Achieving a Higher Level of Maintenance and Reliability to Help You Increase Uptime

Transcription

1 Achieving a Higher Level of Maintenance and Reliability to Help You Increase Uptime Kris Dornan PlantPAx Device Integration Manager, Rockwell Automation Tim Burchell Regional Manager, Endress+Hauser PUBLIC INFORMATION Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

2 Helping You Increase Uptime Agenda When a critical asset in a highly complex production system fails without warning, the cost in damage and downtime can be high, not to mention the potential risk to personnel and the environment. Asset reliability can be a competitive business differentiator which causes many organizations to rethink how they can leverage existing resources to improve the performance of their critical assets. Learn how Endress+Hauser & Rockwell Automation can help prevent and predict unplanned downtime Industry Challenges & Industry Study Asset Reliability User Cases & Capabilities How We Can Help You Increase Uptime PUBLIC INFORMATION Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. 2

3 Industry Challenges For the Next Decade Pressure on Efficiency and Reliability Shrinking Expertise in Workforce Aging Assets New Assets Increasing in Complexity Increasing Regulatory Pressures PUBLIC INFORMATION Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

4 Aberdeen Study Findings Many companies still under economic uncertainty; have held up capital expenditures and lowered operational budgets When Survey asked what the top risk with biggest impact to operations, the number 1 response was Failure of Critical Assets How are business executives leading companies to avoid costly downtime while reducing maintenance costs? PUBLIC INFORMATION Predictive Maintenance is an approach that allows maintenance, quality and operational decision makers to predict when an asset needs maintenance, which changes unplanned downtime into a planned stop and avoids costly disruptions. Best-in-Class outperformed RoA expectations by 20% Source: Aberdeen Asset Management: Using Analytics to Drive Predictive Maintenance March 2013 Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. 4

5 Aberdeen Study Takeaways Best-in-class are implementing strategic actions to provide visibility of information across various systems, plants & equipment lifecycle stages, empowering employees to make better decisions. Many companies managing assets and maintenance through predictive approaches are enabling key resources to embed asset analytics with business intelligence for greater decision making processes. PUBLIC INFORMATION The use of predictive analytics and business intelligence is essential for a company to be successful in their predictive maintenance endeavors. Source: Aberdeen Asset Management: Using Analytics to Drive Predictive Maintenance March 2013 Best-in-Class performing 1.7% unscheduled asset downtime Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. 5

6 Asset Management & Optimization Leveraging Process/ Production systems Driving standardized processes within both asset management and process / production systems can be a big business differentiator! As you seek to achieve higher level maintenance and reliability to improve uptime: How will you be managing your most critical assets? Are you leveraging smart device information to drive predictive maintenance decisions? Are my networked devices running within known control limits and healthy? How am I tracking asset data? Will replacement parts meet required specifications? How much downtime is caused by parts issues? Do I have governing policies to manage asset change and alternative configurations? How can I culturally evolve maintenance program to be more predictive? Reliability is more than asset management and quality control. It s a company-wide mindset that never veers from the goal. - Jeff Dudley, Dow Chemical PUBLIC INFORMATION Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. 6

7 Taking a deeper dive with E+H and RA Looking at how Asset Reliability drives business value, we want to explore... Endress+Hauser instrumentation/smart metering approach Rockwell Automation controls network/smart devices approach Asset Reliability User Cases & Capabilities How We Can Help You Increase Uptime PUBLIC INFORMATION Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. 7

8 User Case: Heartbeat Diagnostics Heartbeat Diagnostic Continuous self monitoring General health check Result: Diagnostic events and remedy measures Benefits: Immediate availability of device status information Quick and safe decision in case of error by remedy information Reduction of needed time in case of error Slide 8

9 Heartbeat Monitoring Observation Continuous output of diagnostic parameters and diagnostic status events influenced by process conditions PAS Continuous output of diagnostic parameters Heartbeat Monitoring Slide 9

10 Determination of Optimal Calibration Period 0.60 In-Cell Deviation (ph) Time Between Calibrations (Days) Calibrations and maintenance must be brought in <90 days to stay within operating parameters Slide 10

11 Data Analysis: Operating within Control Limits Redundant sensors behaving similar in same application environment. Control limits can be set by loop and viewed over multiple time horizons. Slide 11

12 Data Analysis Caustic Loops Components of Analysis Quickly Diagnosed and Detected Clogged Filter Improved Process Uptime Slide 12

13 Total Program Performance Electrode Costs ($/Loop) Sensor Failures $1,000 $800 $600 $400 $200 $- Pre Program 2012 Current PM Work Orders JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL UnScheduled Work Orders JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL Slide 13

14 Reliability Program Milestones No safety incidents at either of the hub locations! (Hub #1-4295/ Hub #2-5321, safe man hours for 2013 through September) Electrolyzer Six Sigma study exceeded expectations with 1.13 sigma improvement compared to the 1.00 sigma target ($300K/yr) Additional analysis increases related savings to $3.5MM/yr - decreases chlorate impurities in the product - debottlenecks downstream chlorine recovery system - reduction of treatment chemicals used (caustic/sodium bisulfite) Additional yield of chlorine and energy cost savings also realized! Slide 14

15 Verification and Calibration of Flowmeters On-site calibration Factory calibration Workshop calibration On-site control measurement Quality of Testing Heartbeat Verification on demand Control measurement from the outside Flowmeter functionality verification Mobile test rigs Effort Stationary calibration facilities Calibration: Flow performance confirmation Slide 15

16 Realizing a Connected Enterprise - TOGETHER Temperature Out of Range Due for Calibration Sensor Diaphragm Broken PUBLIC INFORMATION Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. 16

17 Joint Integration Office Why? Customer Concerns & Answers Faster Time to Market Through Increased Operator Efficiencies Connected Enterprise Provided Through detailed information from E+H Instrumentation connected to PlantPAx systems Proven Customer Value TIME SAVINGS Faster Integration Time Ongoing Savings of 34% COST SAVINGS Reduces device integration costs by 68%, on average Key Deliverables Installation how to: Connect E+H instruments to RA PlantPAx Configuration how to: Configure network interface Configure instrument Visualization Faceplates for Smart Devices PUBLIC INFORMATION Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

18 What does it look like? PUBLIC INFORMATION Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

19 Final Comments & Questions PUBLIC INFORMATION Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn. Rev 5058-CO900E Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.