Post on 12-May-2018
Advanced Condition Based Maintenance
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Why Focus On Maintenance?
• Maintenance Impact on Financials
– Maintenance Typically Accounts for ~3% of OpEx at ~$100-250k/store
– Effectively Every $1 Spent = ~$50 In Lost Sales
• Economy Still Tough
• Potential Impact:
– A 2% Reduction in Maint. & Energy = 1.3% Increase in Profits
– For a 1,000 Store Chain = $4M Increase Profits
Typical Equipment Failure Impact
$0
$1,000
$2,000
$3,000
$4,000
$5,000
$6,000
$7,000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Co
st Im
pac
t
Time
Consequences of Traditional Maintenance Practices During Equipment Failure
Product Impact
-Lost Product -Lost Sales-DissatisfiedCustomers-Food Quality Perception-Store Personel Time
Maintenance
-Equipment Repair/ReplaceCosts-Emergency or Overtime Service Costs-Out of Contract Charges e.g. refrigerant
Energy Impact-Higher Energy Usage Related to Equipment Degraded Performance, Efficiency
Normal Wear & Tear
Regular PM's
-No Issues
Early Equipment Operation Degradation
Regular PM's, T&M, Call-outs Maintenance
-Performed But Not For Undetected Early Equipment Operation Problems
Complete Equipment
Failure
Emergency Call-out
Maintenance Challenges
• Chain Consolidation and Maintenance Outsourcing
– Positives:
• Increased Buying Power = Lower Cost
• Contractor Economies of Scale
– Negatives:
• Lower Visibility of Actual Maintenance Quality
– Repair what needs repairing while there and before it breaks and becomes an emergency call-out at overtime rates
– Good Faith? Do The Right Thing?
• Increase in Out of Contract Charges (e.g. After-hours Emergency Call-outs)
• Higher Energy Costs
• Adversarial Relationship
– “if fan was dirty and failed, isn’t that your fault for not cleaning during PM?”
What‘s Optimal?
• Best Practices = Maintenance Contracts with Well Defined PM’s
– Typically Best Quality but May Have Short-term Higher Cost
– Low Visibility…”did they actually clean the coils”
Source: Cadick Corp.
What is Condition Based Maintenance?
Source: OnStar
What is Condition Based Maintenance? • Maintenance Performed Based On Equipment Condition i.e. Before It Has
Deteriorated To Point Where It May Fail If Not Serviced
• Similar To Today’s Automotive Diagnostics Systems ODB-II Messages and
Fault Codes :
• “Time For Oil Change”
• “Air Filter Replacement”
• “Low Tire Pressure”
• Mechanics Advised of Faulty Part Without Having to Perform Diagnostics Enables Timely and Cost Effective Maintenance
• Similarly CBM for HVAC/R Utilizes Equipment Sensor Data To “Learn” Equipment Expected Behavior and Compares Against Actual To Detect Anomalies
• Condition Anomalies or Exceptions Triaged for Optimized Dispatching
CB Maintenance Graphical Status
Typical Equipment Failure Impact
$0
$1,000
$2,000
$3,000
$4,000
$5,000
$6,000
$7,000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Co
st Im
pac
t
Time
Consequences of Traditional Maintenance Practices During Equipment Failure
Product Impact
-Lost Product -Lost Sales-DissatisfiedCustomers-Food Quality Perception-Store Personel Time
Maintenance
-Equipment Repair/ReplaceCosts-Emergency or Overtime Service Costs-Out of Contract Charges e.g. refrigerant
Energy Impact-Higher Energy Usage Related to Equipment Degraded Performance, Efficiency
Normal Wear & Tear
Regular PM's
-No Issues
Early Equipment Operation Degradation
Regular PM's, T&M, Call-outs Maintenance
-Performed But Not For Undetected Early Equipment Operation Problems
Complete Equipment
Failure
Emergency Call-out
With CB Maintenance Advisories
CBM
Notice
Advisory
CBM
Warning
Advisory
CBM
Alarm
Advisory
• Notice Advisory: Service
Next Visit ~30 Days
• Warning Advisory:
Service Soon Next 3-7
• Alarm Advisory: Service
Immediately
Maintenance is Optimized and Costs are Reduced
Equipment Requirements for CB Maint.
Suction
Discharge
Condenser
Ta
Pc Pd
Ts Ps
Lr
T Temperature
Sensor
P Pressure Sensor
Installed
Standard
CoreSense™
Diagnostics
E2 RX/BX
Controller
CB Maintenance Application For Supermarkets
Service Request Root Cause CB Maintenance Support
Case High Temp 1. Frosted evap. caused by failed fan
2. High/Low superheat caused by blocked or stuck TXV
Superheat Monitoring
3. Low refrigerant Slow Leak Detection
High Suction Pressure
1. Compressor trip on oil, phase loss, welded contactor
CoreSense™ Protection & Diagnostics
2. Compressor trip on high discharge pressure, temperature
Condenser Performance Monitoring & Superheat Monitoring
High Discharge Pressure
1. Condenser airflow blocked/fouled Condenser Performance Monitoring
2. Condenser fan fail Condenser Performance Monitoring
Top System Failure Modes
CoreSense™ Support
CoreSense™ Support
CBM Available Applications and Benefits
CBM Feature Asset / Maint.
Savings
Refrigerant
• Detect Slow Leaks
• Record Refrigerant
Additions/Losses
Reduce Leak Rate
10-20%
Track Leaks and
Additions for
Compliance
Condensers
• Control Strategy
Optimization Monitoring
• Condenser TD Performance
Monitoring
Fouled Coil Can
Increase Energy
Use 5-10%
Lower Condensing
Pressures Reduces
Comp. Wear and
Failure Rate
Cond. Cleaning
Based on Severity of
Fouling
Compressors
• Refrig. and A/C Compressor
Cycling Monitoring
• Performance Monitoring
with CoreSense™ Diagnostics
• Return Gas Monitoring
High Cycling Can
Increase Energy
Use +10%
High Superheat
Decreases
System Efficiency
Faster, Accurate
Diagnosis and
Failure Prevention
Extends Life
Optimize Dispatching
with Severity Based
Advisories
A 50% Refrigerant
Loss Can Reduce
System Efficiency
5-10% (Source:
EPA)
Energy
Savings
Optimized
Control Strategy
and Setpoint
How Does CB Maint. Work?
Refrigerant Slow Leak Detection
The Problem:
• Slow Leaks Hard to Identify Due to Normal Fluctuations In Level
• May Be Viewed As Tolerable
• Unresolved Leaks Means More Refrigerant Charges
Test Store Receiver Level
How Does CB Maint. Work? cont.
Refrigerant Slow Leak Detection
• Good Modeling Enables Early Detection and Potential Resolution
• Action Can Save Refrigerant, Equipment, Product, Labor Time
How Does CB Maint. Work? cont.
Refrigerant Slow Leak Detection
• In This Example ~30% of Refrigerant Was Lost and Recharged
How Does CB Maint. Work? cont.
Refrigerant Slow Leak Detection Process
Equ
ipm
ent
Sen
sor
Dat
a Ambient Temperature
Discharge Pressure
Liq. Level
Time of Day
Lear
nin
g M
ach
ine
Soft
war
e
Tests and Builds Models for Normal Liquid Level Behavior
Stores Multiple Models for Varying Operating Envelopes
CB
M E
xcep
tio
n G
en
erat
ion
Best Model for Given Operating Envelope Compared to Actual Level Over Time
If Increasing Difference Leak Advisory Generated
CB Maintenance Field Test Results
Incidence of CB Maint. Advisories Against WO’s
CB Maintenance Advisories Distributed Across The Year
CB Maintenance Field Test Results cont.
Incidence of CB Maint. Refrigerant Advisories Across Year
Slow Leaks Detected Proportionally To Fill Events
CB Maintenance Field Test Results cont.
47% Normal Leakage and Catastrophic Leaks
Detected Slow Leaks24%
Non-Preventable
(Catastrophic
Leaks)11%
Non-Preventable
(Normal Leaks)
36%
Preventable (Difficult to
Predict/Model)
29%
Indentified Leak Types
CB Maintenance Field Test Results cont.
CB Maintenance Field Test Results cont.
$1,100
$500
$375
$1,168
$2,482
$440
$0 $500 $1,000 $1,500 $2,000 $2,500 $3,000
Refrigerant Slow Leak Detection
Condenser Performance
Compressor Cycle Count Exceeded
Compressor Cycle Rate Exceeded
High Suction Superheat
Low Suction Superheat
Est. Value per Site/Yr
Estimated Potential Maintenance & Energy Savings of $6,064
Note: Any potential cost of works to correct CBM issue or any savings from reduced PM's not included.
Summary of Benefits of CBM Practices Maintenance
• Typical Equipment Maintenance Savings of 18% to 40% Compared to PM or Run-
to-Failure Source: US Plant Maintenance Survey
• Reduce Expensive Major Failures “Fires” Occurring at Worst Time
• Reduce Shorten Equipment Life Caused by Compromised Operation
• Optimize Maintenance Dispatching Right Technician Skill Level for Right Problem
At the Right Time
Energy
• Reduce Energy Waste Caused By Low System Efficiency Conditions Like:
– High Condensing Pressures, Excessive Compressor Cycling, High Return Gas Temperature
– Low Refrigerant Levels
Product
• Reduce Product Loss Occurrences Caused By Preventable Major Equipment
Failure
• Improve Food Quality Reputation
Q&A
Back up slides
CBM Software and Service Architecture
Hosted CBM Servers Data Acquisition and
Algorithm Processing
ProAct Portal - CB
Maintenance Dashboard
LAN or Web Access
Customer vLAN VPN
P T
Store E2
Liq. Level,
Press., Temp.
Sensors
Lv P T
Store E2
Liq. Level,
Press., Temp.
Sensors
Lv P T
Store E2
Liq. Level,
Press., Temp.
Sensors
Lv
ProAct Site Manager -
CB Maintenance
CBM Service Process • FAQ…
ProAct Portal CBM
NOTICE: Need for Routine
Maintenance Detected & Required
WARNING: Urgent Near Term Service
or Maintenance Required
ALARM: Component or System
Requires Emergency Service
Monitoring Technician is Able to Triage
Alarms and Dispatch Service
Technicians to Handle Critical issues
First
Benefits of CBM
CB Maintenance Feature Feature Description and Benefit
Energy
Customer
Value
Asset
Optimization
Customer
Value
Maintenace
Customer
Value
Compliance
Customer
Value
Total
Customer
Value *Savings Assumptions and Basis
Refrigeration compressor
faults and performance
monitoring via
CoreSense Diagnostics
Compressor mounted Copeland CoreSense Diagnostics
refrigeration diagnostics monitor compressor operation and
provide advanced protection and diagnostics alerts, making it
easier to accurately diagnose and prevent refrigeration
system failures.
$800 $2,300 $3,100
see Copeland CoreSense value proposition
literature
Refrigerant Slow Leaks
and Additions Monitoring
Refrigerant slow leaks detection across full system, aiding in
refrigerant loss prevention and reducing equipment failure,
system downtime, and product losses. Refrigerant additions
dedection aids costs tracking and audits.
$1,625 $1,000 $2,625
Industry avg of 4,000lbs/store with 25% leak
rate reduced by 25%. Refrigerant leaks lead
to product losses 5% Source:
http://w w w .epa.gov/greenchill/dow nloads/bureauaffai
rs.pdf
Refrigeration System
High and Low Return
Suction Gas Superheat
Monitoring
Detects refrigeration high and low suction superheat
conditions that can lead to compressor failure. Common
examples include, faulty TXV's, uninsulated suction lines,
cases not properly isolated during defrost.
$438 $800 $1,238
15% of systems operate at high or low
superheat due to incorrect TXV setting,
clogged screen, fan coil fail, or missing
insulation 3% savings
Compressor On/Off High
Daily Cycling and Total
Cycles Monitoring
Detects high compressor cycling and total cycles which can
result in a shorten compressor life and increased energy
usage, as well as effecting food quality.
$200 $385 $585
Customer data shows 3% of compressors
high cycle shorten life by 50% and increase
energy usage of 2%
Condenser Performance
(TD) and Control
Monitoring
Detects condenser low performance (high TD) due to debris
on the condenser coil (fouling), fan failure, or incorrect
control, all of which can lead to decreased system efficiency
and possible system failure.
$825 $200 $200 $1,225
Energy savings based on 25% of condensers
operate 20% below mfr ratings due to fouling
with 5-10% increased energy use. Savings
on equipment life of 10%. Reduce Comp
wear
*Estimates for annual energy savings derived from the annual primary energy use for commercial buildings data found in the DOE funded study “Energy Savings Potential and R&D Opportunities for Commercial Refrigeration” (Navigant
Consulting, Inc., 2009) and Emerson Retail Solution's customer testing.
CBM Provides Insight To Action Workflow
Proactive Insights
Reactive Insights
• Hi Temp Alarm • Tripped
Compressor • Board Offline
• Slow Refrigerant Leak Detected
• Excessive Comp Cycling Detected
• High or Low Rack Superheat
• High Condenser TD • CoreSense
Diagnostics
• Dispatch Contractor • Notify Store Manager • Act Immediately • Ignore As Noise
Fault
Info. Type
Fault
Condition
Fault
Analysis
Action
• Verify Condition • Smart Dispatch
Workflow (IP) • Verify Resolution
• Analyze Related Parameters or Conditions
• Compare To Normal Operation via Algorithm
• Identify Sites/ Equipment with Specific Condition
• Implement CBM Workflow (IP)
• Enterprise Wide Condition Based Maintenance
• Deficiency List For Enterprise For Proactive maintenance
• Facility Health Metric
• Notify Maintenance Manager
CBM Algo’s
Equipment
Alarms
Equipment
Performance
Data
CBM
Advisories
1
Service Use Cases
Upon Seeing A High Cycling Condition A Technician Will Investigate Potential Root Cause (eg. Incorrect Control Strategy, Component Failure etc) And Determine Resolution:
(1) Remotely Change E2 Setting To Correct Problem (eg. Fix Control Strategy)
(2) Suggest On-Site Investigation In PM Schedule
(3) Provide A Weekly Report Of All Compressors, Sites With High Cycling Problems To Customer Maintenance Team
Compressor High Cycles Incidence ~ 16 Out Of 480 In Test Case ~
3% Of All Supermarket Compressors Is Our Estimate
(1) Many Maint. Providers Don’t Know When Condition Exists
(2) No Action Being Taken Until Failure In Majority Of Incidences
(3) When Action Is Taken It Is In Response To Other Alarm
Today
With CB
CB Maintenance = Predictive Maintenance
• Which Of My Refrigeration Systems
Are Operating Improperly or
Inefficiently?
- Compressor CoreSense
Diagnostics
- Condenser Performance
- Compressor Cycling
- Rack Superheat Monitoring
• Which Of My Refrigeration Systems
Are Leaking Refrigerant?
• How Can I Implement A Better
Maintenance Scheme or Optimize
Maintenance Dispatches?
• Where Should I Focus My
Maintenance $$?
Questions CBM Can Answer Nature Of CBM
Refrigeration
Leak
High
Cycling
• Not Urgent But Important Equipment
Performance Degradation Monitoring
• Conventional Alarms Point To
Current Problems But CBM Points To
Conditions That Will Lead To
Potential Big Problems
ProAct CBM Service Summary
Availability
• Beta Customer Sign-up in May 2012
• Service “Go Live” July 2012
Future Features
• Smart Dispatch Integration Fall 2012
• Extended HVAC Support
• Cases and Walk-ins Diagnostics Support
37 Emerson Confidential
Complexity Increases With Every SubSystem That Makes Up A Retail Facility
Sensory Data
•Discharge Press. & Temp.
•Suction Press. & Temp.
•Ambient Temp.
•Condenser TD
•Refrigerant Level
•Suction Gas Superheat
•Condenser Setpoint
•System Voltage
•Rack Current
•Modulation Status
•System Overall Health
•Developing Problems
•When To Perform Maint
•Contactor Remaining Life
•Compressor Cycling
•Condenser Efficiency
•Remote Diagnostics
•High Cycling
Insights
•System Uptime
•Efficiency
•Product Quality
•Maint. Cost Savings
Customer Value
38 Emerson Confidential
Simple Component Level Information Can Drive Big Savings Value
•Asset Information
•Compressor Proofing
•Power Consumption
•Run & Fault History
•Remote Diagnostics
•High Cycling
•Compressor Protection
•Energy Efficiency
•Cost Savings
Sensory Data Insights
Customer Value
•Ambient Temp.
•Discharge Temp.
•Motor Tem.
•Contactor Status
•Unloader Status
•Power Voltage
•Control Circuit Voltage
•Current
•Demand Signal
•Oil Press.
•Low/ High Pressure Cut-Out
•Digital Modulation Status