Key elements of real time Analytics & Diagnostics
Phil Millette
28-Apr-2016
PREDICTIVE MAINTENANCE IN PROCESS INDUSTRY Presentation to Hannover Messe 2016
Depth & Breadth of Process Industry surveillance challenge
Industry
Monitoring
Applications
Type of
Equipment /
Complexity
Process Health Efficiency Safety Energy
Instrument
Valve Pump
Heat Exchanger
Compressor
Haul Truck
Turbine
Unit
Software
Oil & Gas Refining & Chemicals Pipelines Power Mining
© 2016 by Honeywell International Inc. All rights reserved
1
Value – Reduce Risk of Possible Unplanned Capacity Loss:
achieve real time analysis, anticipation, prediction of Process & Asset issues
Rare Frequent
High
Cost Im
pact
Low
Frequency
Process Deviations
Unit Shutdown
Degraded Efficiency
Non-Critical Eq. Failure
Critical Eq. Failure
Reduced
Capacity Loss
Original
Capacity Loss
Mitigation
Strategies
Leading
Cause
• Improved unit operations
• Energy savings
• Knowledge capture
• Standardization -performance &
process monitoring
• Remote collaboration / Subject
Matter Expert support
© 2016 by Honeywell International Inc. All rights reserved
2
Mitigate and
achieve…
Labor Intensive / Periodic / Informal / Privatised Knowledge
As-Is - Ad-hoc Engineering Work Environment
3
Tag, Lab & Other Data Reports
Tag Name Tag Desc
XUTT901.PV HE91 Shell In Temp
XUTT902.PV HE91 Shell Out Temp
Excel & Other Tools
Manually Search & Collect
Cumbersome Isolated Tools
Manual Periodic Calculations
Informal Work Processes
T1 T2 T3
Blind Spots
Time Consuming Missed Opportunities
Difficult to Sustain
Varied Approaches
& Results
Silos of Information
86.19
88
91.4
© 2016 by Honeywell International Inc. All rights reserved
Notifications
Events
Ad Hoc
Fixed Schedule
Maintenance &
inspection
Convert time usage to Higher Value Tasks
Surveillance Function – complexity and cost
4
• Large process plant Study
- 1 (only one of many) Major Process Area
~600 Process Eng. monitoring activities (daily, weekly, monthly…)
57 Types (Emissions, Catalyst, Energy, Yield, Hx Mon, Compressor Mon…)
60 Daily Monitoring Tasks - ~ 70% could be automated
Hrs per Activity 0.25
Hrs / Day Saved 10.4
Additional Engr Time/Yr (@70% applied rate) 1893 hrs/yrs
© 2016 by Honeywell International Inc. All rights reserved
Organisation, expertise as well as the tools:
joined up across functions
5
Management
Operations Engineering
Common Business Goals
Improved quality Reduce operating costs Increase reliability
Maintenance &
Reliability
© 2016 by Honeywell International Inc. All rights reserved
Increase profitability Safety
Automating Engineering Processes for Digital Transformation
Real-time Process & Asset Surveillance:
Performance Monitoring – link to predicted state
6
0
1
1 0 0
1 1
0
1
1 0 0
1 1
0
1
1 0 0
1 1
Management
Operations Engineering
Maintenance &
Reliability
Data in Asset Context Standard
Connectors Consolidate
OPC-HDA
Reduce Effort & Complexity Find & Access Data
1. Automate / Simplify Data Access, provide context
OPC-DA
OPC-A&E
OPC UA
Attributes (not tags)
Sensor (tag) Data
Historian Data
Alarms/Events
Other…
Trends
Events
© 2016 by Honeywell International Inc. All rights reserved
7
2. Addresses broader IIOT – yes devices talk, but others do
too!
8
64KF_01TT.PV = 102.3
64KF_01TT.SP
64KF_01TT.OP
66KA_01PR.PV
66KA_01PR.SP
66KA_01PR.OP
63KA_01B_PO.PV
63KA_01B_PO.SP
63KA_01B_PO.OP
Head=3960*HP
Flow
Local Calcs
Forgotten IIOT Data Typical
IIOT Focus
© 2016 by Honeywell International Inc. All rights reserved
C_Speed
C_In_Press
C_In_Temp
C_Effeciency
Unit101_Effeciency
Unit101_Yield
M_Speed
M_Temp
M_Vibration
M_Power
Calcs
Spreadsheets
proliferate
Cloud
Formalise all derived data
Process Intelligence
Embedded & Custom
Models
Continuously Monitor & Take Action
3. Continuous Calculations & Monitoring, link events to Maintenance &
other functions via notifications
9
Compressor Heat Exchanger
Turbine
Head=3960*HP
Flow
Pump
Fault Models
Calculations
Make Problems
Visible
Single Version of
Truth
Continuous Trends
Dashboards
Notifications
Rollup KPIs & Dashboards
Rollup Metrics
Continuous
© 2016 by Honeywell International Inc. All rights reserved
Outputs • Alerts & Notifications
• Management Reporting & KPI’s
• Maintenance & Reliability
Scorecards
• Downtime Reporting, OEE
• Health Assessment
• Automatic Work Order request
Generation
4. Tools are good – yet expertise still needed:
build into more automated analysis
10
…Accumulate team
knowledge
…unlike
manual/excel/home
grown applications
…capture logical
structure of plant
information
© 2016 by Honeywell International Inc. All rights reserved
Questions?
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