OpEx Advantages + Asset Optimization Francois Ichtertz / Dominik Brand Manager FOUNDATION Fieldbus Endress+Hauser Process Solutions AG. Panos Giannakoulias Certified FF Systems Manager Endress+Hauser II AG Middle East Support Center
CapEx / OpEx savings and life cycle phases Operation Design Installation FAT,SAT, Commissioning Maintenance Renewal CAPEX Savings Use of an open standard technology Reduction in cost for wiring, barrier, marshalling rack and Junction box Reduction in cost for control system - I/O interface Reduction in cost for power supply unit and number of cabinets Reduction in control room size Engineering and documentation Fast commissioning, lower start-up costs OPEX Savings Use of an open standard technology Increased information for better operation, accuracy of measurement & control Enhancement in control function and the performance Improved throughput On-line diagnosis enables true preventive maintenance Improved trouble shooting
Increase Plant Availability
Where are the OpEx savings? Operation and Production Costs Additional production time by: Improved maintenance for: Fewer process upsets High availability Easier and faster incremental expansion Improved throughput by: Improved quality and productivity Improved Alert capabilities for better operation Improved accuracy of measurement and control Data access for Business Intelligence
Where are the OpEx savings? Maintenance Costs Right time or proactive maintenance to: Reduce unnecessary trip to plant Avoid failure instead of solve failure Reduce time to repair Root cause identification and elimination Reduce inventory cost Infrastructure with: Centralized maintenance Centralized tooling and data management
Operation and Production Costs
Control In the Field Performance Benefits CIF provides superior reaction to deterministic disturbance in the process Possible to synchronize data sampling and control Possible to reduces Latency effect in the control chain CIF provides enhanced process integrity
Reduced Variability 62 Process Output (%) 60 58 56 10 20 30 40 50 Time (s)
Tighter Loop Control Control Limit Digital Analog Pneumatic Manual For fast process application: Improvements in response time of between 10% and 30 % Improvements in disturbance rejection of up to 20% Digital Analog Pneumatic Manual
Migrate CIF progressively. maximizing ROA! DCS Advanced Control M A X Ethernet A S S E T S FF - H1 Field Controller Hybrid CIF Pure CIF U T I L I Z A T I O N
Maintenance Costs
Potential for improvements Potential for Predictive Maintenance with Pressure Transmitters 35% 30% 25% 35% 28% Shell Global Solutions 20% 15% 20% 10% 5% 0% Routine check No Problem Calibration shift 6% 6% 4% Zero Off Plugged lines Failed 63% of instrument maintenance labor results in no action taken -> waste of resources
Potential for improvements Maintenance today: 65% of work orders generated for transmitters are unnecessary either no problem or problem with other equipment 75% of control valves removed from process lines did not require removal 50% of instrument tech s time is spent on paperwork
Role Based Diagnostics Plant operators Process Control Engineering Station Asset Management Maintenance Station Plant maintenance engineering Control Network H1 1
Maintenance Urgency Wear Reserve
Maintenance Urgency Wear Reserve Alarm Warning Prediction of time Before affecting the process wear reserve
Equipment Monitoring in the Plant Process Condition Monitoring Devices Functions Sub-processes Other key performance indicators Quality Ft LC FC Ff FC Machine Condition Monitoring Condition Monitoring Runnability Monitoring Oil lubrication Monitoring Field Device Performance Monitoring Field Devices on different field buses It is all about Diagnostic Information!
Device Performance Monitoring (DPM) Software Application DPM FF Web reporter E-Mailer ODBC Notifier Performance Monitoring Database H1 Travel Deviation High Alarm
Increase Maintenance Efficiency Less trip to the plant Improve general efficiency Improve security Work is scheduled and proactive for a better quality and less unplanned shutdowns Stop reactive firefighter actions and anticipate problems Intensify collaboration between Operation and Maintenance But it is all about People Mindset!
Additional Key Improvements Centralized Tooling and Configuration data Easy back-up of the configuration data Easy audit trail and data management Easy update and migration of the Tooling Basis and fundament for real Asset Management Better Calibration Management Improved Management of the Installed Basis
Asset Optimization Control Network Asset Management Software uses fieldbus for Asset Optimization Solutions ❸ 1 0 0 1 0 0 1 ❷ ❶ Digital Communication from Sensor to Asset Management inductive signal transmission inductive energy transmission
Asset Optimization Asset Data Access Control Network 1 0 0 1 0 0 1 ❸ ❷ ❶ Parameter access via fieldbus for both Transmitter and Sensor to enable: Configuration Diagnostic
Asset Optimization Calibration Mngt. Control Network ❸ 1 0 0 1 0 0 1 ❷ ❶ Manage complete life cycle of a sensor Trace the calibration and adjustment history Customized calibration protocols are generated automatically
Asset Optimization Link to CMMS Level W@M portal Control Network CMMS Internet 1 0 0 1 0 0 1
Business Intelligence - Managing Data
Questions?