PBX_214_Pred_AssetMgmt_OpsMng11_v1x - Invensys ...

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© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are pr
opr
ietary marks of Invensys or its subsidiaries. All third party
trademarks and service marks are the proprietary marks of their respective owners.

© Invensys 00/00/00

Invensys proprietary & confidential

Slide
2

Predictive Instrument Asset
Management

Session Name: Predictive Asset Management

Session ID #:PBX 214


Charlie Piper

11/09/2011

Slide
3

Invensys Enterprise Control Offerings

Manufacturing / Production Operations

Corporate


Integration and

Collaboration Platform

Automation

Invensys and Third Party


Software Applications

Invensys and Third Party


Enterprise Control System


IT

Platform

Corporate Systems

Industry
Solutions


Services:

Consulting,
Project

Execution,

Learning,

Operational
Improvement,
Maintenance &
Support


Partner
Ecosystem



Slide
4

Integration &
Collaboration

Platform

Enterprise

Integration

Workflow

Open Device

Integration

Web
Portal

Application

Toolkit

Historian

Third
-
Party Offerings

Software Applications

Execution

Manufacturing Execution


Systems

Batch

Enterprise Asset
Management

Mobile Workforce
Management

Performance

Enterprise Manufacturing
Intelligence

Performance Measurement

and Reporting

Visualization

Quality

Asset
Performance

Optimization

Operator Training

Design

Advanced Process
Control

Simulation /
Optimization

Control

DCS

PAC

SCADA

HMI

Safety

Safety Instrumented Systems

General
Purpose

Safety

Turbomachinery Control


Measurement &


Instrumentation

Instrumentation

Controllers

Recorders

Automation

Software Applications

Where The Offerings We Will Discuss Fit Within The

InFusion

Enterprise Control System

Slide
5

Pillars of Operational Excellence and
Focus of This Discussion

Level 3

(Multi
-
plant/Multi
-
site)

Level 2

(Plant Floor/Area)

Level 1

(Resource/Asset)

Operational

Excellence

Environment

And Safety

Control

People

Asset

Slide
6

Asset Excellence

Maximizing

Client Profitability via Actions on Assets

Maximizing the return on enterprise assets



Balancing effective availability and utilization



Physical, inventory, human, and knowledge assets



Optimizing profit through operations and maintenance

Asset Excellence

Optimizing performance through production and
business control



Optimizing production efficiency through better control



Combining business control with automation



Bringing real
-
time business variables under control

Control Excellence

Maximizing the effectiveness of people and systems



Empowering all operating personnel



Enabling collaboration efficiencies



Minimizing variable cost impact of plant operations

Productivity Excellence

Balancing profitability with safety and environmental
sustainability



Minimizing emissions and waste from industrial assets



Increasing equipment, people and environmental safety



Relieving environmental constraints on business value

Environment & Safety

Excellence

Slide
7

Asset Related Business Drivers

Asset

and Operational Risk

Management

PROFIT

WORKFORCE

ENABLEMENT

SOCIAL

RESPONSIBILITY

SAFETY

MANAGEMENT

Asset Uptime

Asset Longevity

Asset Utilization

Lifecycle Cost Reductions

Energy Reductions

Problem and Risk Awareness

Decision Support

Corrective Tools

Collaboration Tools

Productivity Tools

Workflow Tools


Accident Prevention

Safer Work Environments

Safety Practices


Accident Prevention

Emissions Control

Carbon Footprint

Regulatory Compliance


Slide
8

Modeling Asset Excellence

Maximizing Profitability

Increasing the Positives


Higher production rates


Better product quality


Boosting or maintaining asset
efficiency


Improving uptime and reliability


Increase operations & maintenance
staff effectiveness


Optimize activity scheduling


Improve inventory efficiency


Balance operational and
maintenance investments


Extend Asset Useful Life


Decreasing the Negatives


Avoiding downtime


Avoiding accidents


Avoiding employee injury


Avoiding environmental damage


Avoiding plant or equipment damage


Decrease energy, water, fuel
consumption


Decrease carbon footprint and
emissions


Slide
9

Collaboration for Asset Excellence

OPERATIONS



Asset utilization



Asset decisions



Asset risks

MAINTENANCE



Asset uptime



Asset efficiency



Asset risks

MANAGEMENT



KPIs



Asset decisions

BUSINESS

SUPERVISORY

& CONTROL SYSTEMS

Collaboration

Safety

Constraints

Environmental


Constraints

Slide
10

Asset Excellence Requires a Team Effort

Plant
Leadership

Maintenance Supervisors

Control & Process
Engineers

Instrument
Specialists

General Maintenance

Technicians

Operations

Maintenance

Unit Managers

Slide
11

Instrument Life Cycle Management

Plan

Configure

Commission

Operate

Fix

Operate

Replace

ECONOMIC OPPORTUNITIES

Templates
-

avoid mistakes, speed propagation

Wizards, Bulk Actions


reduce time, avoid mistakes,
faster plant startups

Predictive Alerts


create risk awareness

Business Integration & Metrics


identify economic
opportunities

Diagnostic Analysis


decision making, best corrective
action

Workflow


improve collaboration, decision making,
faster fix process

Templates, Wizards, Database Management


reduce time, avoid mistakes

Slide
12

Extending Performance and Life


Higher performance


Correct with minimal impact at best opportunity


Minimal replace time


Longer useful life

Asset

Performance

Useful

Life

Asset

Performance

Tools

Wear

Mechanisms

Replace Time

Slide
13

Invensys Instrument Management Offerings

Slide
13

Field Device Manager

Instrument Maintenance Supervisors

Instrument Specialists

Plant Operators

I/A Series System

IntelaTrac

ArchestrA Workflow

ERP Integration Toolkits

Status

Application
Objects

Message

Repository

Predictive Alerts

ArchestrA Supervisory Platform & FCS Software

Alarms &
Reports

Avantis

Enterprise Asset Management

Plant Managers

Operations Managers

HART
NEW !!

FOUNDATION Fieldbus

Profibus

Slide
14

Assets Are Not All the Same

Control & Automation Systems

DCS, SCADA, Safety, communication networks, fieldbuses


Instruments & Actuators

Transmitters, Actuators, Drives

FF
, HART,
Profibus,

DeviceNet protocols

Production Machinery

Rotating Equipment

Fans
, Pumps, Motors

Process Equipment

Vessels, Heat
Exchangers,

Distillation
Columns, Ovens

Slide
15

Assets Differ in Needed Health Monitoring Speeds

Control System Assets

Instrument Assets

Production Machinery

Processing Equipment

Embedded
Diagnostics
& Alerts

Polled or
Collected
Data

X

X

X

X

2 second
response


10 second
response

1 hour

response

1 hour

response

Electrical / Internal Diagnostics

Mechanical / Models & Cond Monitor

Slide
16

The Asset Excellence Challenge

AVAILABILITY

UTILIZATION

Asset Excellence requires a balance between Maintenance and Operations

Invensys proprietary & confidential

Slide
17

Maintenance Strategies


One Size Does Not Fit All

1.
Predictive



Maintenance is done
proactively based on real time diagnostic
information from smart devices

2.
Reliability Centered


preventive
schedule is optimized based on failure
history

3.
Scheduled



Traditional approach with
fixed schedule for preventive
maintenance

4.
Reactive

-

Run to failure approach
-

appropriate if low failure impact

Reactive

Scheduled

Reliability
Centered

Predictive

Increasing Profitability

Slide
18

Instrumentation

Planning & Design

Slide
19

FCS Field Device Manager Templates

Dramatically Reduce Engineering Time, Mistakes

Capture Expert Knowledge

Reusable Engineering

Automatic Propagation of Corrections and
Changes

Customizable to Use of a Device in Your
Plant

Customizable Maintenance User Screens

Nesting Increases Flexibility

Configure
once,
replicate often

Slide
20

Fast Drag & Drop Device Creation
-

HART

Slide
21

Fast Foolproof HART Point Selection

Pull down point choices

Slide
22

Automated Easiest FF Scheduling

Algorithm understands differences
between CIF and CIH (control in host)

Automatically optimized for minimum
dead time within the loop

Automatically validated and viewable just
prior to deployment




Slide
23

Instrumentation

Install


Commission


Loop Check
-

Startup

Slide
24

2
4

Fastest Device Prep


Automatic preparation and downloading of each device


Typical System Device
Commissioning

1.
Attach device

2.
Match actual device to system
database

3.
Set the Device Tag

4.
Set the Device Address

5.
Open RB and Download

6.
Open TB and Download

7.
Open Each FB and Download

8.
Place blocks in Auto Mode

9.
Repeat for next device



The Invensys Fieldbus System

1.
Attach
all devices

2.
Match actual device to system


Prep Wizard
automatically sets
tag
and
address, then automatically
downloads all data

3.
Turn segment on control

> 30 min per device

4 min per device

Slide
25

Fastest Device Commissioning

Device Preparation Wizard


Automatic matchup of device model
types & tag names


Completes quickly on only changes that
are necessary, e.g. tags, addresses,
system management parameters

Fast, parallel database download

Easy, fast way to turn on control


Slide
26

Fastest Device Database Downloads

Engineering & Field Device Management
Environment

Parallel downloads

As soon as device of

Correct model and tag is attached

1.
Deploy control strategies

2.
Attach Device

3.
Set tags

4.
Automatic downloads

5.
Enable control on segment


DOWNLOAD
COMPLETE PLANTS IN
HOURS INSTEAD OF
DAYS

Slide
27

Instrumentation

Run and Maintain

Slide
28

Slide
28

Instrument Health Predictive Alarms

Slide
29

FDT DTM Support
-

Tuning, Calibration,
Health Analysis


Example Invensys Positioner

Slide
30

Device Type Manager


Metso


Example Valve Stroke Analysis

Slide
31

Device Type Manager


Fisher

Example Alarm Status

Slide
32

Device Startup
Enhanced Description Support

Preformatted Device Data Viewing

Slide
33

EDD Diagnostic Status Display

Slide
34

All Asset Types


Real Time KPIs

Performance Data

Maintenance Management

ERP Interfaces

Slide
35


WW MES


OLE DB

OSIsoft

PI Server
TM

WW

Historian

Application
Server
Runtime

ArchestrA IDE

Wonderware Intelligence

Wonderware Intelligence
Standard Clients

Wonderware Intelligence Server

Wonderware Intelligence data services

Data Store

Runtime
Services

Wonderware
Intelligence

Analytics Clients

Click once deployment

Information
Model
Manager

Launched
from IDE

Published to
Intelligence
Server

Adapter
Services

3
rd

Party Clients

Microsoft Office
Reporting Services

SharePoint Portal

View Dashboards & Information Browser

Create Dashboards & Analytics

Dashboard Server

Published
Dashboards

Galaxy
Repository

Build Model

Slide
36

KPIs using Intelligence



Asset


Related

Applications





Manufacturing

Execution

Systems





Historians,
Alarm Logs



System Platform



Wonderware Intelligence Software



Asset

Data

MES

Data

Process

Data



Peer Systems

Operations, ERP

LIMS, CMMS



CMMS

Data

LIMS

Data

Asset Excellence KPIs

Information

LIMS

Data

Reports

Dashboards

Analytics

Slide
37

Work Order Collaboration
-

CMMS / EAM Connectors

MIMOSA

Interop

Server

Asset

MDM

Asset

Registry

Work

Generation

FMECA

Reliability

Measurement

Points

O&M Event

Monitoring

I&C Device

Monitoring

Portable

Monitoring

Online

Monitoring

Sample

Monitoring

Maintenance

System Drivers

Slide
38

Thank you!


Q&A