Plant Data Systems:

Asset information systems for proper asset lifecycle management

• Vicki Naudé PrEng

• Project Manager

• Bytes Universal Systems a division of Altron TMT

• South Africa

Asset Lifecycle Management

• By managing each asset through its entire

lifecycle, organizations can:

– improve performance,

– reduce operating costs,

– extend asset life and

– subsequently improve Return on Assets.

The Traditional Approach

So how would you do it?

• Design the asset according to your expected

operating requirements.

• Then implement, operate and maintain this

asset according to the design.

• Finally plan the asset’s

end-of-life according to the

design.

Life Happens

However…

• What if the operating conditions change?

• What if the asset does not perform as designed?

Well, then your asset lifecycle plan means nothing.

ROI

What Now?

• Asset lifecycle management requires more than

just static information.

• You need to build in Flexibility and Adaptability.

• You need real time information about the asset.

Enter Asset Information System…

Asset Information Systems

Process Flow Diagrams

• Indicate the flow of plant processes and equipment.

• Displays the relationship between major equipment of a

plant facility.

Design your Plant Smart

• Document the as-designed as well as the final as-built

• Provide the information in the context of the physical plant

PFDs and Smart Designs

New Age Technologies

Asset Information Systems

When the actual condition of working devices is

continuously monitored and assessed,

• maintenance will be carried out timely and fast –

• based on the signals of deterioration and

increased failure probability.

Independent & Specific

The Value of Data

Information Based Maintenance

PDS Case Study

• The vision of an asset information system

making information available to the business is

celebrating its 10th year in production at Eskom

in the form of the PDS.

PDS is the common integration layer between

the plant systems and the outside world

PREDICTIVE ANALYTICS

NERVE CENTERS

CONDITION MONITORING

LIMS

RENEWABLES MONITORING

PDS

ENGINEERING CENTERS

PERFORMANCE MONITORING

ITMS

The PDS Backbone

PDS Engineering Overviews

PDS Integrated Technical Management

PDS Renewables In the Middle of Nowhere

PDS Renewables Continuous Monitoring

PDS Asset Analytics

• Fan Amps

• Motor Winding Temp

• Motor NDE Bearing Temp

• Motor DE Bearing Temp

• Fan DE Bearing Temp

• Fan NDE Bearing Temp

• Inlet Vane Position

• Ambient Temp

• Air Flow

Plot-0

4/6/2008 4:39:21.791 PM 4/9/2008 4:39:21.791 PM3.00 days

60

62

64

66

68

70

72

74

76

58

78

96

108

86

102

107

113

94

102

46

64

0

14

110

170

52

70

25

75

PDS Condition Monitoring

Traditional DCS Alarm @ 155 C

PRiSM Pattern Recognition Alarm

PDS Predictive Monitoring

PDS Nerve Centres

PDS Evolution

• PDS is currently in the process of being

transformed into an Enterprise Historian

solution.

Transformation

This transformation is aligned to the evolution of

the MES model which now includes:

• c-MES and i-MES concepts.

This means a model which is:

• integrated, more flexible and adaptable

• collaborating with systems such as:

– asset lifecycle management systems and

– various condition monitoring systems.

Enterprise Historian

• Its BIGGER…

• Its BETTER…

Flexibility - Hierarchy and Data By Location By Equipment By System Process

Manufacturing Enterprise System

An Integrated and Collaborative MES

It’s a Journey

Maintenance

Production