Transition to online AMS reduces maintenance costs and improves operations

Transition to online AMS

reduces maintenance costs

and improves operations

Transition to online AMS

reduces maintenance costs

and improves operations

Workshop 1A-2942

PresentersPresenters

David Rabon

Control Systems Specialist

Mike Ruhle

Account Manager

IntroductionIntroduction

Summary : Utility department’s evolution to smart devices and transition from offline to online AMS during DeltaV upgrade helps reduce maintenance costs and improve operations

Agenda– History of smart devices and AMS at the Site– DeltaV Upgrade project– Work Process Changes– Challenges– Business Results– Summary

History of Smart Devices and AMSField Devices and VisionHistory of Smart Devices and AMSField Devices and Vision

Original install - Boiler upgrade in 1994/95– Used as opportunity to establish a vision– Investment made in Rosemount smart transmitters,

DVC5000 with advanced diagnostics, and Valvelink Software

– Interface was point to point – offline to start– Immediate return during start up and commissioning of new

equipment• Faster loop checks

• Easier Field calibration of valves

History of Smart Devices and AMSEvolution of Diagnostic use and integrationHistory of Smart Devices and AMSEvolution of Diagnostic use and integration

Began using technology to improve boiler overhauls– Improved calibration efficiencies for I&C group

– Champion used Valvelink Diagnostics to validate valves re-assembled correctly after open/inspect

Optimized instrument calibration list.– Reduced frequency of calibration based on performance history

Gradual evolution from scheduled maintenance to predictive– Went from open/inspect all to some depending on diagnostics

Started integrating smart data– Provox

• Alerts - travel deviation & temperature• Difficult to decipher but some value

History of Smart Devices and AMSHistory of Smart Devices and AMS

– Delta V installed in 2001• Integration much easier

– HART IO Cards– Developed face plates with actual valve travel

for operators– Rosemount 3095MV transmitters

Continued to look for opportunities to move to online AMS

• Take advantage of advanced diagnostics

Going online – DeltaV v9.3 upgradeGoing online – DeltaV v9.3 upgrade V9.3 upgrade

– Good opportunity to get the AMS infrastructure installed– AMS – Intelligent Device manager and Valvelink snap on installed as

part of upgrade to support future FF devices and Pfizer’s online vision

– Originally installed on Pro-plus

A number of projects also in the works– WW upgrade to DeltaV– Boiler upgrade from Provox to DeltaV – New CTG/HRSG with FF devices

Majority of smart devices would now be wired direct to DeltaV HART IO

Pfizer Groton DeltaV & AMS System OverviewPfizer Groton DeltaV & AMS System Overview

Foundation Fieldbus,

HART I/O & Field

Devices

DeltaV

Engineering &

AMS Server -

AMS Client – Device

alerts routed to

Maintenance station

DeltaV Network

AMS Communications

I&C Shop DeltaV Controller and

I/O System

Control Room- Pro Plus

Operator Stations – Process

alerts and Device feedback

only. No device alerts

configured.

Going online – After the upgradeGoing online – After the upgrade

Transition from installed software to optimized tool– Champion assigned to own system– Leveraged additional licensing from plant– Configured system

• Installed Maintenance station in I&C Shop

• Set up Plant Web Alerts

• Installed a DeltaV Operate graphic for PW Alerts

• Did FF and AMS training for Champion and technicians

– Set up quarterly mentoring visits as part of local support contract

• Ongoing Training and optimizing configuration

Going online – After the upgradeGoing online – After the upgrade

Work Process changesWork Process changes

Maintenance station critical to success– Convenient for technician

– Operator not burdened by device alarms

– Allowed for EASY change in work process Needed to get buy in from Maintenance and Operations

– No need to do schedule only based maintenance

– Believe in the data Maintenance set up Work order for Champion to do a Daily PM

– Reviews any device related alerts

– Does further troubleshooting

– If issue sets up a work order to fix equipment

Overall ChallengesOverall Challenges

Continuous improvement of skills to keep up with technology– Leveraged local DeltaV service contract

Continuous reinforcement with complementary groups within the Organization– Maintenance- Develop trust in the diagnostic data.– Reliability- Integrate diagnostic data into overall reliability

program.– Operations- Understand new architecture - techs will be

responding to alarms operators do not see.– Projects- Continue to invest in the SMART technologies.

Business Results AchievedBusiness Results Achieved

Increased Maintenance efficiency and costs– Triage allows for right tools for job and less time

• Example : Replacement sensor in pH probe

– Trusting in the data• Open/inspect ALL valves on an as needed basis versus time

• Use data to plan maintenance

Avoided Unplanned outages• Find valve and instruments problems before they become

process issues

• Self scheduling: I&C shop now writing corrective work orders based on data from the daily review of AMS. These WO’s resolve problems before they are operational issues.

Example- EQ-02 pH ProbeExample- EQ-02 pH Probe

Diagnostic evaluation revealed an “Offset Error” Warning and the Help files assisted in correcting

error. Saved replacement of the probe. Reduced troubleshooting time. Savings- $2,500.00

– Unneeded part replacement– Reduction in troubleshooting time– Quicker release back to production

Example – XTCCHW-100-01 BeforeExample – XTCCHW-100-01 Before

Example - XTCCHW-100-01 AfterExample - XTCCHW-100-01 After

Example - XTCCHW-100-01 SummaryExample - XTCCHW-100-01 Summary

Chiller 100 Flow Control valve not working properly Found a PD online/in-service alert record PD alert simplified troubleshooting Corrected relay issue before high demand months Savings- $940.00

– Reduction in energy – more efficient chiller– Air consumption savings

Examples – XPCVBFP-12-1 BeforeExamples – XPCVBFP-12-1 Before

Examples – XPCVBFP-12-1 AfterExamples – XPCVBFP-12-1 After

Examples – XPCVBFP-12-1 SummaryExamples – XPCVBFP-12-1 Summary

Call in to fix valve issue Visually found travel feedback arm disconnected

– Mechanical interference with Travel feedback arm

Used Diagnostics to find additional issues– Pneumatic lock in last valve not tubed to supply

Found the right root cause and faster Fixed the issues on both valves before a trip required

switchover to other feedpumps Savings- $2,904.00

– Reduction in troubleshooting time and potential mech. maint.– Avoided switchover to redundant pump

Examples - Effluent mag meterExamples - Effluent mag meter

EQ02-1-2 is a magnetic flow meter associated with the discharge of the effluent.

It was locked into an over-ranged PV condition thereby rendering it useless to operations. 

Utilizing AMS, I was able to troubleshoot and correct the issue at the Maintenance station

This flow meter electronics box is located in B-192 and has a very cumbersome user interface.  AMS made working with it more efficient

Reduced maintenance cost and reduced time without effluent data

Savings- $972.00– Reduction in maintenance/troubleshooting costs

Example- XFVB-5-5 BeforeExample- XFVB-5-5 Before

Example- XFVB-5-5 AfterExample- XFVB-5-5 After

Example- XFVB-5-5 SummaryExample- XFVB-5-5 Summary

Boiler # 5 Feed reg valve operating erratically Used diagnostics to prove positioner issue versus

mechanical issue and prevented unnecessary opening of valve.

6 weeks until diagnostics findings were accepted. Reduced Maintenance cost by not assuming mechanical

issue and unnecessarily opening valve After resolution - Improved control and allowed for run on

#5 on high load days Savings- $7,980.00

– Avoided mechanical maintenance– Able to run more efficient boiler

Financial BenefitsFinancial Benefits Since 2009, we have analyzed 11 issues, where

AMS played a prominent role, and have calculated the following savings.– Avoided Maintenance time $11,760– Avoided Downtime $5,668– One time Costs $8,700

• Switching equipment, Un-required spare parts used

– These 11 examples represent about 30% of all issues addressed with AMS.

Total Extrapolated savings: ~$75-$100K Also avoided an average impact to the I&C group

schedule of 4.8% per event. I&C Team self scheduling work based on data from

the daily AMS review.

SummarySummary

We have presented the history of implementing the on-line AMS diagnostics in a maintenance group to assist the transition from reactive maintenance to a reliability based model.

We have shown the benefits of implementing on-line AMS diagnostics.– More efficient maintenance process– Increased equipment availability and reliability.

We would appreciate any feedback you have on the presentation

Are there any questions?

Questions?Questions?

Contact Information:

[email protected]

[email protected]