OpEx Advantages Asset Optimization - Fieldbus · Additional Key Improvements Centralized Tooling...
Transcript of OpEx Advantages Asset Optimization - Fieldbus · Additional Key Improvements Centralized Tooling...
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
OpEx Advantages+
Asset Optimization
Francois Ichtertz / Dominik BrandManager FOUNDATION Fieldbus
Endress+Hauser Process Solutions AG.
Panos GiannakouliasCertified FF Systems Manager
Endress+Hauser II AG Middle East Support Center
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
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 unitand number of cabinets�Reduction in control room size�Engineering and documentation�Fast commissioning, lower start-upcosts
FAT,SAT,Commissioning
RenewalOperation
MaintenanceInstallationDesign
OPEX SavingsCAPEX Savings
�Use of an open standard technology�Increased information for betteroperation, accuracy of measurement &control�Enhancement in control function andthe performance�Improved throughput�On-line diagnosis enables truepreventive maintenance�Improved trouble shooting
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Increase Plant Availability
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
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
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Where are the OpEx savings ?
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
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Operation and Production Costs
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Control In the Field – Performance Benefits
� CIF provides superior reaction todeterministic 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
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Reduced VariabilityP
roce
ss O
utpu
t (%
)
Time (s)
56
58
60
62
10 20 30 40 50
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Tighter Loop ControlControl Limit
Manual
Digital
Digital
Analog
Analog
Pneumatic
Pneumatic
Manual
For fast process application:
�Improvements in response timeof between 10% and 30 %
�Improvements in disturbancerejection of up to 20%
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Migrate CIF progressively …. maximizing ROA !
Ethernet
FieldController
FF - H1
Pure CIF
Hybrid CIF
MAX
ASSETS
UTILIZATION
DCSAdvanced Control
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Maintenance Costs
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Potential for improvements
Potential for Predictive Maintenance with Pressure Transmitters
0%
5%
10%
15%
20%
25%
30%
35%
Routinecheck
NoProblem
Calibrationshift
Zero Off Pluggedlines
Failed
35%
28%
20%
6% 6% 4%
Shell GlobalSolutions
63% of instrument maintenance labor results in no action taken-> waste of resources
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Potential for improvements
Maintenance today:
�65% of work orders generated for transmitters areunnecessary either no problem or problem with otherequipment�75% of control valves removed from process lines didnot require removal�50% of instrument tech’s time is spent on paperwork
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Role Based Diagnostics
1
Asset ManagementMaintenance Station
Process ControlEngineering Station
Control Network
H1
Plant operators
Plant maintenance engineering
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Maintenance Urgency – Wear Reserve
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Maintenance Urgency – Wear Reserve
Warning
Alarm
Prediction of timeBefore affectingthe process
wear reserve
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Equipment Monitoring in the PlantProcess Condition Monitoring• Devices• Functions• Sub-processes• Other key performance indicators
Quality
Machine Condition Monitoring• Condition Monitoring• Runnability Monitoring• Oil lubrication Monitoring
Field Device Performance Monitoring• Field Devices on different fieldbuses
Ft
FC
Ff
FC
LC
It is all about Diagnostic Information !
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Device Performance Monitoring (DPM)
DPM
Performance Monitoring
Database
Webreporter
E-Mailer ODBCNotifier
SoftwareApplication
H1
TravelDeviation High
Alarm
FF
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Increase Maintenance Efficiency
� Less trip to the plant� Improve general efficiency� Improve security
� Work is scheduled and proactive for a betterquality and less unplanned shutdowns� Stop reactive firefighter actions and anticipate
problems� Intensify collaboration between Operation
and Maintenance
But it is all about People Mindset !
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
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 AssetManagement� Better Calibration Management� Improved Management of the Installed Basis
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Asset Optimization
inductive energy transmission
inductive signal transmission
Control Network
1 0 0 1 0 0 1
���
Asset Management Softwareuses fieldbus
for Asset OptimizationSolutions
Digital Communicationfrom Sensor to Asset Management
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Asset Optimization – Asset Data Access
Control Network
1 0 0 1 0 0 1
��� Parameter access
via fieldbus for bothTransmitter and Sensorto enable:•Configuration•Diagnostic
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Asset Optimization – Calibration Mngt.
Control Network
1 0 0 1 0 0 1
���
•Manage complete lifecycle of a sensor
•Trace the calibrationand adjustment history
•Customized calibrationprotocols are generatedautomatically
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Asset Optimization – Link to CMMS Level
Control Network
1 0 0 1 0 0 1
���
Internet
W@Mportal
CMMS
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Business Intelligence - Managing Data
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Questions ?