Asset Management Asset Management -- The Emersonhe Emerson · PDF fileAsset Management Asset...

21/09/2012

1

Asset Management Asset Management --TThe Emersonhe Emerson WayWayTThe Emerson he Emerson WayWay

IfeaIfea seminar Gardermoen seminar Gardermoen 1919-- 20 September 201220 September [email protected]@emerson.com

Tlf 90 54 56 35Tlf 90 54 56 35

Mer info: Mer info: www.assetweb.comwww.assetweb.com

Emerson Emerson Process Management Process Management Core Offerings & Key BrandsCore Offerings & Key BrandsEmerson Emerson Process Management Process Management Core Offerings & Key BrandsCore Offerings & Key Brands

PlantWeb® Digital Plant Architecture

Systems & Asset Management

Measurement & Analytical

Control Valves & Regulators

Industry Solutions & Expertise

Award-winning network platform that seamlessly integrates plant-wide automation to deliver real-time insight for

Systems and software for precise plant process control, safety, reliability and operations

Precision instruments for measuring pressure, level, temperature, flow or composition of gases

Properly matched control devices that ensure accuracy, reliability, safety and productivity of plant

Robust array of process automation & asset optimization services, engineering and project

[File Name or Event]Emerson Confidential27-Jun-01, Slide 2

real time insight for better decisions and better results

operations management

composition of gases and liquids

productivity of plant processes

and project management

21/09/2012

2

Typical Device information that should be Typical Device information that should be onlineonlineTypical Device information that should be Typical Device information that should be onlineonline

Instrument Valve

Rotating & Vibration Static Equipment

VFDs

Safety


Transient Analysis

Predictive Diagnostics

API 670Protection

Both protection and prediction in one offering

With smart field devices the Right Person can get With smart field devices the Right Person can get Meaningful and Actionable InformationMeaningful and Actionable InformationWith smart field devices the Right Person can get With smart field devices the Right Person can get Meaningful and Actionable InformationMeaningful and Actionable Information

Business(ERP)

Diagnostics provide early warning and action steps

Operations Maintenance& Reliability


21/09/2012

3

Improve Product

Reduce Start-up Time

Advanced instruments with drivers give Advanced instruments with drivers give better Information for Decisionsbetter Information for DecisionsAdvanced instruments with drivers give Advanced instruments with drivers give better Information for Decisionsbetter Information for Decisions

Increase Process

Reduce MaintenanceProduct

Quality

Determine if unexpected readings require action

Start up Time

Verify installation and device configuration information

Process Uptime

Predict and prevent abnormal situations

Maintenance Costs

Optimize schedules and reduce calibration frequency

2

3

4

5Structural Integrity Normalized Stiffness

u spec

KLPOoutle t

KRPOinle t


Echo Curve Visualization

Statistical Process Monitoring

Meter Verification Hot BackUp®

1950 2000 2050-5

-4

-3

-2

-1

0

1

Unc

erta

inity

%Meter Verification Counter

l spec

Clear Indication of Device Health with EDDLClear Indication of Device Health with EDDLClear Indication of Device Health with EDDLClear Indication of Device Health with EDDL


21/09/2012

4

What’s happening in the process?What’s happening in the process?What’s happening in the process?What’s happening in the process?


What can jeopardize integrity of the What can jeopardize integrity of the electrical loop?electrical loop?What can jeopardize integrity of the What can jeopardize integrity of the electrical loop?electrical loop?


21/09/2012

5

Daniel Daniel –– UltrasonicsUltrasonics –– AMS Device ManagerAMS Device ManagerDaniel Daniel –– UltrasonicsUltrasonics –– AMS Device ManagerAMS Device Manager

Supports AMS Device Manager (DD-files)


Easy access to diagnostic information enables faster startupEasy access to diagnostic information enables faster startup

Easy TroubleshootingEasy Configuration

Device Status

Easy Access

Smart Wireless THUM™ AdapterSmart Wireless THUM™ Adapter

Conditional graphics

E A

S Y

Common Tasks

E A

S Y


Tips toTroubleshoot

GuidedSetup

HART Tri-Loop

475 Field Communicator

4-20mAHART

21/09/2012

6

AMS Device ManagerAMS Device ManagerAMS Device ManagerAMS Device Manager What is AMS Device Manager?

– Software application for managing field instruments and valves from all vendors

– Close to 1000 instrument drivers and 100 vendors

– 10 000 licenses delivered– Single application for:

• Predictive Diagnostics• Device Configuration• Calibration Management• Documentation

S t lti lti t k i t


– Support multi-user, multi-task environment– Track instruments on tag and device id – Based on open standards: HART,

FOUNDATION fieldbus, OPC, XML, Web Services

– SNAP-ON applications offer advanced capabilities with connected devices

AMS Device ManagerAMS Device ManagerComprehensive Connectivity OptionsComprehensive Connectivity OptionsAMS Device ManagerAMS Device ManagerComprehensive Connectivity OptionsComprehensive Connectivity Options


21/09/2012

7

Data Level Data Level IntegrationIntegration

Levels Levels of Integration with AMS Device of Integration with AMS Device ManagerManagerLevels Levels of Integration with AMS Device of Integration with AMS Device ManagerManager

Operator / Engineering Operator / Engineering StationsStations AMS Device AMS Device

ManagerManager

Bus LevelBus Level

System Interface System Interface Level IntegrationLevel Integration

Controller

Remote I/O

System Data Highway

P fib

( or )

TCP/IP

Profibus DB V1

xEPI


Bus Level Bus Level IntegrationIntegration

ProfibusDP V1 I/O Bus

HART Multiplexer

I/O Level I/O Level IntegrationIntegration

Controller with Local I/O

RS485 2-wire loop

TCP/IP

Serial server

Wireless HART


Valve Performance is run on the FieldVue which have been upgraded to Performance Diagnostic (PD) from the normally

supplied version with Advanced Diagnostic (AD)

21/09/2012

8

Anti surge valves movment is trended


Safety Instrumented Systems DiagnosticsSafety Instrumented Systems DiagnosticsSafety Instrumented Systems DiagnosticsSafety Instrumented Systems Diagnostics

In-Service PartialDynamic Scan

Emergency Shutdown Service

Dynamic Scan


21/09/2012

9

Solenoid Testing Solenoid Testing --Triggered ProfileTriggered ProfileSolenoid Testing Solenoid Testing --Triggered ProfileTriggered Profile

S

TravelTravelEnsures Solenoid Availability Ensures Solenoid Availability during Demand and improves during Demand and improves

Reliability of SIF LoopReliability of SIF Loop

B

A

A/S

S

P4-2O mA

24VDC

Additional tubing from


Additional tubing fromport B to actuator

100ms Solenoid Trip100ms Solenoid Trip

Solenoid Valve TestingSolenoid Valve TestingSolenoid Valve TestingSolenoid Valve Testing The solenoid valve can be pulsed for a split The solenoid valve can be pulsed for a split

secondsecond–– Long enough so that the solenoid vents Long enough so that the solenoid vents

( ifi ti th t th l id l i f ti l)( ifi ti th t th l id l i f ti l)(verification that the solenoid valve is functional)(verification that the solenoid valve is functional)–– Short enough so that the actuator doesn’t bleed Short enough so that the actuator doesn’t bleed

enough pressure to make the SIS valve move.enough pressure to make the SIS valve move.


21/09/2012

10

Detailed info can be given on each alarm.


Several Several applicationsapplications areare summerizedsummerizedSeveral Several applicationsapplications areare summerizedsummerized


Example Ormen Lange

21/09/2012

11

SOLUTIONSOLUTIONSOLUTIONSOLUTION

• Technology:• Asset Management Online for all devices• CBM work order notification

Shell Shell OrmenOrmen Lange Lange –– Valve Condition Valve Condition MonitoringMonitoringShell Shell OrmenOrmen Lange Lange –– Valve Condition Valve Condition MonitoringMonitoring

• People:• Collaboration center in Bergen (Norway)• Use of supplier experts to diagnose valves problems

• Result 2011:• 70% CBM initiated Work orders• 7% reduction in maintenance work per/year

Cost Reductions 7%


27

25% Preventive Maintenance 15%

35% Corrective Maintenance 15%

40% Predictive Maintenance 70%

2007 20092008

100% 100

%

Solberg & Andersen AS reports to Solberg & Andersen AS reports to ShellShellSolberg & Andersen AS reports to Solberg & Andersen AS reports to ShellShell


21/09/2012

12

Equipment Degradation Equipment Degradation ––Remote MaintenanceRemote Maintenance

Equipment Degradation Equipment Degradation ––Remote MaintenanceRemote Maintenance

Remote monitoring and diagnostics is a core strategy of many companies

Important and desirable facilities but these are resource constrainedare resource constrained

Diagnostic services and repair in Norway to:

Shell, Statoil, ENI, ConocoPhillips ,Gaz de France.

– 13 offshore sites, and 5 onshore sites.

– Approximately 1600 valves online

– AMS ValveLink and DVC6000 on-line.

- DVC6000 SIS for partial stroke


Integrated with online maintenance management system

AlsoAlso F&G transmittersF&G transmittersAlsoAlso F&G transmittersF&G transmitters


Slide No: 30Emerson Confidential

21/09/2012

13

Smart Wireless in Projects Smart Wireless in Projects ––Offshore PlatformsOffshore PlatformsSmart Wireless in Projects Smart Wireless in Projects ––Offshore PlatformsOffshore Platforms Schedule Pain:

– Wireless is Flexible and Easy to change– Wireless enables Module

commissioning 6 to 8 weeks earlierg

Weight Pain: Wireless Transmitters reduces platform weight– 500 Devices = 12.5 Tonnes

Space Pain: Footprint Dramatically Reduced

Safety Pain: No Wiring and Cable trays in the Wellhead Area

Budget Pain:


Budget Pain:– No Infrastructure Required– Reduced Capital, Installation and Commissioning

Cost

Uptime Pain: Reduce unscheduled downtime on Major Platform Assets (Turbines, Compressors, Etc)

AgendaAgendaAgendaAgenda Introduction

Wireless Update

Standard Wi-FiIEEE 802.11

New Products

Forward Direction


IEEE 802.15.4

21/09/2012

14

A Broad Portfolio Has Been A Key A Broad Portfolio Has Been A Key Component To Rapid GrowthComponent To Rapid GrowthA Broad Portfolio Has Been A Key A Broad Portfolio Has Been A Key Component To Rapid GrowthComponent To Rapid Growth

6081 pHS t Wi l

Smart Wireless THUM Adapter

Hydrocarbon Leak Detection

648 Temperature

p

6081C C d ti it

Smart Wireless Gateway

781 Field Link

Wireless I/O Card for v11


4300 Series Position Monitor

CSI 9420 Vibration

702 Discrete

2160 Vibrating Fork Liquid Level Switch

3051S SeriesPressure, Level & Flow

848T Multi Input Temperature

Conductivity

Wireless Plant Network Capabilities

But Wait But Wait –– There’s More!There’s More!But Wait But Wait –– There’s More!There’s More!

SST Smart Wireless

Hydrocarbon Leak DetectionSummer 2011

SST Smart Wireless THUM Adapter

Now

Redundant Smart Wireless Gateway

Q3FY11

3051C/T PressureFY12

702 Discrete OutputSummer 2011

Pervasive Field

2051 PressureFY12

ROC & Control Wave Wireless I/O Card with

Field Link Roxar CorrLog


4300 Discrete Valve Output

FY12

248 TemperatureNow 848T With10V

AdapterNow

708 Rosemount Acoustic

Summer 2011

NetworkSummer 2011

1 Second UpdatesSummer 2011

Now Roxar CorrLogFY12

21/09/2012

15

Seamlessly integrated to system, same engineers,

same tools

Fully Redundant Wireless Allows Users to Fully Redundant Wireless Allows Users to Replace Wires for Critical ApplicationsReplace Wires for Critical ApplicationsFully Redundant Wireless Allows Users to Fully Redundant Wireless Allows Users to Replace Wires for Critical ApplicationsReplace Wires for Critical Applications

Redundant Smart Wireless Field Link

Redundant communications and power option

Redundant Wireless I/O and redundant power


Field Link (can be mounted in a Class 1

Div 1/ Zone 0)

Portable and Online Predictive Portable and Online Predictive Machinery HealthMachinery Health™™ Management SolutionsManagement SolutionsPortable and Online Predictive Portable and Online Predictive Machinery HealthMachinery Health™™ Management SolutionsManagement Solutions


21/09/2012

16

CSI 6500 Machinery Monitoring SystemCSI 6500 Machinery Monitoring SystemCSI 6500 Machinery Monitoring SystemCSI 6500 Machinery Monitoring System

Transient AnalysisPredictive DiagnosticsAPI 670Protection


Easy Integration

AMS Suite: Machinery Health ManagerAMS Suite: Machinery Health ManagerDiagnostic Diagnostic Analysis; orbit and transients Analysis; orbit and transients AMS Suite: Machinery Health ManagerAMS Suite: Machinery Health ManagerDiagnostic Diagnostic Analysis; orbit and transients Analysis; orbit and transients


21/09/2012

17

Scheduled Readings:Scheduled Readings:Overall Vibration & PeakVue OverallOverall Vibration & PeakVue OverallScheduled Readings:Scheduled Readings:Overall Vibration & PeakVue OverallOverall Vibration & PeakVue Overall

DeltaV /Ovation

AMS MachineryM

AMS DeviceM

32 14

Operator

1 2 3 4 5 6 7 8 9

Manager

WirelessGateway

Manager

.32 14

.32 14 Operator switches on

additional pump

Pump begins t it t


Scheduled

Overall: .32 in/sPeakVue: 14 g’s

On Demand

to cavitate

The two wireless vibrationtransmitters where first configured in field with correct The two wireless vibrationtransmitters where first configured in field with correct number for wireless gateway and 4 pcs join keys by use of Field Communicator 375. number for wireless gateway and 4 pcs join keys by use of Field Communicator 375. They then shows up in AMS Device Manager after ”rebuild Hierarchy”. They then shows up in AMS Device Manager after ”rebuild Hierarchy”.

The two wireless vibrationtransmitters where first configured in field with correct The two wireless vibrationtransmitters where first configured in field with correct number for wireless gateway and 4 pcs join keys by use of Field Communicator 375. number for wireless gateway and 4 pcs join keys by use of Field Communicator 375. They then shows up in AMS Device Manager after ”rebuild Hierarchy”. They then shows up in AMS Device Manager after ”rebuild Hierarchy”.


21/09/2012

18

AMS Machinery AMS Machinery Manager stores wireless Data, in addition to Manager stores wireless Data, in addition to offline and online Data.offline and online Data.AMS Machinery AMS Machinery Manager stores wireless Data, in addition to Manager stores wireless Data, in addition to offline and online Data.offline and online Data.

Action: Submit Request for

High resolution spectrum

High resolution waveform

Overall vibration trendq

Current Dataspectrum waveformvibration trend

High resolution PeakVue spectrum

High resolution PeakVue waveform

PeakVue vibration trend


Energy Band trends

Statoil Condition Monitoring Center, SandsliStatoil Condition Monitoring Center, SandsliStatoil Condition Monitoring Center, SandsliStatoil Condition Monitoring Center, Sandsli Offline vibration monitoring /analysis with 2-

channel CSI 2130– Best practice established

– Very efficient executionSite: multiple O&G

– Efficient maintenance driver

• Limits machine failure

• Repair when and where as necessary

Portable CSI XP32 32-channel– Same functionality as stationary CSI6500

– Used for temporary measurements of critical machines

– Njord anti-surge test compressor

– Statfjord compressor gearboxes

platforms

Scope: Machinery Health Manager

software Server XP32 32 - channel


– Gullfaks troubleshoot gas compressor

Machinery Health Manager software – Server(s) at Sandsli

– Remote access to XP32 on platform

– Store and analyze offline measurements

portable anayzer 6 pcs CSI 2130 2 -channel

analyzers Balancing kit Wireless vibration CSI9420

21/09/2012

19

AMS Suite with MHM onlineAMS Suite with MHM onlineAMS Suite with MHM onlineAMS Suite with MHM online Background

– Need to replace obsolete protection and prediction systems SKF PRISM4 and others

Scope14 CSI 6000 d 8 CSI 4500 l M hi

Norske Shell

Site: Norsk Shell Draugen – 14 pcs CSI 6000 and 8 pcs CSI 4500 plus Machinery Health Manager software

– Asset Portal and CSI 2130 vibration collector – Installation March 2010

Prosess equipment online– Crude Oil Booster Pump A and B– Crude Oil Loading Pump A and B– Booster Compressor – 1st, 2nd and 3rd Stage Compressors– Condensate Pump A and B

Site: Norsk Shell Draugen, Norway

Scope• AMS MHM On Line


– ABB Power Turbine A, B and C – Fire/Sea Water Pump A, B and C – Water Injection Booster Pump A and B– PWRI Booster Pump – 2 pc Water Injection Skids

• Asset Graphic• 14 pcs CSI 6000• 8 pcs CSI 4500

• Asset Portal• 1 pc 2130 collector

Shell Integrated OperationsShell Integrated Operations(Shell Draugen)(Shell Draugen)Shell Integrated OperationsShell Integrated Operations(Shell Draugen)(Shell Draugen)


Operation room linked to Draugen Platform systems & Operations

Video link to offshore for collaboration

Follow live startups using MHM from onshore

21/09/2012

20

Easy Integration of Online Machinery Protection Monitoring into DeltaV - Setup done in 3 stepsEasy Integration of Online Machinery Protection Monitoring into DeltaV - Setup done in 3 steps• Integration with DeltaV and Ovation process

automation systems

• AMS Machinery Manager Scans CSI 6500 hardware Integrated Machinery Protection –

MADE EASYCSI 6500 hardware

• Selects alarms and parameters

• Information can then be imported into DeltaV or Ovation

Integrated Machinery Protection –MADE EASY

3 steps!10 minutes

3) Import to DeltaV / Ovation

2) Select alarms & parameters

1) Scan CSI 6500 hardware

MADE EASY

Dynamos to build machinery graphics

Alarm Banner automatically populated

Machinery Health Faceplate as standard


Automatically create:– Control modules

– Mapping of control modules to designated controller

– Alarms and limits

Easy!

Thermodynamic Performance MonitoringThermodynamic Performance MonitoringThermodynamic Performance MonitoringThermodynamic Performance Monitoring


21/09/2012

21

MAXIMOSAP

CONNECTOR SERVICES

•Queries & Reporting

AMS Suite APM + AO Services

ORACLE

CONNECTOR

Other CMMS

SERVICES

• Recommendation Management •Asset Health Indicators

Historians

CONNECTOR/SERVICES

• AMS Analytics


Other Data Sources

AMS MachineryManager

AMS Performance Advisor/Monitor

CONNECTOR CONNECTOR CONNECTOR CONNECTOR

OPCXML

AMS DeviceManager

Modules offered or developed by Emerson, in addition to services and connectors.

Zero footprint client for Plant Management

Clients can be customized per user role


Intuitive Asset Dashboards Built In

21/09/2012

22

KPIs / DASHBOARD

0

10

20

30

40

50

60

70

80

90

100

KPIs / DASHBOARD

0

10

20

30

40

50

60

70

80

90

100 Management

PRODUCTION DATA, REAL TIME COST

PRODUCTION DATA, REAL TIME COST

RELIABILITY PLANNING / ROLLUP

RELIABILITY PLANNING / ROLLUP

Real Time Reliability System

Real Time Production System

ERP & work order system

Integration Operation with CBM data and Process DataIntegration Operation with CBM data and Process DataIntegration Operation with CBM data and Process DataIntegration Operation with CBM data and Process Data

Supervisors

Engineers

REAL TIME COST, INVENTORY,

OPTIMIZATION, ETC.

REAL TIME COST, INVENTORY,

OPTIMIZATION, ETC.

(OSI, ASPEN, etc.)(OSI, ASPEN, etc.)

DCS / PROCESS DATADCS / PROCESS DATA

(EMR, YEW, HON, etc.)(EMR, YEW, HON, etc.)

ROLLUPROLLUP

(Meridium, point solutions)(Meridium, point solutions)

ELECTRICAL

PLANT EQUIP

ROTATING

DEVICE& VALVE

Others AMS Suite

Production relevant alerts

Process data for analysis


TechniciansEQUIPMENT DATA / ALERTS

(Corrosion, vibration, temperature, diagnostics, etc.)

Mostly manual today

PROCESS MEASUREMENTS (P, T, L, F, etc.)

Wireless Plant reliability

Plant operations

Supported PROFIBUS DP DevicesSupported PROFIBUS DP DevicesSupported PROFIBUS DP DevicesSupported PROFIBUS DP Devices Devices included in AMS Device

Manager 11.5:

Control Techniques Commander SK

Siemens Simocode (ProV and ProC)

Micro Motion 2400S

Control Techniques Unidrive SP

Devices in the works:


Siemens MicroMaster

E+H devices (TBD)

Drehmo devices (TBD)

Asco devices (TBD)

21/09/2012

23

IEC 61850 AMS SuiteIEC 61850 AMS SuiteIEC 61850 AMS SuiteIEC 61850 AMS Suite

Asset HierarchyAsset name, icon, type, application launching/login info…


info…Alerts

Asset name, time, event type, event text, state

EventsAsset name, time, event type, event text

PlantWeb Services Ensure Maximum PlantWeb Services Ensure Maximum Value from Predictive IntelligenceValue from Predictive IntelligencePlantWeb Services Ensure Maximum PlantWeb Services Ensure Maximum Value from Predictive IntelligenceValue from Predictive IntelligenceNew Facility /

ProgramExisting Facility / Program

Setup andConfiguration

Optimize Alerts

Generate Planned Work

BusinessObjectives


Training Written Procedures

Quantify Results

FormalizeMaintenance

Strategy

21/09/2012

24

PlantPlant--Wide Asset OptimizationWide Asset OptimizationMonitoring & Integration Monitoring & Integration –– Emerson 4P StrategyEmerson 4P StrategyPlantPlant--Wide Asset OptimizationWide Asset OptimizationMonitoring & Integration Monitoring & Integration –– Emerson 4P StrategyEmerson 4P Strategy

AMS:AMS:MachineryMachineryHealth ManagerHealth Manager

AMS: Asset Performance ManagementAMS: Asset Performance Management

CMMSCMMS

AMS: AMS: Performance Performance AdvisorAdvisor

AMS:AMS:IntelligentIntelligentDevice ManagerDevice Manager

AMS SUITE: ASSET GRAPHICS …

PREDICTIONPREDICTION

PlantHistorian

PERFORMANCE PERFORMANCE

PROTECTIONPROTECTIONAPI /TSI

SMARTWIRELESSGATEWAY

OPCOPC

WorkWorkOrdersOrders

MAINT. MAINT. ActionsActions

Instrument,Valves &Drives

CRITICAL MACHINESCRITICAL MACHINES

MODBUS

BALANCE OF PLANT (Monitoring)BALANCE OF PLANT (Monitoring)ESSENTIALESSENTIAL IMPORTANTIMPORTANT SECONDARYSECONDARY

Existing Protection Sys

PROCESSPROCESSCONTROLCONTROL

Asset Optimization Services: DESIGN, INSTALL, IMPLEMENT, INCORPORATE, SUSTAIN

Field Devices are Strategic Assets That Drive Field Devices are Strategic Assets That Drive Better Business ResultsBetter Business ResultsField Devices are Strategic Assets That Drive Field Devices are Strategic Assets That Drive Better Business ResultsBetter Business Results

Superior field devices provide Superior field devices provide

better information for better better information for better

b siness res ltsb siness res ltsbusiness resultsbusiness results


Asset Management Asset Management -- The Emersonhe Emerson · PDF fileAsset Management Asset...

Documents

Transcript of Asset Management Asset Management -- The Emersonhe Emerson · PDF fileAsset Management Asset...