opexadvantages + asset optimization · opex advantages + asset optimization db slide 20 2009.12...

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Slide 1

2009.12

OpEx Advantages + Asset Optimization

Dominik Brand

Manager FOUNDATION Fieldbus

Endress+Hauser Process Solutions AG.


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Slide 2

2009.12

CapEx / OpEx savings and life cycle phases

�Use of an open standard technology

�Reduction in cost for wiring, barrier, marshalling

rack and Junction box

�Reduction in cost for control system - I/O

interface

�Reduction in cost for power supply unit and

number of cabinets

�Reduction in control room size

�Engineering and documentation

�Fast commissioning, lower start-up costs

FAT,SAT, Commissioning

Renewal

Operation

Maintenance

InstallationDesign

OPEX SavingsCAPEX Savings

�Use of an open standard technology

�Increased information for better operation,

accuracy of measurement & control

�Enhancement in control function and the

performance

�Improved throughput

�On-line diagnosis enables true preventive

maintenance

�Improved trouble shooting


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Slide 3

2009.12

Increase Plant Availability


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Slide 4

2009.12

Where are the OpEx savings ?

Operation and Production Costs

Additional production time by:

� Improved maintenance for:

� Fewer process upsets

� High availability

� Easier and faster incremental expansion

Improved throughput by:

� Improved quality and productivity

� Improved Alert capabilities for better operation

� Improved accuracy of measurement and control

� Data access for Business Intelligence


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Slide 5

2009.12

Maintenance Costs

“Right time” or proactive maintenance to:

� Reduce unnecessary trip to plant

� Avoid failure instead of solve failure

� Reduce time to repair

� Root cause identification and elimination

� Reduce inventory cost

Infrastructure with:

� Centralized maintenance

� Centralized tooling and data management

Where are the OpEx savings ?


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Slide 6

2009.12

Operation and Production Costs


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Slide 7

2009.12

Control In the Field – Performance Benefits

� CIF provides superior reaction to deterministic

disturbance in the process

� Possible to synchronize data sampling and control

� Possible to reduces Latency effect in the control chain

� CIF provides enhanced process integrity


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Slide 8

2009.12

Reduced Variability

Pro

cess O

utp

ut

(%)

Time (s)

56

58

60

62


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Slide 9

2009.12

Tighter Loop Control

Control Limit

Manual

Digital

Digital

Analog

Analog

Pneumatic

Pneumatic

Manual

For fast process application:•Improvements in response time

of between 10% and 30 %

•Improvements in disturbance rejection of up to 20%


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Slide 10

2009.12

Migrate CIF progressively …. maximizing ROA !

Ethernet

Field

Controller

FF - H1

Pure CIF

Hybrid CIF

M

A

X

A

S

S

E

T

S

U

T

I

L

I

Z

A

T

I

O

N

DCSAdvanced Control


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Slide 11

2009.12

Maintenance Costs


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Slide 12

2009.12

Potential for improvements

Potential for Predictive Maintenance with Pressure Transmitters

0%

5%

10%

15%

20%

25%

30%

35%

Routine

check

No

Problem

Calibration

shift

Zero Off Plugged

lines

Failed

35%

28%

20%

6% 6% 4%

Shell Global

Solutions

63% of instrument maintenance labor results in no action taken

-> waste of resources


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Slide 13

2009.12

Potential for improvements

Maintenance today:

�63% of work orders generated for transmitters are unnecessary

either no problem or problem with other equipment

�75% of control valves removed from process lines did not require

removal

�50% of instrument tech’s time is spent on paperwork

2009.12

Equipment Monitoring in the Plant

Process Condition Monitoring• Devices• Functions

• Sub-processes

• Other key performance indicators

Field Device Condition Monitoring• Field Devices on different field

buses

Ft

FC

Ff

FC

LC

It is all about Diagnostic Information !

Machine Condition Monitoring• Condition Monitoring• Runnability Monitoring

• Oil lubrication Monitoring

Quality


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Slide 15

2009.12

Role Based Diagnostics

1

Asset ManagementMaintenance Station

Process ControlEngineering Station

Control Network

H1

Plant operators

Plant maintenance engineering


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Slide 16

2009.12

Maintenance Urgency – Wear Reserve


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Slide 17

2009.12

Maintenance Urgency – Wear Reserve

Warning

Alarm

Prediction of time

Before affecting the

process

Wear

reserve


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Slide 20

2009.12

Additional Key Improvements

� Centralized Tooling and Configuration data

� Easy back-up of the configuration data

� Easy audit trail and data management

� Easy update and migration of the Tooling

� Basis and fundament for real Asset Management

� Better Calibration Management

� Improved Management of the Installed Basis


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Slide 21

2009.12

Asset Optimization

inductive energy transmission

inductive signal transmission

Control Network

1 0 0 1 0 0 1

��

Asset Management Software

uses fieldbus

for Asset Optimization

Solutions

Digital Communicationfrom Sensor to

Asset Management


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Slide 22

2009.12

Asset Optimization – Asset Data Access

Control Network

Parameter access

via fieldbus for both

Transmitter and Sensor

to enable:

•Configuration

•Diagnostic


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Slide 23

2009.12

Asset Optimization – Calibration Mngt.

Control Network

•Manage complete life

cycle of a sensor

•Trace the calibration

and adjustment history

•Customized calibration

protocols are generated

automatically


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Slide 24

2009.12

Asset Optimization – Link to CMMS Level

Control Network

1 0 0 1 0 0 1

��

Internet

W@M

portal

CMMS


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Slide 25

2009.12

Business Intelligence - Managing Data


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Slide 26

2009.12

Questions ?

opexadvantages + asset optimization · opex advantages + asset optimization db slide 20 2009.12...

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