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Confidential & Proprietary.
What is Condition Manager (CM)?
An easy to use, rules-based asset condition
manager that intelligently and automatically raises
alerts to actual or potential problems.
Confidential & Proprietary.
Why Condition Based Maintenance? Allows organizations to move beyond simple calendar based maintenance
Moving From Re-active to Pro-active Operations
Maximize Reliability and Availability, Balanced with Utilization while managing complexity
Managing the huge number of devices and assets from many different suppliers
Building and maintaining operations expertise as workforce ages
Provide Collaboration environment for Operations and Maintenance
Empowers operators by providing the ability to track maintenance activity associated with an asset
Increases asset availability by reducing unplanned downtime
Confidential & Proprietary.
Can we predict the failures? 25% are preventable but not prevented because of an arbitrary decision that is simply
not rooted in knowledge or experience.
15% are predictable but not predicted.
20% are predicted but not stopped to undertake repair.
25% are predicted and equipment is shut down.
14% are other (consequential to an external activity).
1% are neither preventable nor predictable.
Machines don’t Die we kill them.
Source HPI 2011:- 91% of bearings do not reach their conservative design life.
Confidential & Proprietary.
Machines Don’t Die, we kill them
Causes of Process Upsets
HumanErrorEquipmentFailureOther
Causes of Equipment Failure
Operating out ofrange
Improper design
Impropermaintenance
2% 2%
No Defect Found Improper Installation Improper material
76%
10%
5% 5%
40%
40%
20%
Source ASM Consortium Presented by N Koseric at 2005 Defect Elimination Conference
Confidential & Proprietary.
User Confirmation “Automated Eyeballs. Instead of wasting an engineer’s time reviewing charts, that engineer is freed-up to do other tasks”
“You can have CM create a Work Request well ahead of anyone noticing the change”
“CM is a tool that provides a very cost effective way to optimize Preventative Maintenance programs. Through its creative application we have improved reliability and avoided costly emergencies”
“The Preventative Maintenance Optimization alone provides enough savings to pay for the CM implementation”
“The value proposition is in the early detection of change, well ahead of any problem. You can plan, schedule and in some cases budget for the problem”
“You own the problem, instead of the problem owning your operation”
Confidential & Proprietary.
Think of Condition Manager in Three Simple Stages
Collect Data Sources include OPC, Process Historians, Asset Performance Models, and ODBC (Open Database Connectivity) for MSSQL, Oracle, Access, Excel etc.
Analyze Single to multi-variable rules based engine, simple and complex expressions, advanced statistical control (Western Electric Rules with standard deviation capability), thresholds, etc.
Act Automatic generation of Work Orders, Work Requests,
Equipment Activity Records, E-Mails & Text, Wonderware Skelta BPM orchestration, etc.
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Collect
●Device/instrument reading examples: ●Fluid / Vibration analysis ●Pressure / Temperature / Flow ●Current / Voltage / Power ●Device Status / Diagnostics ● Loop tuning ●Operational Hours
Confidential & Proprietary.
CM Data Sources Analyzes real-time data from leading plant floor systems ●Standard OPC client interface simplifies integration
with other advanced monitoring technology ●Plant Historians (ie. Wonderware Historian, Foxboro
AIM*AT) ●Modeling Engines ● Instrumentation Management/Monitoring Solutions ●ODBC Database Access
Confidential & Proprietary.
ODBC Data Source
●A standard database access method designed to make it possible to access any data from any application, regardless of which database management system is handling the data.
●Allows Condition Manager to be used for offline or manually inputted data collected during inspection rounds.
●By setting up an ODBC connection to the Avantis database, statistic readings or other Avantis metrics can be included as part of a new condition.
Confidential & Proprietary.
ODBC Example – Offline Assets
ODBC
IntelaTrac Database
Condition Manager
{ • Work Requests • Work Orders • Notifications • Workflow
Collect Readings
Analyze Rules
Confidential & Proprietary.
Analyze
●Monitor applies rules previously established in CM ●Data is collected from RTP’s at time intervals as defined in rule ●Collected data is analyzed according to rule ●Determines if action should be carried out in EAM
Confidential & Proprietary.
Analyze - Variables
●Single or multiple variables ●AND/OR flexibility
●Analysis/result can be based on single or multiple readings, e.g. ●Mean, Average, Frequency within time period, etc.
●Flexible definition of frequency of scanning RTP points and updating EAM
Confidential & Proprietary.
Lubrication based on motor run-time. (after 3,000h create a Lubrication activity requesting Lubricant
from the Warehouse, with operations providing the resource)
Monitor the Motor Bearing Temperature. (If exceeded create a WO bearing replacement)
Compare Pump Power consumption with Volume Flowrate to
detect mechanical degradation of pump (highlighted by excessive power consumption for know pumping
capacities) Compare Temperature, Vibration, Density, RPM etc to detect
mechanical degridation.
Analyze with Condition Manager CM is able to monitor and aggregate more then one Real Time Point (RTP) from different sources.
Confidential & Proprietary.
Act – Possible Results
● Notification ● E-mail ● Pager/Cell Phone
● Call another function ● Record last activity date (EFS data source) ● Initiate workflow using Biztalk (Maximo and SAP)
● Auto creation of activity in Avantis.PRO or Asset Registry ● Create statistic type ● Record statistic reading ● Generate Work Request ● Generate Work Order ● Generate Equipment Activity Record
Confidential & Proprietary.
Adoption of ArchestrA Service Bus (ASB)
● ASB provides a common set of services (ArchestrA Services) to exchange information with other Schneider Electric software applications, as well as external systems…
Wonderware InTouch
Wonderware AppServer
Wonderware Historian
Avantis.CM Wonderware Intelligence
Wonderware Skelta BPM
External Systems
ArchestrA Service Bus (runtime data, history, events, browse, …)
ArchestrA Services
Confidential & Proprietary.
Adoption of ArchestrA Service Bus (ASB)
● Avantis. CM v3.1 has adopted “ArchestrA Event Services”… and uses this service to publish monitoring events (e.g. inlet temperature has exceeded 30 degC), as well as CM actions (e.g. work request 123 created)
● Other “ASB-aware” applications can consume events published by CM and take action
Confidential & Proprietary.
Conclusions… Condition Management Challenges ● Allows organizations to move beyond simple calendar based maintenance
● Moving From Re-active to Pro-active Operations
● Maximize Reliability and Availability, Balanced with Utilization while managing complexity
● Managing the huge number of devices and assets from many different suppliers
● Increase Manpower efficiency by exception-based reporting and automation of data analysis
● Provide Collaboration environment for Operations and Maintenance
● Interval extension or reduction in PM leading to higher availability
● Reduce catastrophic failures to minor repairs by catching problems early
Confidential & Proprietary.
Avantis.PRO: Entities
●Equipment and plant devices are represented as "Entities" in Asset Registry
●These rich documents allow users to view all pertinent information about an asset.
●Other files can also be attached.
Confidential & Proprietary.
Avantis.PRO: Statistics
●Statistics in the Asset Registry have a checkbox that denotes that the stat is used in a Real-Time Integration
●Only Entities with the appropriate statistics will be listed in the CM Configurator
●Only statistics defined in this manner will be listed
Confidential & Proprietary.
CM Configurator ●The CM Configurator is used to associate Real Time Points, Models
and Intelligent Devices with Entities in the Asset Registry for the purpose of generating notifications.
Runtime Hours Starts & Stops
Device Status Device Parameters
Avantis Entity
Confidential & Proprietary.
Configuring an Association
●Drag & drop a source of data to an Avantis Statistic ●A simple wizard based user interface guides you through the
configuration process.
Confidential & Proprietary.
Step 1 – Define the Association ●Select a unique name for the
association ● If creating a new statistic,
enter the type (counter, meter, gauge)
●Optionally, select a previously created template to use for this association
●Optionally configure historization for runtime values (AIM* or ODBC)
Confidential & Proprietary.
Step 2 – Define the Statistic ●Select a unit of measure to
be used by the statistic ●Default value type can be
overridden if required. ●Optionally, add a description
to be included with the posted statistic
●Description can include dynamic attributes
Confidential & Proprietary.
Step 3 – Select Triggering Options ●What values will we assess?
(Real, Absolute, Delta, Rolling Average)
●How often will we scan the data source?
●How often will Avantis.PRO be updated?
●Select a Rule that will be used to trigger maintenance events
Confidential & Proprietary.
Step 4 – Define the Condition ●Meter Reading ●Thresholds ●Simple Expressions ●Western Electric Rules ●User Defined Expressions ●More…
●Define the Statistic
Generation Rule (min, max, avg, count, etc…)
Confidential & Proprietary.
Step 4 – Define the Condition ●Meter Reading ●Thresholds ●Simple Expressions ●Western Electric Rules ●User Defined Expressions ●More…
●Define the Statistic
Generation Rule (min, max, avg, count, etc…)
Confidential & Proprietary.
Step 4 – Define the Condition ●Meter Reading ●Thresholds ●Simple Expressions ●Western Electric Rules ●User Defined Expressions ●More…
●Define the Statistic
Generation Rule (min, max, avg, count, etc…)
Confidential & Proprietary.
Step 4 – Define the Condition ●Meter Reading ●Thresholds ●Simple Expressions ●Western Electric Rules ●User Defined Expressions ●More…
●Define the Statistic
Generation Rule (min, max, avg, count, etc…)
Confidential & Proprietary.
Step 4 – Define the Condition ●Meter Reading ●Thresholds ●Simple Expressions ●Count Errors ●Western Electric Rules ●User Defined Expressions ●More…
●Define the Statistic
Generation Rule (min, max, avg, count, etc…)
Confidential & Proprietary.
Step 5 – Define the Action ●What to do when the
condition is triggered ● Work Orders ● Work Requests ● Equipment Activity Records ● BizTalk Orchestrations ● E-Mail Notifications
●Templates can be selected ●Description can include
dynamic attributes ●Re-issue Interval can be set