OpExAdvantages + Asset Optimization · OpEx Advantages + Asset Optimization DB Slide 20 2009.12...
Transcript of OpExAdvantages + Asset Optimization · OpEx Advantages + Asset Optimization DB Slide 20 2009.12...
DB
Slide 1
2009.12
OpEx Advantages + Asset Optimization
Dominik Brand
Manager FOUNDATION Fieldbus
Endress+Hauser Process Solutions AG.
OpEx Advantages + Asset Optimization
DB
Slide 2
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CapEx / OpEx savings and life cycle phases
�Use of an open standard technology
�Reduction in cost for wiring, barrier, marshalling
rack and Junction box
�Reduction in cost for control system - I/O
interface
�Reduction in cost for power supply unit and
number of cabinets
�Reduction in control room size
�Engineering and documentation
�Fast commissioning, lower start-up costs
FAT,SAT, Commissioning
Renewal
Operation
Maintenance
InstallationDesign
OPEX SavingsCAPEX Savings
�Use of an open standard technology
�Increased information for better operation,
accuracy of measurement & control
�Enhancement in control function and the
performance
�Improved throughput
�On-line diagnosis enables true preventive
maintenance
�Improved trouble shooting
OpEx Advantages + Asset Optimization
DB
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Increase Plant Availability
OpEx Advantages + Asset Optimization
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Where are the OpEx savings ?
Operation and Production Costs
Additional production time by:
� Improved maintenance for:
� Fewer process upsets
� High availability
� Easier and faster incremental expansion
Improved throughput by:
� Improved quality and productivity
� Improved Alert capabilities for better operation
� Improved accuracy of measurement and control
� Data access for Business Intelligence
OpEx Advantages + Asset Optimization
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2009.12
Maintenance Costs
“Right time” or proactive maintenance to:
� Reduce unnecessary trip to plant
� Avoid failure instead of solve failure
� Reduce time to repair
� Root cause identification and elimination
� Reduce inventory cost
Infrastructure with:
� Centralized maintenance
� Centralized tooling and data management
Where are the OpEx savings ?
OpEx Advantages + Asset Optimization
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Operation and Production Costs
OpEx Advantages + Asset Optimization
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Control In the Field – Performance Benefits
� CIF provides superior reaction to deterministic
disturbance in the process
� Possible to synchronize data sampling and control
� Possible to reduces Latency effect in the control chain
� CIF provides enhanced process integrity
OpEx Advantages + Asset Optimization
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2009.12
Reduced Variability
Pro
cess O
utp
ut
(%)
Time (s)
56
58
60
62
OpEx Advantages + Asset Optimization
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2009.12
Tighter Loop Control
Control Limit
Manual
Digital
Digital
Analog
Analog
Pneumatic
Pneumatic
Manual
For fast process application:•Improvements in response time
of between 10% and 30 %
•Improvements in disturbance rejection of up to 20%
OpEx Advantages + Asset Optimization
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Slide 10
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Migrate CIF progressively …. maximizing ROA !
Ethernet
Field
Controller
FF - H1
Pure CIF
Hybrid CIF
M
A
X
A
S
S
E
T
S
U
T
I
L
I
Z
A
T
I
O
N
DCSAdvanced Control
OpEx Advantages + Asset Optimization
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Maintenance Costs
OpEx Advantages + Asset Optimization
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Slide 12
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Potential for improvements
Potential for Predictive Maintenance with Pressure Transmitters
0%
5%
10%
15%
20%
25%
30%
35%
Routine
check
No
Problem
Calibration
shift
Zero Off Plugged
lines
Failed
35%
28%
20%
6% 6% 4%
Shell Global
Solutions
63% of instrument maintenance labor results in no action taken
-> waste of resources
OpEx Advantages + Asset Optimization
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Potential for improvements
Maintenance today:
�63% of work orders generated for transmitters are unnecessary
either no problem or problem with other equipment
�75% of control valves removed from process lines did not require
removal
�50% of instrument tech’s time is spent on paperwork
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Equipment Monitoring in the Plant
Process Condition Monitoring• Devices• Functions
• Sub-processes
• Other key performance indicators
Field Device Condition Monitoring• Field Devices on different field
buses
Ft
FC
Ff
FC
LC
It is all about Diagnostic Information !
Machine Condition Monitoring• Condition Monitoring• Runnability Monitoring
• Oil lubrication Monitoring
Quality
OpEx Advantages + Asset Optimization
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Role Based Diagnostics
1
Asset ManagementMaintenance Station
Process ControlEngineering Station
Control Network
H1
Plant operators
Plant maintenance engineering
OpEx Advantages + Asset Optimization
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Maintenance Urgency – Wear Reserve
OpEx Advantages + Asset Optimization
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Maintenance Urgency – Wear Reserve
Warning
Alarm
Prediction of time
Before affecting the
process
Wear
reserve
OpEx Advantages + Asset Optimization
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Additional Key Improvements
� Centralized Tooling and Configuration data
� Easy back-up of the configuration data
� Easy audit trail and data management
� Easy update and migration of the Tooling
� Basis and fundament for real Asset Management
� Better Calibration Management
� Improved Management of the Installed Basis
OpEx Advantages + Asset Optimization
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Asset Optimization
inductive energy transmission
inductive signal transmission
Control Network
1 0 0 1 0 0 1
���
Asset Management Software
uses fieldbus
for Asset Optimization
Solutions
Digital Communicationfrom Sensor to
Asset Management
OpEx Advantages + Asset Optimization
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Asset Optimization – Asset Data Access
Control Network
Parameter access
via fieldbus for both
Transmitter and Sensor
to enable:
•Configuration
•Diagnostic
OpEx Advantages + Asset Optimization
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Asset Optimization – Calibration Mngt.
Control Network
•Manage complete life
cycle of a sensor
•Trace the calibration
and adjustment history
•Customized calibration
protocols are generated
automatically
OpEx Advantages + Asset Optimization
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Asset Optimization – Link to CMMS Level
Control Network
1 0 0 1 0 0 1
���
Internet
W@M
portal
CMMS
OpEx Advantages + Asset Optimization
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Business Intelligence - Managing Data
OpEx Advantages + Asset Optimization
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Questions ?