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Value of Asset Management
StrategiesI need to insure that my facility is operating the way I built it to
run!
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Common Water Supply & Water Treatment System
Objectives
reduce risk to service outages
improved site security
improve maintenance staff
effectiveness
reducing commissioning time & costkeeping employees safe
disaster recovery
complying with regulations
monitor & protect
systems
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Water Supply & Water Treatment System Benefits
Reduction in long term operating & maintenance costs and loweringthe risks to the community served by
Improve maintenance staff effectiveness Root cause analysis & locked door device analysis automatically
Monitor & protect systems Monitor devices on networks for abnormal operation including degradation or
failure
Automatic integrated condition monitoring including notification
Automatic tracking of versions with security on all production intellectualproperty
Messaging (email) appropriate personnel
Facilitate more migration from reactive & preventive maintenance topredictive & reactive maintenance models
Increase site security for device access
Creating audit trails for asset configuration changes, detect unwanted
changes
Back up asset intellectual property to a secure system for disaster recovery
Store every version of asset configurations in a secure system for archivaland retrieval
Automatic verification of some device configurations against controlledmasters
Extend service life of equipment through verification, conditionmonitoring & security
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Assets Influence on Objectives
Even the smallest
change can affect operations!
Each asset no matter how large
or small is linked to the next asset.
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RSMACC Systems
RSMACC Systems consist of an
architecture that includes at least one
core function.
That RSMACC System can be added to,
creating a much more comprehensive
solution.
The 4 core functions are:
Change Management, CM
Network Health, NH
Enterprise Online, EOL
Automated Asset Manager, AAM
You can purchase CM alone and addAAM at anytime
Or you can purchase a NH System and
add EOL, etc
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Typical Device Configuration Scenario
User starts RSLogix program
User locates the RSLogix controller
program
User connects to the controller
Downloads or makes online changes,
saves program on local disk drive, floppy
or somewhere else
What version of the program is in your
controller and where did the program
come from & where did it go after the
change?
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Change Management
Archive
Audit
Verification/Recovery
Reporting
Access Control
Authentication
Reconciliation
Detection
Accountability
Control
Prevention
The Value is greatest when applied proactively
rather than after the fact!The stream of managing change starts with
Prevention and flows throughReconciliation.
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Change Management
User starts RSLogix program
RSMACC security system ask your
domain controller to authenticate the
user
Regardless of results, RSMACC records
workstation and user launching
RSLogix
RSMACC security applies the definedsecurity permissions
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Change Management
User retrieves application program from
RSMACC archive using RSLogix 5 or 500
file open or the RSMACC client using theRSMACC security system to verify
permissions
RSMACC records who retrieved the
application program & where it went
Any type of file can be stored in this Archive system!
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Change Management
File management system
Holds any kind of
document
Manage user folder rights
Supports
Pinning/ mastering
Sharing
Branching
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Change Management
User connects to the controller
RSMACC records device connection
User makes online modifications to
control program
RSMACC records each user change as it
occurs
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Change Management
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Change Management
Secure operator changes from
RSView SE or PanelView Plus
during production Set-point change (Tag write)
Command
Alarm acknowledgement
Recipe download
Signature required beforeoperation occurs
Generates compliance enabling
21 CFR Part 11 audit trail
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Change Management
Documenting Configuration
Changes
Supports self-documentingChange Management
procedure
Ability to prove scope of
change is limited to approved
change
Contains information
necessary to enable FDA 21
CFR Part 11 compliance
Date/Time of audit event
Source (Application)
Location (Workstation)
Username (Domain ID, and
Full Name from Domain Id)
Automatically generateddescription of change with
old and new value
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Change Management
User returns the application program to
the RSMACC archive system
RSMACC archive compares the files andincrements the version if it is different
regardless of the type of program
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Change Management
RSMACC verifies automatically at the
prescribed periodicity that the controller
program matches the master programand version in archive
A message can notify that the function ran
correctly or not, and differences were
found or not.
A report of the differences found is saved.
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Brief Overview, Managing Device Configuration
CM
24vdc
509-BOD
RSLogix 5 or 500 Standard v6.10
RSLogix 5 or 500 Professional v5.50
RSLogix 5000 (English) v10.03...
Security for:
Archived files
RSMACC functions
RSLogix 5 v4.00.00 or greater
RSLogix 500 v4.00.00
RSLogix 5000 v11.00
RSMACC Client v1.00.00
RSMACC Change Management v1.00.00RSLinx v2.20.01
More products are coming as
FactoryTalk Security is integrated!
FlexLogix
ENet
CNet
DH+
MicroLogix
DH485
DF1
CompactLogix
ENet
CNet
DH+
PLC3
DH+
PLC2DH+
PLC5
DH+ENet
CNet
DF1
PanelView Standard
Enet, CNet, DNet, RIO, DH+, DH485, DF1
(Enhanced on RIO only)
ControlLogix
DriveLogix
ENet
CNet
DH+
SLC*
ENet
DH+
DH485
DF1PanleView Plus
ENet, CNet, DH+, DH485
Verification for:
All devices shown belowfiles on computers
and some robots
Archive for:
Virtually any form or type of file
Audit:
RSLogix editors listed
RSViewSE & ME, RSBatch(some integration)
More products are coming as
FactoryTalk Audit is integrated!
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RSMACC Systems
RSMACC Systems consist of an
architecture that includes at least one
core function.
That RSMACC System can be added to,
creating a much more comprehensive
solution.
The 4 core functions are:
Change Management, CM
Network Health, NH
Enterprise Online, EOL
Automated Asset Manager, AAM
You can purchase CM alone and addAAM at anytime
Or you can purchase a NH System and
add EOL, etc
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Typical Device Status Events
Event
Radio message or alarm
~75
%
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Automatic Device Health Status
Periodically the Diagnostic Scheduler
Service, running on a local computer,
scans the health of DeviceNet,ControlNet, and Ethernet/IP network
devices and reports on their status to
the RSMACC system.
Smart devices, when prompted, will
identify their health status by respondingwith a coded number
Comparing that number to the type of
device using the network configuration
file allows us to automatically generate
information about the failure
Diagnostic
Scheduler
Services
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Automatic Device Health Status
That number corresponds to a real
problem for the device at that node.
These are automatically logged to thecentralized RSMACC Diagnostics
and Health log database
Diagnostic
Scheduler
Services
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Automatic Device Health Status
RSMACC log message includes a link to
root cause and solution information from
distributed RSMACC Clients RSMACC requires no additional code or
configuration to recognize a device code
and communicate the device status to the
system and subsequently the appropriate
personnelDiagnostic
Scheduler
Services
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Automatic Device Health Status
Diagnostic
Scheduler
Services
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RSMACC Systems
RSMACC Systems consist of an
architecture that includes at least one
core function.
That RSMACC System can be added to,
creating a much more comprehensive
solution.
The 4 core functions are:
Change Management, CM
Network Health, NH
Enterprise Online, EOL
Automated Asset Manager, AAM
You can purchase CM alone and addAAM at anytime
Or you can purchase a NH System and
add EOL, etc
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Traditional Condition Monitoring
Machinery in the plant might malfunction
so we must do our preventive
maintenance periodically regardless ofreal indicators like cycles, revolutions,
temperature, vibration, level or viscosity.
This requires a person to take local
readings and then analyze those readings
typically back at their desk. In several industries this may even require
travel
In all, it is extremely time consuming
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Automatic/Integrated Condition Monitoring
Our integrated and automatic protection
systems are designed to provide
continuous monitoring and protection tomachinery
RSMACC system provides a live
connection to sensor data from the XM
modules
Vibration Analysis Process Parameters
Temperature, Pressure, and Flow
Turbine Supervisory Instrumentation (TSI)
Thrust, Differential and Case Expansion,
Valve position, and Eccentricity
No more traveling to the location or
climbing on machines to take readings!
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Automatic/Integrated Condition Monitoring
RSMACC Client combines digital images
of your plant equipment with monitored
data for simple asset monitoring andalarm annunciation
EnWatch data can be combined with the
XM data on the live monitor
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Automatic/Integrated Condition Monitoring
Online remote configuration capability
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Automatic/Integrated Condition Monitoring
Live Time data display from any XM
channel
Trend, Spectrum, Waveform, Waterfall,Polar, Orbit, Shaft-Centerline
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Automatic/Integrated Condition Monitoring
Historical data can be added to real-time
using our Emonitor systems
Emonitor Enshare Data Storage, Alarming, Frequency
Analysis, & Connectivity
Emonitor Odyssey Deluxe
Data Storage, Alarming, & Frequency
Analysis
Emonitor Odyssey Data Storage & Alarming
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RSMACC Systems
RSMACC Systems consist of an
architecture that includes at least one
core function.
That RSMACC System can be added to,
creating a much more comprehensive
solution.
The 4 core functions are:
Change Management, CM
Network Health, NH
Enterprise Online, EOL
Automated Asset Manager, AAM
You can purchase CM alone and addAAM at anytime
Or you can purchase a NH System and
add EOL, etc
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Automatic Messaging
RSMACC binds process information fromintelligent assets and RSMACC internal systems &messaging to MAXIMO to facilitate WORK ORDER
generation and tracking Predictive Interaction
Process data like N:7:0 > desired level
A work order for checking/calibrating thethermocouples should be issued
Operator interface sends signal requesting maintenance onmachinery based on a reading or operator input
Reactive Interaction An intelligent sensor or device is malfunctioning Photo eye signal is degrading, work order issued to clean
RSMACC detects that an assets configuration does notmatch the master on file
Work order created to asses the situation a
RSMACC detects a security violation Message sent to IT or Security to investigate issue
Process data
B120/12 not 0 A work order for fixing a leaking valve should be
issued
RSView SE Interface for Work Ordergeneration/messaging
Track status of work orders & data Plan for work based on status & changes
Adjust schedules and priorities of planned work
MAXIMO
(Automatic) Work
Order Generation
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Automatic Messaging
A lot of plants are struggling with the
increased work load including increased
complexity of systems.
Consequently plants have moved to more
of a run-to-failure, RTF, mode for some
maintenance
This is as expensive in some cases as
hiring more people and doing preventivemaintenance
A balanced approach is more appropriate
based on individual requirements
This type of system is deigned to help in
the balance between RTF and total PMS
Moving some appropriate systems toReactive models
Compensates for not having time to do
PMS
Facilitates better time management
Facilitates a more appropriate cost model
for maintenance
MAXIMO
(Automatic) Work
Order Generation
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RSMACC Systems
RSMACC Systems architecture includes
some basic functions like
Reporting
Both manual ad-hoc and automatic
Security
Service Monitoring
Archive
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Manual & Automatic Reporting
RSMACC can be configured to generate
automatic reports for changes to
machines and their respective assets. For instance, a maintenance manager
might want a report for changes that
occurred over the weekend or during the
past evening.
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Manual & Automatic Reporting
Other Uses For Reporting
Generate a morning report for
Maintenance/ Engineering Managerreview showing ALL changes to PLC
programs during 2nd and 3rd shift
Forces
Empty branches
Changes to rungs, ignoring valuemodifications
All employees that made modifications
Generate a weekly report for the Plant
Manager showing all programmable
assets that have been modified by name
Generate a report monitoring criticalapplications (e.g., pasteurization process)
that have not been changed
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System Planning & Architecture
Common Architecture with Plug-In Functions
RSMACC Server & RSMACC Client common to all applications
Plug-In Functions RSMACC Network Health
Monitor, report, and diagnose device and network health
RSMACC Automated Asset Manager
Automate preventive, predictive, and reactive maintenance
RSMACC Enterprise Online Condition Monitor
Integrated automation condition monitoring
RSMACC Change Management
Authenticate, audit, archive, and verify device configuration
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System Planning & Architecture
RSMACC Server(s)
Windows 2003
Server
Windows 2000
Server w/SP4
Pentium 4, 2GHz ormore
1GB RAM
1.5GB free on
system volume
20GB sharedvolume, RAID-5
capable Only ifhosting
Microsoft SQL 2000
Server
RSMACC Client
Windows 2000
w/SP4 or XP Pro
SP1 DO NOT USE XP SP2
Pentium III, 500MHz 256MB RAM
1GB free on system
volume
Recommended Platform Requirements:
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System Planning & Architecture
RSMACC Client
`
Windows 2000
Server PDC
RSMACC ServerRSMACC Server
Service Monitor
Security Server
Administration UtilitiesVerification
PLC5
SLC500
ControlLogix
PanelView
Reporting
RSLogix 5
RSLogix 500
RSLogix 5000
RSMACC Client
Security client
Archive client
RSLogix 5RSLogix 500
RSLogix 5000
SQL Server 2000
Profile dBEvent & AuditdB
Archive dB
Tables
Stored procedures
Ethernet TCP/IP / Microsoft Windows Domain
S Pl i & A hi
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System Planning & Architecture
RSMACC Client
`
Windows 2000
Server PDC
RSMACC ServerRSMACC Server
Service Monitor
Security Server
Administration UtilitiesVerification
PLC5
SLC500
ControlLogix
PanelView
Reporting
RSLogix 5
RSLogix 500
RSLogix 5000
RSMACC Client
Security client
Archive client
RSLogix 5RSLogix 500
RSLogix 5000
SQL Server 2000
Profile dB
Event & AuditdB
Archive dBTables
Stored procedures
Ethernet TCP/IP / Microsoft Windows Domain
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Assets Influence on Objectives
Even the smallest
change can affect operations!
Each asset no matter how large
or small is linked to the next asset.
C S Obj i
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Common System Objectives
reduce risk to production
improved site security
improve maintenance staff
effectiveness
reducing commissioning time & costkeeping employees safe
disaster recovery
complying with regulations
monitor & protectsystems
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Wh t t
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Whats next
Action