OpEx Advantages +
Asset Optimization
Francois Ichtertz / Dominik Brand Manager FOUNDATION Fieldbus Endress+Hauser Process Solutions AG.
Panos Giannakoulias
Certified FF Systems Manager
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
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 Installation Design OPEX Savings CAPEX 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
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
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
Where are the OpEx savings ?
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
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
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
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 %
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Migrate CIF progressively …. maximizing ROA !
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
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
Potential for improvements
Maintenance today:
65% 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
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Role Based Diagnostics
1 Asset Management Maintenance Station Process Control Engineering Station Control Network H1 Plant operators
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Maintenance Urgency – Wear Reserve
Equipment Monitoring in the Plant
Process Condition Monitoring
•Devices
•Functions
•Sub-processes
•Other key performance indicators
Quality
Machine Condition Monitoring
•Condition Monitoring
•Runnability Monitoring
•Oil lubrication Monitoring
Field Device Performance Monitoring
•Field Devices on different field
buses Ft FC Ff FC LC
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Device Performance Monitoring (DPM)
Increase Maintenance Efficiency
Less trip to the plant
Improve general efficiency Improve security
Work is scheduled and proactive for a better quality and less unplanned shutdowns
Stop reactive firefighter actions and anticipate problems
Intensify collaboration between Operation and Maintenance
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
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
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 Communication
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Asset Optimization – Asset Data Access
Control Network
1 0 0 1 0 0 1
Parameter access via fieldbus for both Transmitter and Sensor to enable:
Asset Optimization – Calibration Mngt.
Control Network
1 0 0 1 0 0 1
•Manage complete life cycle of a sensor
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
Asset Optimization – Link to CMMS Level
© 1999 – 2007 Fieldbus Foundation
EMEA 2009
