Asset Management Solutions Overview

8/11/2019 Asset Management Solutions Overview

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Honeywell Asset ManagementNovember 2012


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Asset ManagerNotifications sent to EAM/CMMS

Asset ManagerNotifications sent to EAM/CMMS

RAMP (Reliable Asset Management Performance)

DATA SOURCES

Condition Monitoring

DCS & Historian

Smart Instruments

OUTPUTS

Alerts & Notifications

ManagementReporting & KPIs

OUTPUTS

Alerts & Notifications

ManagementReporting & KPIs

EAM/CMMS

Work Execution Mgmt

Maintenance M mt

3 Honeywell Proprietary

Asset Managerinfo used in

Reliability programs

Asset Managerinfo used in

Reliability programs

Enterprise Asset Management Workstream & Relationships

Operator Rounds

Corrosion Data

Simulation (UniSim)

Oil Analysis

Vibration Monitoring

a n enance

ReliabilityScorecards

Downtime Reporting

Health Assessment

Automatic WorkOrder Generation

a n enance

ReliabilityScorecards

Downtime Reporting

Health Assessment

Automatic WorkOrder Generation

HoneywellHoneywellAsset ManagerAsset Manager

Reliability Programs & Strategies RCM/RCA Asset Health Matrix Equipment Maintenance Plan KPI/Benchmarking Change Management Training

Workflow Document Mgmt

Financial Mgmt

Purchasing Mgmt

Inventory/MRO Mgmt

Scheduling


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Condition Based Monitoring

Real-Time


DCS & Historian

Operator Rounds (Field Advisor)

5 Honeywell ProprietaryEnterprise Asset Management Work-stream & Relationships

Real-Time Corrosion monitoringSimulation (UniSim)

Real-time Vibration Monitoring

Smart Instruments (FDM)

Oil AnalysisOther Condition Monitoring


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Honeywell Asset Manager


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Asset Manager

Single Tool for Asset Management


Performance Monitoring

Control System & Instrumentation Monitoring

Inputs from DCS, Historian, etc.

Inte rate data from oint solutions - vendor inde endent


Integrateinformation

Varioussources

New andexisting

Fault Models

Mechanical&Performance

User or LibraryEvaluate usingintegratedinformation

Alerts

Based on thefault modelexecutionresults

Alert-basedAutomatic Actions

Operatornotifications

E-mailnotification

Work Requestnotification

Problem Solving

Collaborationbetween teams

Historicalinformation

Link to relevantdocumentation

Identify bad actors and equipment that needs attention

Sustain the benefits of an equipment reliability program

Common Framework for Maintenance and Operations


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Integrate Information

Integrated real-time monitoring of

equipment health data Collate data for monitoring, condition

assessment and analysis

Connects dis arate data sources


Fault Models Alerts Alert-basedAutomaticActions

Problem Solving


through OPC Links to Asset Information

Vendor Information

Documents

manuals, repair history Hyperlinks to other applications

Web (URLs)

Programs


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Build Fault Models

User Configurable Faults

Simple (Process Value, eg. Temp)

Complex Mathematical Expressions

Logical Expressions

Library of Standard Equipment Fault Models

Mechanical Reliability Fault Models (GPAllied)



Problem Solving


Smart Instrument Fault Models HART device models

Automated fault and symptom assessment

Performance Models

Compare actual performance with design

Centrifugal Compressor, Steam Turbine, Shell andTube Heat Exchanger, Gas Turbine, Centrifugal Pump

Model Integration

Excel integration

UniSim Design Rigorous Models


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Monitor for Alerts

Monitor for Alerts

Tree Map Based on Asset Criticality and Priority

Hierarchy

Fault Management



Problem Solving


Fault History Recommendations

Asset and Activity Logs

Dashboards

Graphical Display Conditions

Alerts


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Respond to Alerts

Operators are often first responders for any plant problem

Alerts on the operator console

Email notification

Automate email to responsible engineers and groups



Problem Solving


Integrates with SAP and Maximo and other CMMS systems

Manual or Automatically Generated


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(102)

( , & )

Allied ReliabilityModels

Bearing Model

Abrasion

Misalignment

Packing Seal Leaking

Base Skid

Spalling

Settling

Cracked

User DefinedModels

Process

Low Flow

NPSHR VSNPSHA

Performance HeadDeviation


Asset ManagerBuilt inModels

Process

Performance

%Efficiency

Energy Power

Vibration

Shaft

Impeller

Bearing

InstrumentsHealth

Transmitters

Control Valves

:

.

/


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: 102

(102)



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: 102



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Asset Manager

Real-time symptom assessmentand fault detection

Based on sophisticated engineeringfault models

Tri er work to reduce


Integrate

information

Varioussources

New andexisting

Fault Models

Mechanical&Performance

User or LibraryEvaluate usingintegratedinformation

Alerts

Based on thefault modelexecutionresults

Alert-based

Automatic Actions

Operatornotifications

E-mailnotification

Work Requestnotification

Problem Solving

Collaborationbetween teams

Historicalinformation

Link to relevantdocumentation

maintenance and avoid failures Sustain the benefits of an

equipment reliability program


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What is Field Advisor?

Mobile Productivity Solution for executionand tracking of field tasks

Supports maintenance excellence initiativesEnable Operator Driven Reliability (ODR)

programs


, , ,

and reliability

Currently deployed at 25+ sites

Estimate over 1000 handheld computers deployed


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What is Honeywell Field Advisor?

Personal Safety and

Health

Personal Safety and

Health

Process

Optimization

Process

Optimization

Reliability

Improvement

Reliability

Improvement

WorkProces

s

Process Safety and

Compliance

Process Safety and

Compliance


Configuration

Execution

Reporting


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What is Honeywell Field Advisor?

Personal Safety and

Health

Personal Safety and

Health

Process

Optimization

Process

Optimization

Reliability

Improvement

Reliability

Improvement

WorkProces

s

Process Safety and

Compliance

Process Safety and

Compliance


Configuration

Execution

Reporting

Honeywell Field Advisor


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Field Advisor Benefits

Paper based data is difficult to distribute, analyze and track

Eases data sharing across teams concerned with asset health

Maintenance, operations and reliability

Appropriate actions can be taken when critical limits are exceededfor an asset. Limits are integral to all tasks.


x en equ pmen e an avo secon ary amage y ca c ng

impending failure earlier

Ensure field operators adhere to best practices when performingtheir tasks

Train new field operators quickly and ensure they achieve the

required competency level


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Field Operator Workflow


Select Work Execute Tasks Enter comments

ReviewConsequences When limits are

exceeded

Review History

Corrective Actions Execute reconditioning

tasks

Upload Work


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What is a Task?

Monitoring tasks currently listed in equipment log sheets

Oil level, pressure, temperature, vibration, equipment condition, etc.

All tasks include limits which help the operator identify problems. All data entered is compared to a set of limits

Verify the process/equipment is operating within limits


Mode switching tasks (switching line-ups)

Taking samples

Routine safety checks (e.g. Relief Valves)

Test tasks

(testing personal gas detectors, radios) Housekeeping tasks


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Planning and Scheduling

Planning results in work scheduled for the OutsideOperators

Operators scheduled work load can be checked by theplanning


Work is scheduled several shifts in advance

Task scheduling can be done in many different ways

Examples: 1/shift, 1/month, twice/year, every Monday on day

shift, etc. Work can be done on an ad hoc basis as well

Supports unique situations or monitoring of one off situations


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Work Selection

Tasks sent to hand held based on:

User

Discipline or skill set

Plant asset assignment

Schedule or shift



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Operator Task Selection

Operator task selection

By task list, asset or fromhierarchical tree view

Eases task selections forchanging field conditions


ers s mp y n ng as s


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Single Task Execution

Asset Location and Status

Generic Work DescriptionSimple description of theoperators task

Limits


Target, Target High/LowSafety High/Low

Quantity and Names areConfigurable

Data Entry and Eng Units Units and Task Status

Supplemental Information


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Task Supplemental Information

Comments: free entry orfrom selection list

Detailed task information andinstructions Historical values and comments

Consequences ofexceeding each limit



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Exceeding a Limit Consequences

The consequences of exceedingthe limit is automatically presented to

the operator



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Exceeding a Limit Comments


the operator When a limit is exceeded the

operator can optionally be forcedto enter a comment



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Exceeding a Limit Reconditioning





A reconditioning task appears withspecific actions for the operator to take


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Exceeding a Limit Detailed Instructions





A reconditioning task appears withspecific actions for the operator to take

Detailed reconditioning taskinstructions are also available tohelp guide the operator in anunfamiliar situation


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E-Mail Notifications

Notifications to key stakeholders when a limit is exceeded



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Data Historian Integration Data with collection

time stamp sent toData Historian (PHD)

Supports otherhistorians withOPCHDA servers

Data Tags


Aspen IP21)

Time StampsAnd Data


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Reporting

46 Honeywell Proprietary8 November 2012


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Field Advisor Hardware



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Hand Held Computers Hazardous Certifications

General Purpose; Class 1, Div 2; Class 1 Div 1

Environmental Specifications - various Temperature -20C to 50C; Humidity up to 95%

Drop 1 1.5m on concrete Protection Rating meet IP65 for moisture and particle sealing

Operating System Windows Mobile 5.x or 6.x

Various Accessories


Tethered Stylus, Leather Bag or Carry Case, Hand Strap, Screen Display Skins,

Docks

ECOMi.roc 52x

EX

ECOMi.roc 62x

EXBartec

MC9090exIntermecCK321S

Dolphin9900/9900ni

Dolphin99EX/99EXni


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Peripheral Devices

ECOM Ex-MX4 BT

Bluetooth Temperature Gun

-30C to 900C-25F to 1600F

ATEX Zone 2

DB Prftechnic VIBROTIP

Bluetooth Vibration Probe

Vibration, Shock pulse & pumpcavitations, Temperature, RPM

ATEX Zone 2



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RFID and Barcode

Selection task gives positive confirmation of operator's location

Direct jump to the required tasks at a location

Dolphin hand held computers support barcodes ECOM hand held computers support

RFID or barcode (but not both)



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Corrosion


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Typical Refinery / Plant

3000 vessels

2000 miles of piping

Vessels & Piping $1.1B/Year in

Maintenance Costs

4

6

8

10

e

LostProductio

n

Corrosion is Very Expensive for Plant Assets


Corrosion: Affects turnaround

frequency

Affects plant safety

A major unsolved issue

Relative loss for a Plant by Asset Type

0

2

Electrical Ins trum ent Rotating Ves sels Piping

Relativ


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Traditional Corrosion Management Conventional methods utilize

Inspection

CouponsCorrosion is not quantified as it happens, it is

found after it happens!

Weight Loss Coupons



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The New Paradigm Real-Time Management Online Real Time Corrosion Management

Assists in identification of critical processes that may cause

damageEnables problem resolution through Boundary and

Deviation management


,

management ability to react quickly and appropriately


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Corrosion SolutionsConsists of four distinct components:

1. Technical Services & Laboratory full range of laboratory corrosion services;including custom experimental evaluations at Houston Lab

2. Joint Industry Projects (JIP) research programs that include multiplecompanies to reduce costs by pooling resources. JIP results are the core ofHoneywell prediction and material selection models.


. Corrosion Modeling Software & Consulting Full range of software forcorrosion modeling/prediction and material selection. Linked through OPC toDCS for real-time evaluation

4. Real time Monitoring with SmartCET Corrosion monitoring technology(wiredand wireless) and support services


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Technical Services

Sophisticated, state-of-the-art laboratory equipment

Expertise in being able to safely test a variety of metallic and

non-metallic materials in extreme conditions, including hightotal and partial pressures of hydrogen sulfide and carbondioxide gas.


orros on eam as over years o exper ence

Corrosion experts well recognized in the industry areavailable for consulting/support


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Laboratory Services



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Joint Industry Projects (JIP) Program co-funded (sponsored) by a group of global

operating companies: Oil & Gas companies

Chemical providers

Service providers

Engineering & design companies


Aggregated funding ($1M to >$2M)Develop new data or information on a corrosion and materials problemarea of high reliability and/or cost impact.

Includes development of a software tool to automate

assessment of service conditions, corrosion risk or materialsselection.

Normally a 2 to 3 year data development effort.


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Joint Industry Projects

Program Detail Value Timing Outcome Some of the Sponsors

Sour Water Corrosion $8M 1998-2007 Predict-SW 3.0 ExxonMobilMarathon

Chevron

BPUOP

Petrobras

Flint Hills

Fluor

Rich Amine $1M 2004 - 2007 Predict-Amine-2.0

Corrosion in CDUOverhead Systems

$2M 2010-2012 Predict-Crude-OH

Nap Acid Corrosivity-

$2M 2010 - 2012 Predict-Crude-PII


ConocoPhillips

Saudi AramcoShell

Syncrude

Schlumberger

TOTAL

Sumitomo

Tenaris

And Others.

Phase II

Nap Acid CorrosivityJIP

$2M 2007-2009 Predict-Crude

Sulfuric Acid Alkylation $1M 2006 - 2009 Predict-SAA

Ti-Alloy JIP $1M 2007-2009 Socrates-Ti

Lean Amine JIP $1M 2008 - 2010 Predict-LeanAmine


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Corrosion Modeling

Over 20 years of experience in modeling anddeveloping software solutions

Models and tools for corrosion prediction, materialselection, kinetic characterization, speciation and risk


A broad array of software products is available forcorrosion modeling and evaluation


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Target Markets and Applications

SoftwareApplication

Application Oil & Gas Refining

Predict 6.0 Predict corrosion rates incarbon steel

PredictPipe 3.0 assessment of corrosionrates in normally dry gastransmission lines


.resistant materials

Strategy 4.0 evaluation of steels in wetH2S service environments

Predict-SW 3.0 corrosion prediction for sourwater systems

Predict-Amine 2.0 corrosion prediction foramine units

Predict-Crude Naphthenic acid corrosion


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SmartCET will work:

Cooling water Process water Potable water Chemicals & aqueous

environments

Conductive environments Liquid phase environments

Vapor phase / condensing environments A number of probe configurations

available to address a variety of

Where Can SmartCET be used?


SmartCET will work:

Oil / water mixtures Overhead systems Sour (H2S) systems

Not applicable for napthenic or very

high (>600 F) temperature sulfidation

environments


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Learn More About Corrosion

Upcoming Webinar from our Experts

Register your interest on Feedback Form

Predict 6.0 Free Evaluation TrialSign up through the web!



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Next Steps

Request more information through the

seminar feedback form..Collateral (USB cards)


Onsite presentation/demonstrationAsset Management Discovery Workshop

Maintenance Effectiveness

Reliability Assessment

OEE Assessment

Asset Management Solutions Overview

Documents

Transcript of Asset Management Solutions Overview