why define your strat during the feed stage

How to Define The Maintenance Strategy and Rationalize PAM Technology During DESIGN for FEED Project45 minute session Augie DiGiovanni Vice President, PlantWeb Services

Presenters

Augie DiGiovanni VP, PlantWeb Services

AgendaSubject PlantWeb Services offers DESIGNa structured approach to implementing PlantWeb technology during FEEDs or in existing facilities

Topics Why Plant Asset Management (PAM) Designing a PAM Program Customer Case Studies PAM Program Data integrated with CMMS

How topics fit together Lowest Cost Maintenance can be part of the FEED







Why Plant Asset Management?Reliability is becoming a competitive business issue Quality is a survival issue in many markets Increased production demands on older equipment Manpower reductions require us to do more with less Cost reductions focus in maintenance and operations Customer requirements are becoming more stringent Environmental, health and safety concerns have become a totalenterprise issue

Value creation is a motivating factor for management decisions

Typical Facilities & Best Cost ProducersWhat is the Difference?1988 Reactive Preventive Predictive Proactive 55% 30% 10% 5% 2002 55% 31% 12% 2% Best Cost 10% 25-35% 45-55% 5-15%

Source: Maintenance TechnologyPercent

Limited manpower Budgetary restraints Too busy reacting to machine problems to be proactive / strategic Lack of management understanding of maintenance strategies Level of maintenance employee training Not sure how to justify improved best maintenance practices

45 38 27 22 21 20

8 53% 9 47% 7 34%

7 29% 3 24% 3 23%

BARRIER: Major BARRIER: Insurmountable

Need a way to deal with the barriers to Best Cost

Sources Of Production Losses & Profile Of Maintenance SpendingEquipment failure is the #1 Equipment failure is the #1 contributor to production losses contributor to production losses

Materials Handling 2% Tools Insulation 2% 2% Paints/Coatings 3% Piping 5%

Other 4%

Instruments 20%

Electricals 7% Furnaces / Boilers 6%KEY: Mechanical Equipment Process Equipment Instruments & Valves Electrical Equipment

Valves 7% Pumps 8% Compressors 7%

Vessels 8% Heat Exchangers 10% Drives 7% Mixers/Agitators 2%




PlantWeb the promise

DeltaVTM

Asset ManagementCondition-based maintenance Increased reliability Increased availability Reduced costs Transmitter Diagnostics Device health Plugged sensing lines Control Valve Diagnostics Sensor failure, etc. Device health Travel deviation Packing Machinery Diagnostics friction, etc. Motor-pump health Vibration Cavitation, etc

Regulatory Control Operator Interface Process Alarming Advanced Control

PlantWeb the challengeDeltaV Regulatory Control Operator Interface Process Alarming Advanced Control Asset Management Condition based maintenance Increased reliability Increased availability Reduced costs

Configuration Tuning Alarm Management Operator TrainingTransmitter Diagnostics Device health Plugged sensing lines Control Valve Diagnostics Sensor failure, etc. Device health Travel deviation Packing Machinery Diagnostics friction, etc. Motor-pump health Vibration Cavitation, etc Transmitter Diagnostics Device health Plugged sensing lines Control Valve Diagnostics Sensor failure, etc. Device health Travel deviation Packing Machinery Diagnostics friction, etc. Motor-pump health Vibration Cavitation, etc Transmitter Diagnostics Device health Plugged sensing lines Control Valve Diagnostics Sensor failure, etc. Device health Travel deviation Packing Machinery Diagnostics friction, etc. Motor-pump health Vibration Cavitation, etc

Prioritization Optimization Asset Mgt Work ProcessTransmitter Diagnostics Device health Plugged sensing lines Control Valve Diagnostics Sensor failure, etc. Device health Travel deviation Packing Machinery Diagnostics friction, etc. Motor-pump health Vibration Cavitation, etc

Transmitter Diagnostics Device health Plugged sensing lines Control Valve Diagnostics Sensor failure, etc. Device health Travel deviation Packing Machinery Diagnostics friction, etc. Motor-pump health Vibration Cavitation, etc



Adding Value over the Life Cycle

Plant Efficiency

Plant performance optimization Predictive diagnostics services Monitoring and analysis servicesTr Start up ad itio na l

Start up

Start up & Commissioning

Turnaround execution

Repair services

Time

Asset Optimization in the PlantWeb ArchitecturePlantWeb uses the predictive power of field intelligence to improve plant performanceSMART MOBILE WORKER

SMART ASSET OPTIMIZATION SMART REMOTE AUTOMATION

SMART DIGITAL CONTROL

SMART MACHINERY HEALTH

SMART MEASUREMENT

SMART FINAL CONTROL

SMART SAFETY

SMART MEASUREMENT

To Increase Availability and Performance, Customers Require PAMAn Asset Management program includes three elements technology, expertise and work processes deployed uniquely to meet the specific needs of each customer These three elements are required, whether considering a single instrument or all production assets in a facility Successful customers work with world-class Asset Optimization program providers for long-term support

PlantWeb Services

Structured Approach to Implementing PlantWeb Asset Criticality / Risk Priority New / Existing Priority Predictive Technology Deployment Maintenance Task Periodicity Planning / Scheduling Optimized

Maintenance Strategy Blueprint

Business Objective Identification Gap Analysis (vs. industry / site) Site Assessment & Benchmark Goals / KPI

Structured implementation approach INSTALL - Setup / Training IMPLEMENT - Alerts / Procedures INCORPORATE CMMS / KPI

Technical Support Path forward considerations

Skills Assessment Skill Development Plan Product / Technology Courses Industry certification

A.O. PlantWeb ServicesNew Facility / Program

Structured Approach: Overview of FEED / New / Existing ProgramExisting Facility / Program(already have PlantWeb technology)

Business Objectives Formalize Maintenance Strategy

Solid Configuration Basic Training

Credible Alerts Written Procedures

Generate Planned Work Quantify Results

A.O. PlantWeb ServicesNew Facility / Program

Structured Approach: Details of FEED / New / Existing ProgramExisting Facility / Program(already have PlantWeb technology)

1. ID business objectives / LOA 2. Assess site | Gaps | Benchmark 3. ID Goals / KPIs or PAM Spec.

4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3 8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integration

1. Review arch / components 2. Install & license software 3. Confirm device communication 4. Create initial database 5. Setup alert monitor 6. INSTALL any SNAP-ONs 7. Review basic functions 8. Review formal training / mentor 9. Backup database 10. End User Signoff

1. Validate device nameplates 2. Level of AwarenessKPI, Work Flow, Priority, Blueprint

1. Attach procedures to CMMS

3. Establish 1-3 goals / KPIs 4. Evaluate work flow 5. Validate priority of assets 6. Written Procedures 7. Optimize alerts & AMS Suite 8. Review New 9. Path Forward / Project Report Procedures1

2. Quantify Financial Impact

Map into Maintenance Strategy Blueprint matrix MTBF / MTBM and Planning / Scheduling 3 based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work1 2

1

Attached procedures to CMMS

Structured Approach: Details of FEED / New / Existing ProgramNew Facility / Program

Business objectivesPlant Manager Availability Uptime Fuel Costs Efficiencies Performance Targets Labor costs Rank of Facility Sales Demand Operations Throughput Daily output targets Unplanned issues Equipment problems Alarm Management Safe Operation Maintenance Work Order priority % PM Completion Availability to Run Safety Work Order Backlog Planning & Scheduling PM Cost by Asset



Now, what is the Maintenance Strategy (PAM Plant Asset Management) that enables me to achieve these business objectives? How do I rationalize investments in predictive intelligence?

Map into Maintenance Strategy Blueprint matrix MTBF / MTBM 3 Based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work1 2


For Existing Facilities

1st Quartile 2nd Quartile 3rd Quartile 4th QuartileExpertise


4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3 8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integrationMap into Maintenance Strategy Blueprint matrix MTBF / MTBM 3 Based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work1 2

Gap Analysis versus Industry World Class(performed for existing facilities rather than new areas)


Outputs from Opportunity Assessment Tasks 1-3 Goals / KPIs TargetsProduction KPI TargetsUptime Downtime 1st Pass Yield Maint. Cost Labor Overtime OEE 97.2% 2.80% (10.2 days) 99.4% 2.50% PRV 2.40% 96.0%

Maintenance Efficiency KPI TargetsPlanned hours: PM monthly Materials Costs Labor Costs % PM on-time completion % WO completed on-time % WO needing Rework after completion % WO completed on schedule Planning Efficiency Downtime: Product Changes Downtime-Scheduled Downtime-Unscheduled 1,700 (weekly) 6,800 (est. Hrs) 2.2% PRV 0.8% PRV 80% 80% 5% 80% 90% 0.8% 2.8% 0.1%


8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integration


New Facilities

4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3

PAM Specification to achieve these goals

Structured Approach: Details of FEED / New / Existing ProgramMaintenance Strategy Blueprint matrix

New Facility / Program

1. ID business objectives / LOA 2. Assess site | Gaps | Benchmark 3. ID Goals / KPIs or PAM Spec. 4. Gather asset information 5. Validate Asset Priority / Risk1 6. ID Task Periodicity2 7. ID Technology Deployment3 8. Develop Maintenance Tasks4 9. Develop Work Flow Execution5 10. Map CMMS/EAM integration

Validate Asset PriorityMap into Maintenance Strategy Blueprint matrix MTBF / MTBM 3 Based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work1 2

Validate Tasks




Key Maintenance Procedures


Step-by-Step Software Tasks (ISO)How to Configure Device Using AMS Device Manager


Identified how Maintenance work is Discovered Initiated Planned Scheduled Performed Closed out ContingenciesWork Process Work Initiation Work Approval and Prioritization PreExecution Resolution NO Can Work Proceed? PreExecution YES Work Execution Work Close Out & Audit

Planning Required?

YES

Planning

NO Major Shutdown Work?

NO

Scheduling YES

Shutdown Scheduling

Work Process



Roles and

responsibilities Success Metrics





Map into Maintenance Strategy Blueprint matrix MTBF / MTBM 3 based upon top ~30% priority assets 4 RCFA / with respect to predictive technology 5 Program: Execute 80% planned work1 2




Asset Optimization PlantWeb ProjectPetrochemical facility Maintenance costs too highSite: North America

Reactive tasks 70% of monthly work orders Lack of sufficient maintenance task documentation Asset Priority on 30,000 assets Develop Maintenance Tasks on 10,000 most critical assets Created 3,000 new tasks

Changing business processes to planned maintenance

Generate Maintenance Strategy Blueprint Technology Deployment AMS Device Manager import ~2,500 smart devices AMS Machinery Manager all route-based machines AMS Asset Portal to sustain changes

Reduce maintenance costs $801K* annually on Phase 1 (4,000 assets) Remove 183 OT hours coupled with reactive work Reduce monthly work orders by 8% (285 260) Shift planned work mix from 25% 41%

Asset Optimization PlantWeb ProjectMajor challenge was feedstock consistency control Site: North America Scope: PlantWeb TechnologyAMS Device Manager FIELDVUE DVC Rosemount 3051, 3095, 8712 Neles ND800, 9000 Siemens SiPart PS2

Gap Analysis drove evaluation of I&V maintenance Task Optimization Discover / create consistent documentation on 2,000 assets Provide OEM data sheets / instruction manuals

Re-establish a structured I&V maintenance program

Develop Maintenance Tasks / Procedures Provide specific procedures for I&V rebuilds or calibrations; provide specific procedures for Smart Device Alerts and diagnostics Map CMMS Integration Build new procedures into EMPAC AMS Device Manager - Consolidate 10 offline copies into single networked license, set up alarms Training program reinforce new procedures / re-train personnel

Maintenance Strategy Blueprint Revise PM intervals, understand opportunities to outsource, develop roadmap for upgrades, inventory optimization Training program developed specifically for installed base of Instruments and Valves Use AMS Device Manager for better control of feedstock Provide new maintenance procedures, transfer into CMMS

Focus: Extract value from existing PlantWeb investment

PlantWeb ServicesDESIGN IMPLEMENT INCORPORATE




AMS Suite: Asset Portal

Aggregates information across plant assets Provides management summaries from underlying AMS Suite applications and other data sources Links predictive diagnostics with Maintenance Planning and other enterprise systems Integrates PlantWeb Services data with asset information Asset prioritization Work planning & scheduling Diagnostic technologies used

AMS Suite in the PlantWeb ArchitectureAMS Asset Portal

AMS Device Manager FOUNDATION fieldbus HART

AMS Machinery Manager

AMS Performance Monitor

PlantWeb technologyBearing Faults Gear Faults Belt Wear Mounting

predictive intelligence that empowers you to planBroken rotor bars Turn-turn shorts High resistance joints Voids in aluminum cast rotors Cracked rotor end rings Steam Traps Air Leaks Grease Points Corona Discharge Over Lubrication Alignment Balance Shaft Wear Coupling Wear Belt Alignment

Mechanical

Oil Health Chemistry Analysis Contamination Alerts Particulates

Boiler Sooting Turbine Blade Wear Capacity Reductions Increased Energy Use Hourly Cost Increase

Process

Heat Exchanger Fouling Cumulative Cost Increase Maintenance Effectiveness Pump Efficiency Dropping Equipment Efficiency Drop

Travel Deviation Drive Signal Supply Pressure Valve Signature Cycle Counter Step Response Dynamic Error Band

Glass Electrode Failure pH Electrode Aging Ref Electrode Coating Ref Electrode Failure Ref Electrode Poisoning

Configuration Warning Process Condition Sensor Failure RTD Drift Electronics Failure RTD Life Estimation

Electronics Failure Sensor Failure Process Condition Reverse Flow Empty Pipe Calibration Error Configuration Warning Sensor Failure Electronics Failure Configuration Warning Process Condition Plugged Impulse Lines

Instruments & Valves

AMS Suite: Realizing Integrated Asset ManagementERP CMMS Reliability Statistical Analysis AMS Asset PortalAMS Device Manager AMS Machinery Manager AMS Performance MonitorLeverage integrated asset information to drive work processes

Easy navigation using graphical dashboards and decision-making tools

Managing HART and Ff devices Managing and detecting faults on rotating / mechanical machinery Monitoring the efficiency of large pieces of process equipment

AMS Suite brings together information from assets across your plant

Electrical Asset Management Documentation Systems Corrosion Monitoring Inventory Control Systems CMMS Work Order History

Many systems have information pertinent to plant assets. AMS Asset Portal consolidates this information.




How it all fits togetherNew Facility / Program

PlantWeb Services ensures effective deployment of your AMS Suite DESIGN structured approach for FEEDs / New Projects / Existing Facilities Execute prior to technology deployment 1. Business Objectives / Goals Gap Analysis on existing facilities / programs Maintenance Strategy Blueprint matrix Identifies asset criticality (priority) and task periodicity (what to do when)

2. Formalized Design

Business Objectives Formalize Maintenance Strategy

Technology Deployment Detectable failure modes / criticality drives technology investments Includes utilization of PlantWeb to execute ~80% planned work

Work Flow Execution

ResultsBest Cost Maintenance by Design Generate ~80% planned work Proper utilization and specification of AMS Suite Executed by PlantWeb factory experts

Business Results AchievedBackground Site: North America Scope PlantWeb Services Program Design Asset Prioritization Task Optimization Maintenance Blueprint CMMS Integration

DESIGN Formalize/Improve Existing Program2 Machine Kraft Linerboard Mill producing ~3000 Tons/day Corporate mandate: establish reliability programs Asset Priority on Maintenance Actionable Assets Task Optimization on top 25% of subject assets Analysis results added to Meridium Data Historian

Execute DESIGN for 3 areas

Develop Maintenance Strategy Blueprint for top 25% CMMS Integration (procedures attached to Indus Passport) Phase 1: (2) Paper Machines - 13 week project Asset Priority: 2,781 assets; Task Optimize: 1,193 assets Reduced Man-hour effort 69.1% (17,079 down to 5,272) Asset Priority on 2,851 assets; Task Optimize 870 assets Reduced Man-hour effort 70.6% (16,832 down to 4,949) Asset Priority: 2,516 assets; Task Optimize: 754 assets

Results

Phase 2: Powerhouse - 10 week project Phase 3: Pulp Mill - 9 week project

SummaryWork Shop Topics Simply purchasing PlantWeb technology does not get it done. Must incorporate technology into your daily processes. Lowest-Cost Maintenance should be part of the FEED PlantWeb Services offers DESIGN A structured approach to implementing PlantWeb technology Applies to FEEDs or existing facilities that want to formalize a Maintenance Strategy Addresses integration with CMMS (new planned Work Order generation)

Benefit Allows you to easily make it part of the design requirement Ensures PlantWeb technology is implemented properly

Case studies: Proven Customer Value

Feedback? Questions?

Where To Get More InformationBooks, articles, electronic sources www.assetweb.com

Consulting services, other sources Asset Optimizations PlantWeb Services group Please ask your local Emerson sales contact

why define your strat during the feed stage

Documents

pam technology

plant asset management

plantweb technology

feed plantweb

lowest cost maintenance

maintenance strategy

existing facilities

cost reductions