presentation to hannover messe 2016 phil millette...

Key elements of real time Analytics & Diagnostics

Phil Millette

28-Apr-2016

PREDICTIVE MAINTENANCE IN PROCESS INDUSTRY Presentation to Hannover Messe 2016

Depth & Breadth of Process Industry surveillance challenge

Industry

Monitoring

Applications

Type of

Equipment /

Complexity

Process Health Efficiency Safety Energy

Instrument

Valve Pump

Heat Exchanger

Compressor

Haul Truck

Turbine

Unit

Software

Oil & Gas Refining & Chemicals Pipelines Power Mining

© 2016 by Honeywell International Inc. All rights reserved

1

Value – Reduce Risk of Possible Unplanned Capacity Loss:

achieve real time analysis, anticipation, prediction of Process & Asset issues

Rare Frequent

High

Cost Im

pact

Low

Frequency

Process Deviations

Unit Shutdown

Degraded Efficiency

Non-Critical Eq. Failure

Critical Eq. Failure

Reduced

Capacity Loss

Original

Capacity Loss

Mitigation

Strategies

Leading

Cause

• Improved unit operations

• Energy savings

• Knowledge capture

• Standardization -performance &

process monitoring

• Remote collaboration / Subject

Matter Expert support


2

Mitigate and

achieve…

Labor Intensive / Periodic / Informal / Privatised Knowledge

As-Is - Ad-hoc Engineering Work Environment

3

Tag, Lab & Other Data Reports

Tag Name Tag Desc

XUTT901.PV HE91 Shell In Temp

XUTT902.PV HE91 Shell Out Temp

Excel & Other Tools

Manually Search & Collect

Cumbersome Isolated Tools

Manual Periodic Calculations

Informal Work Processes

T1 T2 T3

Blind Spots

Time Consuming Missed Opportunities

Difficult to Sustain

Varied Approaches

& Results

Silos of Information

86.19

88

91.4


Notifications

Events

Ad Hoc

Fixed Schedule

Maintenance &

inspection

Convert time usage to Higher Value Tasks

Surveillance Function – complexity and cost

4

• Large process plant Study

- 1 (only one of many) Major Process Area

~600 Process Eng. monitoring activities (daily, weekly, monthly…)

57 Types (Emissions, Catalyst, Energy, Yield, Hx Mon, Compressor Mon…)

60 Daily Monitoring Tasks - ~ 70% could be automated

Hrs per Activity 0.25

Hrs / Day Saved 10.4

Additional Engr Time/Yr (@70% applied rate) 1893 hrs/yrs


Organisation, expertise as well as the tools:

joined up across functions

5

Management

Operations Engineering

Common Business Goals

Improved quality Reduce operating costs Increase reliability

Maintenance &

Reliability


Increase profitability Safety

Automating Engineering Processes for Digital Transformation

Real-time Process & Asset Surveillance:

Performance Monitoring – link to predicted state

6

0

1

1 0 0

1 1

0

1

1 0 0

1 1

0

1

1 0 0

1 1

Management

Operations Engineering

Maintenance &

Reliability

Data in Asset Context Standard

Connectors Consolidate

OPC-HDA

Reduce Effort & Complexity Find & Access Data

1. Automate / Simplify Data Access, provide context

OPC-DA

OPC-A&E

OPC UA

Attributes (not tags)

Sensor (tag) Data

Historian Data

Alarms/Events

Other…

Trends

Events


7

2. Addresses broader IIOT – yes devices talk, but others do

too!

8

64KF_01TT.PV = 102.3

64KF_01TT.SP

64KF_01TT.OP

66KA_01PR.PV

66KA_01PR.SP

66KA_01PR.OP

63KA_01B_PO.PV

63KA_01B_PO.SP

63KA_01B_PO.OP

Head=3960*HP

Flow

Local Calcs

Forgotten IIOT Data Typical

IIOT Focus


C_Speed

C_In_Press

C_In_Temp

C_Effeciency

Unit101_Effeciency

Unit101_Yield

M_Speed

M_Temp

M_Vibration

M_Power

Calcs

Spreadsheets

proliferate

Cloud

Formalise all derived data

Process Intelligence

Embedded & Custom

Models

Continuously Monitor & Take Action

3. Continuous Calculations & Monitoring, link events to Maintenance &

other functions via notifications

9

Compressor Heat Exchanger

Turbine

Head=3960*HP

Flow

Pump

Fault Models

Calculations

Make Problems

Visible

Single Version of

Truth

Continuous Trends

Dashboards

Notifications

Rollup KPIs & Dashboards

Rollup Metrics

Continuous


Outputs • Alerts & Notifications

• Management Reporting & KPI’s

• Maintenance & Reliability

Scorecards

• Downtime Reporting, OEE

• Health Assessment

• Automatic Work Order request

Generation

4. Tools are good – yet expertise still needed:

build into more automated analysis

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…Accumulate team

knowledge

…unlike

manual/excel/home

grown applications

…capture logical

structure of plant

information


Questions?

Capture Visualize Predict Act

presentation to hannover messe 2016 phil millette...

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