Achieving a Higher Level of Maintenance and Reliability to Help You Increase Uptime

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Achieving a Higher Level of Maintenance and

Reliability to Help You Increase Uptime

Kris Dornan – PlantPAx Device Integration Manager, Rockwell Automation Tim Burchell – Regional Manager, Endress+Hauser

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PUBLIC INFORMATION 2

Helping You Increase Uptime

When a critical asset in a highly complex production system fails without warning, the cost in damage and downtime can be high, not to mention the potential risk to personnel and the environment. Asset reliability can be a competitive

business differentiator which causes many organizations to rethink how

they can leverage existing resources to improve the performance of their

critical assets. Learn how Endress+Hauser & Rockwell Automation can help

prevent and predict unplanned downtime

How We Can Help You Increase Uptime Asset Reliability User Cases & Capabilities Industry Challenges & Industry Study

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PUBLIC INFORMATION

Industry Challenges For the Next Decade

• Pressure on Efficiency and Reliability

• Shrinking Expertise in Workforce

• Aging Assets

• New Assets Increasing in Complexity

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Aberdeen Study

Findings

4  Many companies still

under economic

uncertainty; have held

up capital expenditures and lowered operational budgets

 When Survey asked what the top risk with biggest impact to

operations, the number

1 response was ‘Failure

of Critical Assets’

 How are business executives leading companies to avoid

costly downtime while

reducing maintenance costs?

“Predictive Maintenance is an approach that allows maintenance, quality and operational decision makers to predict when an asset needs maintenance, which changes unplanned downtime into a

planned stop and avoids costly disruptions.”

Best-in-Class outperformed RoA expectations by 20%

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Aberdeen Study

Takeaways 5  Best-in-class are implementing strategic actions to provide visibility of information

across various systems, plants & equipment lifecycle stages,

empowering

employees to make

better decisions.  Many companies

managing assets and maintenance through

predictive approaches

are enabling key resources to embed

asset analytics with business intelligence

for greater decision making processes.

“The use of predictive analytics and business intelligence is essential for a company to be successful in their predictive maintenance

endeavors.”

Best-in-Class performing 1.7% unscheduled

asset downtime

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Asset Management & Optimization

Leveraging Process/ Production systems

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Driving standardized processes within both asset management and process / production systems can be

a big business differentiator!

As you seek to achieve higher level maintenance and reliability to improve uptime:

 How will you be managing your most critical assets?

 Are you leveraging smart device information to drive predictive maintenance decisions?

 Are my networked devices running within known control limits and healthy?

 How am I tracking asset data?

 Will replacement parts meet required specifications?

 How much downtime is caused by parts issues?

 Do I have governing policies to manage asset change and alternative configurations?

 How can I culturally evolve maintenance program to be more predictive?

“Reliability is more than asset management and quality control. It’s a company-wide mindset that

never veers from the goal.” - Jeff Dudley, Dow Chemical

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PUBLIC INFORMATION 7

Taking a deeper dive with E+H and RA

Looking at how Asset Reliability drives business value, we want to explore...

• Endress+Hauser instrumentation/smart metering approach

• Rockwell Automation controls network/smart devices approach

How We Can Help You Increase Uptime

Asset Reliability User Cases & Capabilities

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User Case: Heartbeat Diagnostics

Heartbeat Diagnostic

• Continuous self monitoring • General health check

• Result:

Diagnostic events and remedy measures

• Benefits:

• Immediate availability of device status information

• Quick and safe decision in case of error by remedy information • Reduction of needed time in case of error

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Heartbeat Monitoring – Observation

• Continuous output of diagnostic parameters and diagnostic status events

influenced by process conditions

Heartbeat Monitoring Continuous output of diagnostic parameters

Slide 9

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-0.60 -0.40 -0.20 0.00 0.20 0.40 0.60 0 20 40 60 80 100 120 Deviation (pH)

Time Between Calibrations (Days)

In-Cell

Determination of Optimal Calibration Period

• Calibrations and maintenance must be brought in <90 days to stay within operating

parameters

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Data Analysis: Operating within Control Limits

• Redundant sensors behaving similar in same application environment.

Control limits can be set by loop and viewed over multiple time horizons.

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• Components of Analysis

Data Analysis – Caustic Loops

• Quickly Diagnosed and Detected Clogged Filter – Improved

Process Uptime

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Total Program Performance

0 20 40 60 80 100 120 140 160 180 JAN FEB _MA R APR _MA Y JUNE JULY AU G SEP _OC T NO V

DEC JAN FEB _MA

R APR _MA Y JUN JUL 2011 2012 PM Work Orders $200 $400 $600 $800 $1,000

Pre Program 2012 Current

Electrode Costs ($/Loop)

0 5 10 15 20 25 30 JAN FEB _MA R APR _MA Y JUNE JULY AU G SEP _OC T NO V

DEC JAN FEB _MA

R APR _MA Y JUN JUL 2011 2012 Sensor Failures 0 2 4 6 8 10 12 14 16 JAN FEB _MA R APR _MA Y JUNE JULY AU G SEP _OC T NO V

DEC JAN FEB _MA

R

APR _MA

Y

JUN JUL

2011 2012

UnScheduled Work Orders

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Reliability Program Milestones

• No safety incidents at either of the hub locations! (Hub #1 - 4295/ Hub #2 - 5321, safe man hours for 2013 through September)

• Electrolyzer Six Sigma study – exceeded expectations with 1.13

sigma improvement compared to the 1.00 sigma target ($300K/yr)

• Additional analysis increases related savings to $3.5MM/yr

- decreases chlorate impurities in the product

- debottlenecks downstream chlorine recovery system

- reduction of treatment chemicals used (caustic/sodium bisulfite)

• Additional yield of chlorine and energy cost savings also realized!

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Verification and Calibration of Flowmeters

On-site calibration

Factory calibration Workshop calibration

On-site control measurement

• Heartbeat

Verification on demand

• Control

measurement from the outside

• Mobile test rigs • Stationary

calibration facilities Effort Quality of T e sting Flowmeter functionality verification Calibration: Flow performance confirmation Slide 15

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Realizing a “Connected Enterprise”

-TOGETHER

16 Temperature Out of Range Sensor Diaphragm Broken Due for Calibration

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Joint Integration Office – Why?

Customer Concerns & Answers

TIME SAVINGS

• Faster Integration Time – Ongoing Savings of 34%

COST SAVINGS

• Reduces device integration costs by 68%, on average

Proven Customer Value

Key Deliverables

Faster Time to Market

• Through Increased Operator Efficiencies

Connected Enterprise

• Provided Through detailed information from E+H

Instrumentation connected to PlantPAx systems

• Installation – how to:

– Connect E+H

instruments to RA PlantPAx

• Configuration – how to:

– Configure network

interface

– Configure instrument

• Visualization

– Faceplates for Smart

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