2012 Honeywell Users Group Americas. Sustain.Ability. Ron Stallworth Asset Management

Transcription

1 2012 Honeywell Users Group Americas Sustain.Ability. Ron Stallworth Asset Management 1

2 Industry Concerns 1. Shortage of skilled resources 2. Data overload (need insight from data) 3. More profound market volatility - Reaction time and agility more critical 4. Aging infrastructure 5. Complex regulatory standards - PAS55 and ISO

3 Benchmarking Best-in-Class: Top 20% of aggregate performance scorers Industry Average: Middle 50% of aggregate performance scorers Laggards: Bottom 30% of aggregate performance scorers Overall Equipt Eff. (OEE) 93% 86% 67% Plant Throughput 97% 91% 74% Asset Downtime 3% 13% 34% Plant Floor Automation 61% 45% 23% EAM/CMMS 79% 56% 48% Standardized KPIs (across enterprise) Standardized CBM (across enterprise) Asset Mgmt System with Predictive Failure Analysis 53% 40% 18% 44% 40% 15% 28% 17% 6% % OEE = % Availability x % Performance Rate x % 1 st Time Prime Product Quality. Source: Aberdeen Group 2008, Enterprise Asset Management 3

4 Think of Asset Management in 3 Distinct Areas Many Data Sources Maintenance Reliability Condition- Based Monitoring Real-Time & Off-Line Data DCS / Historian Different Frequencies Field Inspection Wired & Wireless Multiple Suppliers PM RCM/RCA 4 Enterprise Asset Management Work-stream & Relationships

5 Think of Asset Management in 3 Distinct Areas Real-Time Condition Monitoring Maintenance Condition- Based Monitoring Real-Time Corrosion Data DCS & Historian Vibration Monitoring (DMx) Smart Instruments (FDM) Operator Rounds (Field Advisor) Reliability Infrared Thermography Oil Analysis Other Condition Monitoring 5 Enterprise Asset Management Work-stream & Relationships

6 Reliability: GP Allied Alliance Partner (GP Allied) Maintenance Condition- Based Monitoring 350 Consultants Globally Excellent Industry Reputation Experience in all Areas ireliability Suite Reliability Reliability Programs & Strategies RCM/RCA Asset Health Matrix Equipment Maintenance Plan KPI/Benchmarking Change Management Training 6 Enterprise Asset Management Work-stream & Relationships

7 Maintenance Management: IBM Maximo & SAP Maintenance Reliability Condition- Based Monitoring Alliance Partner (IBM) Global Reseller & Implementer 30 Maximo Certified Consultants L1, L2 and Premium Support Wide Variety of Industry Expertise Seamless Integration w/asset Manager Maintenance Management Work Execution Mgmt Work Order Generation Document Mgmt Financial Mgmt Purchasing Mgmt Inventory/MRO Mgmt Planning & Scheduling 7 Enterprise Asset Management Work-stream & Relationships

8 Data Management Applications Very Clear & Easy to Understand Maintenance Condition- Based Monitoring Reliability Try them out personally in the demo room!!! 8 Enterprise Asset Management Work-stream & Relationships

9 RAMP (Reliable Asset Management Performance) Asset Manager Notifications sent to EAM/CMMS EAM/CMMS Work Execution Mgmt Maint. Mgmt Workflow Document Mgmt Financial Mgmt Maintenance Condition- Based Monitoring Data Sources Condition Monitoring DCS & Historian Vibration Monitoring (DMx) Smart Instruments (FDM) Operator Rounds (FA) Corrosion Data Infrared Thermography Oil Analysis Outputs Alerts & Notifications Management Reporting & KPI s Maintenance & Reliability Scorecards Downtime Reporting Health Assessment Automatic Work Order Generation Purchasing Mgmt Inventory/MRO Mgmt Reliability Scheduling Programs & Strategies RCM/RCA Asset Health Matrix Equipt Maint. Plan KPI/Benchmarking Change Management Training Asset Manager info used in Reliability programs 9 Enterprise Asset Management Work-stream & Relationships

10 RAMP Underlying Principles 1. Relentless integration of all aspects of people, processes, and technology 2. Applied across the entire life cycle of the assets to include Capital Delivery (CapX), Operations (OpX), and Maintenance (MaintX) 3. Includes the management of all mechanical, electrical, stationary and process automation and control assets 4. Modular and scalable 5. Change Management is woven into the deployment 10

11 Asset Manager R410 Built on the Intuition Platform Single Location for Asset Management Integrate information Wired & Wireless Vibration Monitoring Real-time Corrosion management Control System & Instrumentation Monitoring Inputs from OPC, PHD, any Experion site, others Another bridge between Operations and Maintenance Typical payback less than 1 year! Integration with Honeywell and 3 rd Party Products & Solutions Seamless Integration with CMMS/EAM (IBM Maximo & SAP) Aptitude Analyst & DMx (SKF Corp) ireliability Suite; including a fault model library (GP Applied) Fault Models Alerts Alert-based Automatic Actions See all of these in the demo room!! Problem Solving Various sources New and existing Based on integrated information Based on the fault model execution results Operator notifications notification Collaboration between teams Historical information Link to relevant documentation 11

12 Field Advisor Value in ODR Framework Unplanned Downtime reduced 20% - 80% (50% average) Process safety incidents reduced 50-70% 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 13 Crude Unit Overhead System Example

14 Crude Unit Overhead System Example Failure Mode-Based Asset Management Strategy, RCM/RCA, KPIs, others 14

15 Value Crude Unit Overhead System Example Failure Mode-Based Asset Management Strategy, RCM/RCA, KPIs, others Asset Manager 15

16 Value Crude Unit Overhead System Example Asset Manager Single Dashboard MAXIMO Integration Real-time Monitoring Fault Models Performance Calcs Outputs Alerts & Notifications Mgmt Reporting & KPI s Maintenance & Reliability Scorecards Health Assessment Asset Manager Notification Sent to MAXIMO EAM/CMMS Work Execution Mgmt Maintenance Mgmt Workflow Document Mgmt Financial Mgmt Purchasing Mgmt Inventory/MRO Mgmt Scheduling 16

17 (Nm 3 /m 3 ) CCR Platforming Benefits C5+ Yield with & w/o Asset Mgmt C5+ Yield w/o Asset Mgmt with/asset Mgmt H2 Yield with & w/o Asset Mgmt w/o Asset Mgmt w/asset Mgmt H2 Yield Fewer Shutdowns Planned Unplanned/Emergency Less Time on Turnarounds Lower Maintenance Cost Better handling of spare parts Improved planning Fewer unnecessary inspections Secondary damage (CFE, Scallop Damage) Reduced Collateral Impact H2 to other units Improved HSE Less Reformate sent to slop Less flaring 17

18 Tremendous Benefits Received Improve Safety Improve Reliability Reduce incidents by up to 40% Increase operator competency Support continuous improvement Improve Efficiency Reduce off-spec material up to 50% Reduce transition material up to 30% Catalyst consumption down by 1% Improve throughput 2-8% Reduce energy use 5-10% Improve forecast accuracy 4-20% Reduce inventory % Reduce demurrage by 10-15% Improve plant availability 3-8% Preserve and extend asset life Reduce maintenance costs 3-5% Improve customer service 5-15% Improve Sustainability Green house gas emissions reduced by 25% Ensure compliance standards Reduced total cost of ownership Reduce energy consumption >$5B US in measurable benefits has been added to our customers bottom-line *Results based on past customer experience 18 Typical Return on Investments are 3 Months to 1 Year

19 Recommended Next Steps (At HUG) Visit the demo room Attend the Asset Management Roundtable (ask questions!) Attend the real-time corrosion presentation Wed June 13 th Pinnacle Peak 2 Attend the GP Allied workshop: Building a Failure Mode-Based Asset Management Strategy Fri June 15 th Grand Sonoran C 19

20 Recommended Next Steps (When you get back) Ask for an assessment at your site Start small if needed Be a champion for your company Must get operations and management involved Do something 20

21 21 Questions?