnership

22 22 Questions?

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