data-based maintenance: the killer app for iot

© Copyright 2016 OSIsoft, LLC 1

Data-Based Maintenance:

The Killer App of IIoTMichael Kanellos

Industry Champion, OSIsoft


Unplanned Downtime and Poor

Maintenance Cost Process Industries:

• 5% of their annual production

• $20 Billion in losses

• And 80% could have been

avoided

© Copyright 2016 OSIsoft, LLC

“A plant’s profitability is directly

proportional to the uptime of its

processes.”--Josh Lyon, Flowserve

3


So What Can You Do?


We Believe People With Data Can Transform Their World


The PI System: Operational Data into Actionable Insight

6


The PI System At Work For Renewables

310,000 sources, 250 data

formats, 140+ locations

8

Across Multiple Industries

Saudi Aramco eBay California ISO


Data-Based Maintenance

The Old Way:

monitor and fix

The PI System Way:

monitor and predict

9


The Data-Based Maintenance

Hall of Fame


Staying Out of

the Cold

Syncrude estimates

that data-based

maintenance saves

$16.75 per hour per

truck, or $20 million

per year. The

PI System also

helped reduce the

risk of certain types

of injuries by 85%.


Detecting

Turbine

Trouble

Maintenance can

cost 15x more at

offshore wind farms.

By reducing boat

trips with remote

monitoring, Dong

Energy believes it

can save 20 million

Euros a year by

2020.


Mastering

the

High Seas

Through the

PI System, Petronas

collects real-time data

to monitor the health of

offshore platforms

remotely. No more

flying out IT on

helicopters. The

PI System prevented

five unplanned

shutdowns in the first

year.


Plugging the

Leaks

San Francisco

Public Utilities

Commission

predicts it will save

about 9,600 hours of

labor and reduce the

risk of accidental

discharge by

monitoring 100

critical pumps with

the PI System.


Getting Good

Vibrations

Flowserve gives

customers real-time

performance

insights through the

PI System. One

customer avoided

$630,000 in losses

when a welder’s

blanket almost

clogged a pump.


Keeping The

Lights “On:

FINGRID

implemented a real-

time condition

monitoring system

and they have

avoided major

transformers

failures and several

proactive SF6 leak

detections


Navigating

the Polar

Vortex

Columbia Pipeline

Group has saved $9.6

million since 2002 by

using the PI System to

help manage its

15,000 mile natural

gas network. The

PI System also helped

Columbia avoid

potential outages

during the 2014 Polar

Vortex.

data-based maintenance: the killer app for iot

Technology