Honeywell Proprietary

Honeywell.com

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Document control number

2014 Honeywell Users Group Americas

8 Ways Process & Equipment Health Management Can

Increase Profitability

Bart Winters Asset Management Product Line

Agenda

Sample Problem

Asset Manager Solution

Positioning in Overall Reliability Ecosystem

8 Ways to Value

Case Studies

Problem Statement

Day in the life of plant/equipment engineer

Heat Exchanger problem

Where do you start

Instrument

Valve

Pump

Exchanger

Where am I at vs. where I should be?

What changed, when, how much?

Where get info???

Asset Manager Overview

CMMS/ERP Integration

Maintenance.

Reliability, & Engineering

Performance Calculations & Health

Assessment

Asset Manager

Visual

Inspections Smart

Instruments

Asset

Data Sheets

DCS &

Historian

Corrosion

Monitoring

Condition

Monitoring

Other

Applications

Management

Reporting & KPIs

Operator

Unified Health Monitoring with Asset Manager

Unified Health Monitoring with Asset Manager

Transmitter

Health

Control Valve

Health

System

Health

Control Loop

Health

Pump Health

Heat

Exchanger

Health

Unified Health Monitoring with Asset Manager

Transmitter

Health

Control Valve

Health

System

Health

Control Loop

Health

Pump Health

Heat

Exchanger

Health

1. Integrates real-time information for

analysis and decision making

2. Applies Fault and Performance

models for asset health diagnosis

3. Automates Alerts and Actions for

proactive response to potential

failures

What Asset Manager Does

Information Integration

Define information in context of Process and Equipment Assets

Equipment Model (templates & instances)

Synchronize with other systems

SAP Hierarchy

Experion

Data Integration

OPC DA, HDA, A&E, etc

Links to Asset Information

Manuals

Repair history

Integrate information

Performance Calculations

Event Detection

Decision Support

Reporting & Analysis

Asset Model

Define Equipment Model

Flexible

Multiple Levels

Built from library of asset templates

Pre-defined Library of asset templates

Template defines attributes for each asset type

Plant Model

Templates

Performance Calculations / Monitoring

Calculation Capability

Advanced Performance Library (embedded)

Pump, Compressor, Turbine, Heat Exchanger

Standard Performance Library

Boiler, column, condenser, blower

Thermo Calculation Package

UniSim Model

Excel Calculations

Data Driven & Scheduled

Integrate information

Performance Calculations

Event Detection

Decision Support

Reporting & Analysis

Example Feed Rate Calc.

UniSim Design Asset Manager Integration

Introduction

UniSim Design is a process simulation environment to create rigorous steady state and dynamic models for plant design,

performance monitoring, troubleshooting, operational improvement,

business planning, and asset management

Standard Models

Heat Transfer Equipment, Rotating Equipment, Reactors, Vessels, columns, Thermo dynamic package

Asset Manager - UniSim Design Interface

Map Field Data to UniSim Design Model Boundary Variables (process data model for Input/Output) in Asset Manager

Manage Execution of models from Asset Manager interface

Event Detection

Symptom / Fault Model

Rule logic for triggering event

Event Actions

OPC A&E Event

E-mail

CMMS (SAP or Maximo) work request

Define Fault Severity

Define Recommended Action

Minimize Chatter

Contextualized rule executes only when context is true i.e. pump running

On-Delay & Off Delay

Simple & Complex Rules

Integrate information

Performance Calculations

Event Detection

Decision Support

Reporting & Analysis

Bearing Fault Example

Heat Exchanger Example

HE Performance

Alert

After Maintenance

HE Efficiency

Improved

Experion to Asset Mgr Fault Model

Experion Configuration Mapping in Asset Mgr

Simplified Smart Instrument Monitoring

Define Template for device types ONCE

Organize diagnostic messages (per NAMUR)

Time delay to minimize chatter

Define Severity of fault

Define Action (OPC, Email, CMMS)

Corrective Action

Instances Auto Created

Define Criticality - (instrument on compressor vs back-up pump) to calculate priority

Controller / Loop Performance

Combine device health with control loop health

Performance Index

(2) = FAULT

Valve Stiction

Oscillation Index

Bias / Drift / Frozen

Asset Manager

Control Performance Monitor

Decision Support

Decision Support - Response

Tree-Map Overviews

Based on Fault Priority

View Graphics

Analyze Trends

View Events

Access Recommended Actions

Access Linked Information

Integrate information

Performance Calculations

Event Detection

Decision Support

Reporting & Analysis

Decision Support: Graphics Displays Baseline Model Data

@ current Operating

Condition

Current Model Data

@ current Operating

Condition

Fault Symptom Status Visualization

FMECA (Failure Mode

Effect & Control

Analysis) is used to

identify:

Failure (Faults)

Symptoms(Cause or early warning for a

Failure)

Action to control or repair

Who (Notify user directly by e-Mail,

Operator console,

raise notification for

CMMS to generate

work order)

Reporting and Visualization

Event Analysis

Bad Actors

MTBR, MTBF

Run-hours

Meter usage

Consumption

Energy Utilization

KPIs

Integrate information

Performance Calculations

Event Detection

Decision Support

Reporting & Analysis

Health, Condition & Performance

Monitoring

Reliability

Maintenance Monitoring

Process Health

Equipment Health

Corrosion Mon.

Smart Instruments

Loop & Control Perf.

Programs & Strategies

RCM/RBI

Asset Health Matrix

Maintenance Strategy

Reliability Analytics

Ivara

Maintenance & Reliability Ecosystem

Models

Performance Models

Symptom Fault Models

Corrosion Models

Simulation Models

Statistical Models

Diagnostics

Tracking

Process & Equip Health Mgt. Monitoring / Surveillance / Event Detection

For process and equipment assets providing

Prioritization, Alerting & Notifications

To enable pro-active actions by

Process and Reliability Engineers

To improve overall OEE

8 Ways to Increase Profitability

1. Improve asset uptime / OEE

Pro-active Maintenance, On-Condition, 1st Time Quality, Prevent unplanned and overplanned

2. Reduce maintenance costs

Reactive work takes 3 times longer to complete and is 4 to 10 times more expensive

Predicting maintenance at the optimal time to avoid costly secondary damage

3. Improve operating performance

Minimize disruptions to Operations

Minimize mis-operation of equipment

Maintenance and Operations can collaborate to plan maintenance based on asset condition

4. Make Problems Visible

Connects the disparate Silos of information

Turns data into actionable information

Make maintenance decisions proactively

5. Increase Engineering Productivity

6. Extend Asset Life

7. Improve Energy Utilization

8. Improve Safety

8 WAYS TO INCREASE

PROFITABILITY

#1 Improve Uptime

Pro-active Maintenance

On-Condition Maintenance

1st Time Quality

Prevent unplanned and over-planned

#2 - Reduce Maintenance Costs

Reactive work takes 3 times longer to complete and is 4 to 10 times more expensive

Predicting maintenance at the optimal time to avoid costly secondary damage

#3 - Improve Operating Performance

Minimize disruptions to Operations

Minimize mis-operation of equipment

Maintenance and Operations can collaborate to plan maintenance based on asset condition

#4 - Make Problems Visible

Toyota Way Management Operating System

Connects the disparate Silos of information

Turns data into actionable information

Make maintenance decisions proactively

#5 Increase Engineering Productivity

Ready access to actionable information

Automatic monitoring and notification

Integrated information environment

#6 Extend Asset Life

Extend asset life through

Prevention of abusive operations (operator coaching)

Prevention of secondary damage

Understanding of true health

#7 Improve Energy Utilization

Visibility into efficiency

Monitor efficiency

Take actions on energy usage

Detect performance degradation

# 8 Improve Safety

More reliable plants are safer

Success Story

Middle East Oil & Gas Processing Facility

Honeywell chosen to provide Equipment Condition Monitoring solution for large Oil & Gas processing facility to provide the following benefits:

Monitor over 1200 process and equipment assets Detect performance degradation as leading indicator of equipment health Combine electrical, mechanical, and process performance data in single health

monitoring location

Measures equipment performance to improve energy utilization Support predictive maintenance Support smarter turn-around planning Prevent mis-operation of equipment

Process changes have a significant impact on equipment behavior and reliability, which in turn show up in the process data. We can now see how the

process parameters affect the asset performance. It is the missing link that

Asset Manager provides. In one case leading to 15MgW savings/year

Reliability Manager Middle East Oil & Gas Processor