Plant Asset Management. Reducing capital and operating expenditure on assets by optimizing workflows and business processes

Transcription

1 Plant Asset Management Reducing capital and operating expenditure on assets by optimizing workflows and business processes

2 What is Plant Asset Management? Does your plant have availability problems? Can you react quickly to device malfunctions and failures? These are just two aspects of plant operation where Plant Asset Management brings significant improvements as well as a reduction in operating costs. Maintenance Issues? Your plant is over 10 years old. Although you operate a preventive maintenance policy for instrumentation, there is still the odd failure. Then it s a matter of putting in a replacement as quickly as possible. That s getting increasingly difficult. Not only have you forgotten how to configure older devices, which means a long search in the archives to find the documentation, you also come across the odd dinosaur no spare in stock, out of production! Finding a replacement can take a long time, which for a critical measuring point could mean unscheduled downtime and loss of production. Even with the replacement in place, the job is not done: you have to file a hand-written report! Isn t it time to look for a more user-friendly solution? Quality Issues? Working in a regulated industry you have every measuring point in focus. Information gathering starts with instrument selection and continues throughout the entire life-cycle of a device. Production Issues? You are manufacturing e.g. specialty chemicals and your processes operate to tight tolerances: any instrument operating out of specification may lead to drastic reductions in yield and quality. For this reason you calibrate your instruments at regular intervals, although you sometimes get the feeling that you are overcalibrating. Your planners, commissioners and operators all use different tools, so information can easily go astray at every handover. An additional problem is the different media: paper, disc, PDFs, downloads or xml exchange. Material certificates, status as delivered, maintenance and calibration reports, changes in parameterization, technical data, trends and histories etc., all have to be archived for every device. During an audit, you have to be ready to present the accumulated data at a moment s notice. Would 100% audit-ready data with traceability and e-signature meeting regulatory compliance help reduce the effort and streamline the process? Your scheduling comes from a Computerized Maintenance Management System, but for the most part your reports are still on paper. You have considered switching to an electronic system but lot of your instruments are located in hazardous areas, which means you need hot work permits if you want to work with laptops. You know that there are Ex-certified handhelds, but can you get the data back into the system? 2

3 Plant Asset Management All field devices in a production process are assets. Each has to be configured, maintained and depending on industry, calibrated. The associated asset information must be managed and kept up to date throughout the plant life-cycle. NAMUR Recommendation NE 129 outlines a strategy for managing plant assets that envisages three areas of action: Continuous evaluation of asset health throughout the life-cycle of the plant Provision and archiving of plant information, with seamless transfer of data from the engineering and start-up phase to the operations phase Interaction with users, ensuring that operators and maintenance staff are always aware of any actions required to keep the plant running This three-fold approach provides a solid foundation for continuous improvement of operation and maintenance workflows: Monitoring rather than guessing the health of your assets leads to more costeffective maintenance strategies Having asset information identity, certificates, configuration history, spare parts, etc. at your finger tips allows you to react quickly to current issues and plan improvements for the future Planning, data acquisition and archiving tools allow your maintenance staff to work faster and more efficiently Endress+Hauser s offering in Plant Asset Management (PAM) reflects the NAMUR criteria as well as other de-facto standards and best-practice recommendations. We support you with our asset management solution and services, optimizing your ability to produce, improve quality and reduce operational costs. With a plant asset management system in support, routine maintainance becomes much easier 3

4 Where can Endress+Hauser help? Knowing your assets and keeping them healthy is essential to optimizing maintenance and production. With Endress+Hauser, you have a partner who understands field devices and who can help you to get the most out of them in both start-up and operational phases Endress+Hauser Endress+Hauser will help you to optimize industrial workflows and business processes related to your plant assets with the aim of: bringing your field instrumentation quickly into operation ensuring that it performs correctly when your process is up and running In addition to our instruments, we can offer asset information as well as the solutions and technology to access and manage it over the plant life cycle. We have the know-how to integrate asset information, for example maintenance notifications, into your business processes and systems, for example SAP-PM. Alternatively we can provide hosted services. Consultancy and services for optimized calibration and maintenance management are also part of our offering. Your Benefits Partner with over 50 years experience in manufacturing and the use of field devices Partner with unparalleled knowledge of the integration, set-up and maintenance of field instrumentation Comprehensive range of Plant Asset Management solutions and services Full support in planning and executing Plant Asset Management projects Worldwide Service organization providing local 24/7 support when required Average investment per asset Cost savings: Easy setup Earlier production No asset management Unscheduled downtime due to asset failures increases operating costs Maintenance costs increase with plant age Endress+Hauser s Plant Asset Management portfolio helps you to reduce start-up time and improve and sustain plant performance. It uses the information held by intelligent devices to check their health and provides solutions and/ or services that ensure they remain within specification. By using our offering you can ensure continuous process improvement throughout the entire plant life-cycle while reducing your average investment per asset. The more aspects of asset management you use, the greater your savings. Asset management Consultancy Start-up Operation Lower than average maintenance costs More asset management, more savings Time 4

5 Solutions & Technology Plant Assets Asset Information Services Competence in four areas of activity provides the fundaments of our PAM offering Portfolio Endress+Hauser s Plant Asset Management (PAM) portfolio draws on our experience and expertise in four areas of activity: Plant assets Asset information Solutions and technology Services We offer open solutions that are tailored to your requirements, ranging from mobile configurators to full blown plant asset management systems. At all times we have your requirements firmly in focus, not those of a closed system. Setting up a device with laptop computer Plant Assets Who knows better how to select, set-up, calibrate and maintain our devices than Endress+Hauser? We offer a full range of measuring instruments with various fieldbus communication protocols. Our instruments are self-monitoring and offer a wealth of diagnostic information. In addition to standard status signals, they indicate e.g. the onset of corrosion, abnormal process conditions etc. All new instruments support NAMUR Recommendation NE 107, allowing users to make quick and informed decisions about asset health. Our offering includes the management of 3rd party field devices. Asset Information A major challenge in all facilities is the management of asset information. If not considered in the design stage, information is likely to be generated in a number of forms and provided on a number of media. When all data associated with a plant tag have to be archived on paper, a major effort is required to keep records up to date. Finding accurate information becomes more difficult the longer the plant is in operation. Endress+Hauser s PAM solutions support asset information management over the entire life-cycle. All information associated with a particular device, including drivers, documentation and spare parts, can be securely accessed in our own equipment records via Web Browser by simply entering the device s serial number. User data generated in the field can be uploaded into our solution platforms. Solutions and Technology Endress+Hauser has the solutions and the know-how to access all relevant asset information in a production plant. Our PAM offering extends from modems and handhelds for use in explosion hazardous areas through well-tested plant access points to software and web-based systems that are fully integrated via state-of the-art technologies into CMMS, LIMS and ERP environments. All our tools are based on open standards allowing you to use best of class components for your applications. As pioneers in field communication technology, we have the know-how to get the most from our field devices in any process automation scenario. We are unique in offering plant asset management systems that work in parallel to controllers and can provide all components necessary to built up the associated bypass. Services Endress+Hauser collaborates closely with its customers to ensure consistent support in all situations. Be it trouble shooting, emergency spares, calibration or simply straight forward advice when you need us we are there! We have a range of innovative added-value services to support you at every stage of your business. Your goal is to deliver optimum product quality in a safe and profitable fashion, ours is to support you with the right balance of added-value services to ensure you achieve this with the maximum of process uptime, the optimum amount of maintenance and the minimum of cost. 5

6 Solutions and services Once operating, field assets must be kept fit, i.e. monitored, maintained and, if necessary, calibrated. We provide the solution platforms to do the job as well as the expertise to manage, schedule, execute and document your activities. You can buy a complete package or have us provide a service level agreement. Solution and/or Service Endress+Hauser offers PAM solutions and services tailored to the workflows and business processes found mostly in the MRO phase of the plant life-cycle. They comprise anything from a simple device through asset management systems fully integrated into your MES or ERP environment to service level agreements. In all cases, Endress+Hauser will support you in the planning and realization of your PAM project and can offer specific solutions as a service performed on site by our local Service organization. Device Setup and Replacement We can provide either the means to set up your devices or commission them for you as part of a project. We offer a mobile solution with handheld and a network solution with software. In both cases, you can upload and download configurations saving time when commissioning identical measuring points. You can also generate an archivable report on the configuration of every device at start-up. To simplify device replacement we offer connection to our equipment records where you can instantly check on the availability of replacement devices and download device drivers. We can host your entire instrument configurations or interface with a database in your enterprise. Comparison functions in our tools ensure that replacement devices can be checked and configured with the minimum of effort. Endress+Hauser can help you reduce operating expenditure by optimizing the associated workflows Engineering Commissioning Installation Device Setup Maintenance, Repair & Operation Device Replacement Inspection and Monitoring of Assets Calibration Management Maintenance Management Spare Part Management Documentation Management 6

7 Inspection and Monitoring of Assets A prerequisite for efficient handling of all plant asset management activities is a detailed knowledge of the plant equipment. When Endress+Hauser has been involved with the engineering, installation and commissioning of a new plant or plant extension, one deliverable will be information on the field devices present. For existing plants we can inspect and register your installed base and provide you with a risk analysis highlighting potentially critical devices and proposing remedies. Endress+Hauser s field devices indicate when they have a problem, and the corresponding diagnostic information can be read out using a mobile platform or central solution. It is also possible to continuously monitor the condition of devices. In this case, we will help you to install the system, select critical instruments and tailor the diagnostic messages to your requirements. Diagnostics to NAMUR Recommendation NE107 are implemented in our field devices as standard. Flowmeter calibration can be outsourced to us Calibration Management Our calibration management solution allows you to schedule and track your instrument calibrations as well as to produce electronic reports that are compliant with FDA 21 CFR Part 11. The solution interfaces to our own as well as all common mobile calibration platforms. Integration into Computer Maintenance Management Systems (CMMS) such as Maximo and Ultimo, into SAP Plant Maintenance and other Enterprise Asset Management systems as well as IT consulting services are part of our standard portfolio. Endress+Hauser also offer a number of services around calibration. These range from calibration agreements for execution and management through training to the complete planning, installation and commissioning of calibration systems according to pertinent good manufacturing practice requirements, e.g. GAMP. By having asset information at your fingertips, you will be able to improve the efficiency of your workflows Maintenance Management Our maintenance management portfolio spans a range of services from consulting through to the provision of an on-site maintenance team. We will look at your plant with fresh eyes, identify areas of improvement and bring recommendations to efficiently manage and perform your maintenance and calibration activities. If you outsource your management activities, the relationship with Endress+Hauser can range from simple supplier to strategic partnership. A service level agreement allows you to focus on your core competence, leaving us to perform well defined tasks or assume specific responsibilities under performance agreements. Spare Part Management Spare part management is based on our equipment records, which may be accessed through an internet portal or installed on your site. By simply entering the serial number of your device you have access to its manufacturing history, current availability, spare parts, calibration certificates, device driver and documentation. Documentation Management We offer two ways of managing documents: either by a direct connection to our equipment records or using our plant asset management solution. Here, documentation can be stored and accessed from the virtual measuring point. In both cases, documents, e.g. for third party devices can be added manually. 7

8 People for Process Automation Endress+Hauser is a global supplier of process automation solutions. We develop, manufacture and sell sensors, systems and services for the process industries. Used for both production and inventory control, these products acquire, transmit and evaluate process information. They offer excellent performance at an affordable price, backed up by innovative local and e-service. Their quality, safety and efficiency increase our customers competitiveness. A closely-knit network of production and sales companies, together with local representatives, gives Endress+Hauser a strong global presence. We pride ourselves on our industrial know-how, innovation, employee creativity and commitment to customers. Endress+Hauser stands for financial strength, continuity, an excellent instrument and service basket as well as lasting customer relationships. On site flowmeter verification Supplementary Documentation FieldCare CP00001S/04/en FDT - Field Device Tool CP00010S/04/en Field Xpert CP00014S/04/en Installed Base Audit Field of Activity FA00019H/24/ae W@M Life Cycle Management CP001Z/00/en Service Portfolio Field of Activity FA00018H/29/en CompuCal CP00012S/04/en Field Network Engineering Field of Activity FA00025S/04/en Maintenance Guide Endress+Hauser Catalogue EC00003H/29/en Instruments International 12.06/I.I. Endress+Hauser Instruments International AG Kaegenstrasse Reinach Switzerland Tel Fax info@ii.endress.com FA00024S/04/en/ HD/INDD CS5.5