Asset Optimization uses CMMS Integration and DMS Calibration Integration to make information within the CMMS system and Meriam Process Technologies Device Management System (DMS) database software transparently accessible to users in the process control, maintenance, and calibration management system environments.
CMMS Integration establishes the link that removes the barrier to information exchange between the CMMS and the process control system environments. One of the issues that traditionally inhibits free interchange between these functional areas
is their different naming conventions: an asset often has one name in the operations environment and another in the maintenance environment. This is because these systems have vastly different focuses, purposes, and needs that their naming conventions must satisfy. CMMS Integration removes these barriers by pointing to the right context, regardless of the naming convention.
CMMS Integration brings maintenance management to the operator environment to give a single window interface for multiple systems. Context menus on process graphics, the Alarm and Event List, etc. provide access to several views and actions for the specific CMMS item. This allows plant personnel to collect, compare, and monitor field device data to accurately assess equipment conditions in real time.
The 800xA System supports two CMMS:
• Maximo Integration on page 47.
• SAP/PM Integration on page 56.
The supported functionality varies between Maximo Integration and SAP/PM Integration.
Maximo Integration
Maximo Integration includes a Maximo Equipment ID aspect, a Maximo
Credentials aspect, and CMMS Views aspects. The Fault Report Submitter aspect, which is part of the Asset Optimization Server system extension, makes it possible to submit Fault Reports to the Maximo and DMS systems.
The Maximo Equipment ID provides information for mapping the 800xA System object to the Maximo equipment in the CMMS database for a particular Maximo Server. Multiple Maximo Equipment IDs can be associated with the same asset, thus providing the ability to map to more than one piece of equipment defined in Maximo.
Maximo Credentials contains the Maximo user credentials used to access the Maximo Server by the specific 800xA user.
The CMMS Views consist of the following:
• Active Work Orders View.
• Work Order History View.
• Equipment Status View.
• Preventive Maintenance Schedule View.
• Spare Parts/Availability of Spare Parts Views.
• Maximo Portal Views. For every entry in the CMMS view, it is possible to navigate to related Maximo portal view. The Maximo portal view is a web view that allows direct interaction with the Maximo data if the user has appropriate rights. Change to the data is possible.
The Fault Report Submitter consists of the following:
• Create Fault Report Form/Submit Fault Report.
• Fault Report Viewer/Submit Fault Report.
Active Work Orders View
The Active Work Orders view lists all active Work Orders in the CMMS for a particular asset or group of assets. Figure 5 shows the 800xA System Active Work Orders view. Clicking a column header sorts the list with respect to that header topic.
The CMMS views shown here consist of 800xA System views and Maximo portal views. The supporting text indicates which type of view is being shown.
The Maximo portal views consist of views from Maximo 4.1.1 and Maximo 5.1 to show the compatibility of Maximo Integration with several Maximo versions.
When different, the figure caption indicates which version of Maximo generated the view.
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Figure 5. 800xA System Active Work Orders View (Maximo Integration)
The Work Order column contains links to the CMMS. Clicking on a link opens a portal that contains a CMMS view of the selected Work Order (Figure 6).
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Figure 6. Maximo 5.1 Active Work Order Portal
Work Order History View
The Work Order History view lists the history of all Work Orders in the CMMS for a particular asset or group of assets. Figure 7 shows the 800xA System Work Order History view. Clicking a column header sorts the list with respect to that header topic.
The Work Order column contains links to the CMMS. Clicking on a link opens a portal that contains a CMMS view of the selected Work Order (Figure 8).
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Figure 7. 800xA System Work Order History View (Maximo Integration)
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Figure 8. Maximo 4.1.1 Work Order History Portal
Equipment Status View
The Equipment Status view allows viewing of data returned from a status assessment of an asset or group of assets.
Figure 9 shows the 800xA System Equipment Status view. Clicking a column header sorts the list with respect to that header topic.
Preventive Maintenance Schedule View
The Preventive Maintenance Schedule view lists the preventive maintenance schedule for an asset or group of assets. Figure 10 shows the 800xA System Preventive Maintenance Schedule view. Clicking a column header sorts the list with respect to that header topic.
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Figure 9. 800xA System Equipment Status View (Maximo Integration)
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Figure 10. 800xA System Preventive Maintenance Schedule View (Maximo Integration)
Spare Parts/Availability of Spare Parts Views
The Spare Parts view lists spare parts in the CMMS for a particular asset or group of assets. Figure 11 shows the 800xA System Spare Parts view. Clicking a column header sorts the list with respect to that header topic. The Item Number column contains links to the Availability of Spare Parts view that shows the location, quantity available, measurement unit, and cost of the selected spare part. Clicking on a link produces an Availability of Spare Parts view such as the one shown in Figure 12. Clicking a column header sorts the list with respect to that header topic.
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Figure 11. 800xA System Spare Parts View (Maximo Integration)
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Figure 12. 800xA System Availability of Spare Parts View (Maximo Integration)
Create Fault Report Form/Submit Fault Report
These functions are made possible by the Fault Report Submitter. The Create Fault Report Form makes it possible to create a new Fault Report for the selected asset without an Asset Condition Document (ACD) being generated by an Asset Monitor.
After filling in the fields with the appropriate information and clicking Submit Fault Report, the Submit Status: field indicates whether or not submission of the Fault Report succeeds. If it is unsuccessful, an error message will appear in the Submit Status: field. Upon successful submission, a Work Order is created in the CMMS. There are three different Create Fault Report Forms: one for submission to the Maximo system only, one for submission to the DMS system only, and one for submission to both systems. The form that comes up depends on the configuration of your system. The example in Figure 13 shows the Create Fault Report Form for submission to both systems.
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Figure 13. Create Fault Report Form (for Submission to Maximo and DMS Systems)
Fault Report Viewer/Submit Fault Report
These functions are made possible by the Fault Report Submitter. When an Asset Monitor generates an ACD, a Fault Report is created automatically. The Fault Report Viewer (Figure 14) makes it possible to see all Fault Reports for a selected object.
The FR State column shows the status of Fault Reports at any instance in time.
Since Asset Monitors can report on multiple conditions for each asset, the FR State column can either be the current conditions of the asset, or the Most Severe
Unacknowledged (MSU) conditions of the asset. If a condition of lesser severity than the current condition is received, the new condition replaces the current condition which becomes the MSU. If a condition of greater severity than the current condition is received, the new condition replaces the current condition and the MSU is automatically dismissed. If there is no current condition Fault Report, the asset is normal or has bad (or uncertain) quality.
The Dismiss after successful submittal check box in the Submit Fault Report view is a configurable option. If it is unchecked, the Fault Report is retained with a Fault Report status of submitted. It can be dismissed later or automatically replaced with subsequent Fault Reports.
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Figure 14. Fault Report Viewer
Right-clicking anywhere in a Fault Report row produces a context menu with the option to dismiss the Fault Report or submit it. Selecting Dismiss deletes the selected Fault Report from the Asset Optimization system. It also acknowledges the alarm in the Alarm and Event List.
Selecting Submit launches the Submit Fault Report view. There are three different Submit Fault Report views: one for submission to the Maximo system only, one for submission to the DMS system only, and one for submission to both systems. The view that comes up depends on the configuration of your system. The example in Figure 15 shows the Submit Fault Report View for submission to both systems.
This function will not acknowledge alarms in Process Portal B (refer to 800xA - Asset Optimization for Process Portal B on page 69).
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Figure 15. Submit Fault Report View (for Submission to Maximo and DMS Systems)
SAP/PM Integration
SAP/PM Integration includes a SAP Equipment ID aspect, a SAP Credentials aspect, and CMMS Views aspects. The Fault Report Submitter aspect, which is part of the Asset Optimization Server system extension, makes it possible to submit Fault Reports to the SAP/PM and DMS systems.
The SAP Equipment ID provides information for mapping the 800xA System object to the SAP/PM equipment in the CMMS database for a particular SAP/PM Server.
Multiple SAP Equipment IDs can be associated with the same asset, thus providing the ability to map to more than one piece of equipment defined in SAP/PM.
SAP Credentials contains the SAP/PM user credentials used to access the SAP/PM Server by the specific 800xA user.
The CMMS Views consist of the following:
• Active Work Orders View.
• Work Order History View.
• Equipment Status View.
• Preventive Maintenance Schedule View.
The Fault Report Submitter consists of the following:
• Create Fault Report Form/Submit Fault Report.
• Fault Report Viewer/Submit Fault Report.
Active Work Orders View
The Active Work Orders view lists all active Work Orders in the CMMS for a particular asset or group of assets.
The CMMS views shown here consist of 800xA System views.
Figure 16 shows the 800xA System Active Work Orders view. Clicking a column header sorts the list with respect to that header topic.
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Figure 16. 800xA System Active Work Orders View (SAP/PM Integration)
Work Order History View
The Work Order History view lists the history of all Work Orders in the CMMS for a particular asset or group of assets. Figure 17 shows the 800xA System Work Order History view. Clicking a column header sorts the list with respect to that header topic.
Equipment Status View
The Equipment Status view allows viewing of data returned from a status assessment of an asset or group of assets. Figure 18 shows the 800xA System Equipment Status view. Clicking a column header sorts the list with respect to that header topic.
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Figure 17. 800xA System Work Order History View (SAP/PM Integration)
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Figure 18. 800xA System Equipment Status View (SAP/PM Integration)
Preventive Maintenance Schedule View
The Preventive Maintenance Schedule view lists the preventive maintenance schedule for an asset or group of assets. Figure 19 shows the 800xA System Preventive Maintenance Schedule view. Clicking a column header sorts the list with respect to that header topic.
Create Fault Report Form/Submit Fault Report
These functions are made possible by the Fault Report Submitter. The Create Fault Report Form makes it possible to create a new Fault Report for the selected asset without an Asset Condition Document (ACD) being generated by an Asset Monitor.
After filling in the fields with the appropriate information and clicking Submit Fault Report, the Submit Status: field indicates whether or not submission of the Fault Report succeeds. If it is unsuccessful, an error message will appear in the Submit Status: field. Upon successful submission, a Work Order is created in the CMMS.
There are three different Create Fault Report Forms: one for submission to the SAP/PM system only, one for submission to the DMS system only, and one for submission to both systems. The form that comes up depends on the configuration of your system.
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Figure 19. 800xA System Preventive Maintenance Schedule View (SAP/PM Integration)
Fault Report Viewer/Submit Fault Report
These functions are made possible by the Fault Report Submitter. When an Asset Monitor generates an ACD, a Fault Report is created automatically. The Fault Report Viewer (Figure 20) makes it possible to see all Fault Reports for a selected object.
The FR State column shows the status of Fault Reports at any instance in time.
Since Asset Monitors can report on multiple conditions for each asset, the FR State column can either be the current conditions of the asset, or the Most Severe
Unacknowledged (MSU) conditions of the asset. If a condition of lesser severity than the current condition is received, the new condition replaces the current condition which becomes the MSU. If a condition of greater severity than the current condition is received, the new condition replaces the current condition and the MSU is automatically dismissed. If there is no current condition Fault Report, the asset is normal or has bad (or uncertain) quality.
The Dismiss after successful submittal check box in the Submit Fault Report view is a configurable option. If it is unchecked, the Fault Report is retained with a Fault Report status of submitted. It can be dismissed later or automatically replaced with subsequent Fault Reports.
Right-clicking anywhere in a Fault Report row produces a context menu with the option to dismiss the Fault Report or submit it. Selecting Dismiss deletes the
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Figure 20. Fault Report Viewer
selected Fault Report from the Asset Optimization system. It also acknowledges the alarm in the Alarm and Event List.
Selecting Submit launches the Submit Fault Report view. There are three different Submit Fault Report views: one for submission to the SAP/PM system only, one for submission to the DMS system only, and one for submission to both systems. The view that comes up depends on the configuration of your system. The example in Figure 21 shows the Submit Fault Report View for submission to both systems.
This function will not acknowledge alarms in Process Portal B (refer to 800xA - Asset Optimization for Process Portal B on page 69).
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Figure 21. Submit Fault Report View (for Submission to SAP/PM and DMS Systems)
DMS Calibration Integration
Calibration management is an important facet of the plant maintenance strategy. By streamlining calibration workflow, quality of the process/product is improved while cost is reduced. In many cases, calibration is a manual operation that is scheduled haphazardly, through trial and error. Assessing field device data to determine the optimal schedule eliminates problems of late or unnecessary calibrations.
Information such as historical data, fault analysis, process analysis, and the calibration strategy can be used to create a calibration trigger, which initiates a calibration Work Order. A Work Order can be sent to a CMMS and the Fault Report Submitter supports an interface into DMS Calibration Integration (refer to Figure 15 and Figure 21).
DMS Calibration Integration brings a calibration management solution, for HART or conventional 4-20 mA devices, to the operator environment by integrating Meriam Process Technologies Device Management System (DMS) database software with Asset Optimization. It provides a single window interface to DMS as the DMS aspect system supports calling DMS driven aspects from different objects within the 800xA System. It manages data exchange between DMS and the 800xA System for items such as alarms, synchronization of topology, device instances, and device specific parameters needed for calibration.
Usually Fieldbus Builder PROFIBUS/HART manages and owns the HART device configuration. All device parameters that are needed in the DMS system and the MFT to run a calibration procedure are stored in the 800xA System and are
propagated into the DMS system. DMS does not store configuration information for those devices. Device configuration data from the MFT or the MFC is not loaded back into the DMS system or the 800xA System.
If the configuration of the HART device is not managed by Fieldbus Builder, the DMS system owns the device configuration and stores the data. Device
configuration data from the MFT or MFC can be loaded back into the DMS system.
The device information will not be available as a property in the 800xA System.
DMS Calibration Integration allows plant personnel to monitor field devices for calibration information and opens the workflow towards the CMMS. Work orders required for calibration procedures are submitted to either the DMS system only, or the DMS system and CMMS (if Maximo or SAP Connectivity system extension is installed) using the Fault Report Submitter.
DMS Calibration Integration supports:
• Calibration Administration (DMS).
– Classification of devices and descriptions of general calibration procedures for different device types.
– Calibration schedule for devices in a plant.
– Calibration history and reports per device.
– Calculation of device specific calibration steps depending on device specific parameterization.
– Generation of Work Orders and instructions for devices due for calibration.
• Calibration process in the field with a hand-held calibrator and HART communicator:
– Providing a device TAG specific instruction list for calibration.
– Logging of all executed steps for documentation purposes.
– Generation of the precise signals required to calibrate the device.
– Device trim to bring the device into calibration limits.
– Reporting of the results.
• Calibration Condition Monitoring.
– Notification of device due or overdue for calibration. This condition participates in the Asset Condition Reporting infrastructure.
DMS Calibration Integration consists of the DMS aspect system. It contains the following:
• DMS Division Aspect.
• DMS Aspect.
• DMS Asset Monitor Aspect.
• Parameter Mapping Aspect.
• Calibration Event List Aspect.
DMS Division Aspect
A DMS Division is a high level entity used to group related devices. A DMS Division can be as small as a single device or as large as the entire enterprise. DMS Calibration Integration allows for the mapping of one or more DMS Divisions into 800xA Object Structures. The 800xA System connects on only one DMS server.
Typically one DMS Division is mapped to an 800xA object representing the Control Network in the Control Structure. When the DMS Division aspect is created in the
800xA System, it connects to a corresponding DMS Division in the DMS system (if it is not already connected to another 800xA System object) or creates and connects to one if the corresponding DMS Division is not already there. By default, the DMS Division name is the same as the 800xA System object name.
DMS Aspect
One DMS aspect represents one device belonging to the DMS Division. This aspect allows the DMS Workplace pointing to that device to be opened from the 800xA System (Figure 22).
DMS Asset Monitor Aspect
The DMS Asset Monitor provides notification in the 800xA System when DMS determines that there are devices due for calibration. DMS Asset Monitors are running in the external engine and rely upon the Meriam DMS server running. DMS
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Figure 22. DMS View
Asset Monitor data is served by the AO Server (in the same way as all other Asset Monitors).
Calibration Event List Aspect
The Calibration Event List displays the current status of the actions taken, such as unscheduled, scheduled, work in progress, approved, etc.
The Calibration Event List displays the current status of the actions taken, such as unscheduled, scheduled, work in progress, approved, etc.