Proactive Asset Mgmt

Proactive Asset Management Survey Creates Roadmap to Parts Inventory and Obsolescence Plan

Session: 1B-5133

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Presenters

Angelo Angeleri

Joe Hawkins

Zachary White

Agenda

Presentation Overview APS: Palo Verde Nuclear Generating Station Drivers for Building Asset Database Objectives and Requirements Challenges Data Gathering Database Utilization Results and Benefits Summary More Information Services

Presentation Overview

Inconsistent installed base data was impacting service and parts inventory requirements.

Storage reduction forced parts consolidation, illustrating the importance of an asset management program for proper inventory planning.

A comprehensive asset survey done by Caltrol and Emerson provided the asset benchmark needed to allow data driven parts inventory and outage planning.

Survey data utilized for inventory reduction, parts procurement, and outage planning.

Asset survey paved the way to a proactive management program for process control assets.

APS: Palo Verde Nuclear Generating Station

Owned by consortium of seven Southwest utilities and operated by Arizona Public Service Co. (APS)

Member of STARS Alliance– Promotes consistency and implement best

practices across 7 member nuclear facilities Palo Verde Nuclear Generating Station

is the largest power producer in the US. – 3 Pressurized Water Reactors on 4,000 acres– Generates 30 million megawatt-hours annually– Serves more than 1.1 million customers – Recycles 20 billion gallons of wastewater annually

Drivers for Building Asset Database

Inconsistent data Obsolete product - obsolescence planning

– Older technology affecting efficiency and reliability• Moving from reactive to proactive maintenance program

Extensive parts lead time Inventory management – reduce footprint of warehouse Target maintenance budget for best use, planning,

technology upgrades and optimization Data driven decisions Strategic reduction of taxable

inventory over 12 month period

Objectives & Requirements

Comprehensive asset database– Turnkey system networked into existing

digital infrastructure– “As-Found” images of equipment– Serial records– RSPPLs– Bill of Materials (BOM)– Flagging obsolete equipment for upgrades and optimization

Documenting plant instituted modifications• Cross reference to serial cards as updates occur - evergreen

Challenges

Inconsistent asset data was impacting service and parts inventory requirements and – Proper inventory planning required accurate asset database– Reaction to unplanned downtime was inefficient and labor

intensive A storage reduction forced a parts

consolidation Comprehensive asset survey

needed to provide installed basebenchmark

Data driven decisions for parts inventory and outage planning

40-60 week delivery on key safety related parts– Stepping up pre-outage planning

Challenges

Proactive maintenance and timely parts ordering for future outages

Repetitive parts ordering hard and soft costs Nuclear facility Nuclear qualified and badged technicians

with proper safety and security clearances Potential radiation exposure in plant hot areas Baseline set of deliverables changed once value

recognized, deliverables were increased at request of Palo Verde

Setup and usability of data set

FieldSource - iPads

Internal tool developed by Caltrol IT Group– No paper, enter data straight from the field

Remote data gathering using iPads– Private logons to update data from service

and maintenance activities

Navigation and menus with pull-downs streamlines data entry and minimizes key strokes and human error

Nightly uploads from iPads Fisher® serial records, BOM, RSPPLs provided Field survey and outage planning

Data Gathering

Valve Database

Full accessibility to view or update valve data 24/7/365.

Data Gathering

Walk-down of plant for Fisher equipment (initially)– Scope expansion to include all assets (Phase 2)

“As-Found” images of equipment Serial records pulled, reviewed and updated Recommended Spare Price Parts Lists - RSPPLs Bill of Materials (BOM) Obsolete equipment flagged

for upgrades and optimization during future outages

Database Utilization

More efficient outage planning and scheduling– Calendar reminders for planning and key parts pre-ordering

for tags in each future outage

Obsolescence program – Strategically planned plant-wide

upgrades and optimization

Support for plant modification– Detailed and documented asset database

“Best Practice” for increasing efficiencyof future outages

Business Results Expectations

Proactive approach to maintenance and repair Database access anywhere using iPad or iPhone

– Private access to secure web-portal (https:service.caltrol.com/CompanyName)

Database helped identify control valves to receive new part numbers and update serial cards

Data-driven proactive approach to parts ordering, outage and obsolescence planning – Simplification of recommended spare parts inventory– Live access to replacement parts lists

Business Results Expectations

Database substantially increases interdepartmental communication and coordination of asset information – Ability to view data in multiple formats

Single data source creates alignment and standardization of product information– Live field updates directly into asset database

Maximization of plant reliability for optimal uptime– Ability to send email for parts directly from iPad or iPhone

Reallocation of capital budget savings from inventory and obsolescence planning

Where Are The Potential Cost Savings

Where are the cost savings?– Better Planning – Obsolete product replacement– Obsolete inventory– Labor searching data– Engineering, maintenance and supply chain collaboration– Pricing agreements – identify high use parts and provide

fixed costs reducing internal PO processing costs by 50% Reduction in state taxes paid on obsolete inventory

– State taxes = 15%– $50 Million in inventory– Current estimation of savings $4-6 Million

Where To Get More Information

Visit the Fisher and Instrument & Valve Services stand inside the Emerson Exchange

www.APS.com www.Caltrol.com www.EmersonProcess.com/IVS www.EmersonProcess.com/Fisher

Caltrol provides this service as part of service agreements to manage or survey process control equipment

Thank You for Attending!Enjoy the rest of the conference. Remember to stop by and go through the featured stand on Integrated Turnarounds.