Optimizing plant asset availability and performance

Rinc ->Topic FDT (Field Device Tool) DTM ( Device Type Manager) AO (Asset Optimization)

Industrial IT System 800xA

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Device Management & Device Integration

Continuous Productivity Improvements
Integrated system environment Freedom of choice Information availability Fieldbus solutions to meet all plant requirements
Plug and produce device integration Device Integration for
HART FOUNDATION Fieldbus PROFIBUS

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Intelligent Devices via Fieldbus is a Must

Process Industries worldwide require fieldbus based systems because of cost reduction
Reduction of wiring and cabinet costs Less system and instrumentation hardware Reduced commissioning time

Intelligent devices enable Asset Optimization

Increase of maintenance effectiveness Improves process availability Enhances productivity

Aventis says: Fieldbus technology saves costs and enables innovative applications. Future plant will be equipped with fieldbus
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Expectations on Fieldbus Technology

Industry proven and reliable High system availability through redundancy concepts Intrinsically safe solutions Seamlessly integrated into control system Access to device internal data
Process variables Time synchronization Status

Optimization

Engineering

Operations
0 7

Configuration Parameterization Commissioning Diagnosis Maintenance Calibration

Operation Display Alarm signals

Controller

Openness for all device manufacturers Easy to use

Field Devices

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International Standards
Efficient utilization of Fieldbus technology requires integration of 3rd party devices via open standards Major international protocol standards
HART, the intermediate step towards fieldbus PROFIBUS FOUNDATION Fieldbus

Device Integration
FDT Device Description Language

Data access for Operation and Asset Optimization via OPC

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Fieldbus and Field Device Configuration

Integrated fieldbus management tools and comprehensive Device Libraries for
Configuration of function block applications Device parameterization with graphical user interfaces Online and offline configuration

All devices accessible from a central workplace Early plausibility checks ensure proper and fast configuration

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Fieldbus and Field Device Commissioning

Commissioning of fieldbus networks
Address and channel assignment Network configuration and diagnosis Automatic generation of bus timing and schedule

Device configuration download Online Help functionality Display and modification of device parameters via parameter displays or Device Type Managers (DTM)

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Field Device Operator Interfaces

Device Type Managers

Easy navigation through the use of context-sensitive menus Graphic elements and status displays for specific field device functions. FF function block faceplates for
PID, AI, AO, MAI, DI, DO

DTM as graphical user interface for HART and PROFIBUS devices

Observe, diagnostics, parameterization, simulation, identification,
Faceplates

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Field Device Diagnostics

Detailed diagnostic functions for
Cyclic monitoring of field devices
Asset Monitors

Scheduled monitoring of asset health status Device and fieldbus status through Alarm and Event List Easy navigation to detailed device status information

Alarm and Event List

Simplifies loop checks of devices

Device Type Manager

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Change History
Process Event & Alarm History Calibration Changes Maintenance Event & Work Order History

Operator Changes

Configuration Changes

Audit List
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FDT for HART and PROFIBUS

Fieldbus Builder PROFIBUS/HART uses FDT/DTM technology to configure, operate and maintain devices
FDT frame = Fieldbus Builder P/H

FDT is an open, vendor independent interface for control systems FDT enables advanced diagnosis functionality FDT provides user friendly graphical user interface Support device management over life cycle (diagnostics, configuration, maintenance)

ABB and many other vendors support the FDT standard

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Device Management HART

Device Management HART includes:
Fieldbus management tool Fieldbus Builder P/H OPC Server HART providing field device variables and status information to asset optimization applications HART Device Library with preconfigured object types Object Types Basic HART DTM as universal application for devices without specific DTM
HART devices may also be integrated via DD (Device Description) technology ABB devices supplied with both DTM and DD

HART Multiplexer Connect

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Fieldbus Builder PROFIBUS/HART

Fieldbus Builder PROFIBUS/HART main tasks are:
Support of FDT 1.2 Interfaces Managing HART devices connected to local I/O or remote I/O Topology planning down to HART devices Assignment of HART devices to I/O channels DTM call up from clients Comparison of field device on- and off-line data Upload, download and commissioning Configuration of the OPC Server Support of bulk data handling (basic DTM)

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Basic HART DTM

Supports all HART devices without specific DTM Includes universal and common practice commands Graphical user interfaces for
Device identification Configuration and parameterization Observation Diagnostics Simulation

Interface for Audit Trail functionality On- and offline configuration of HART devices

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Device Specific DTM (overview)

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Device Specific DTM (info)

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Device specific DTM (configure)

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Device specific DTM (monitoring)

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Device specific DTM (live cycle)

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Device specific DTM (live cycle 2)

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Device specific DTM (diagnostics)

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Device specific DTM (offline test)

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Device specific DTM (calibration)

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Device specific DTM (advanced)

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Asset Optimization Overview

Introduction Overview
Asset Monitoring and Reporting CMMS Connectivity

Summary

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The Productivity Challenge

Traditional maintenance practices result in lower return on assets
Corrective and scheduled maintenance Instrument unavailability Inefficient work processes
35%

From a report by DuPont:

Maintenance is today the largest single controllable expenditure in a plant In many plants, maintenance budget is about 2/3 of annual net profit

From a study by Dow Chemicals:

Cost of unnecessary maintenance is about the same size as plant profit

35% 30% 25% 20% 15% 10% 5% 0%

Routine check No Problem

63% of maintenance labor results in no action!!

28%

20%

Potential for Predictive Maintenance with pressure transmitters 6% 6% 4%

From a series of ARC Insights:

Plant Asset Management systems providing real-time asset performance information to operations and maintenance increase Return on Assets (ROA), leading to operational excellence.

Calibration shift

Zero Off

Plugged lines

Failed

Source: Shell Global Solutions

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Maintenance Practices
Reactive
Fix on failure

Preventative
Maintain on a schedule

Predictive
Maintain when conditions detected

Reliability Centered
Apply the appropriate technique based upon the role of the asset, safety, criticality

Proactive
Evolution towards cross functional teams comprised of Operations, Process and Maintenance personnel

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Reactive Maintenance
Fix on Failure Expensive when considering
productivity impacts unplanned downtime secondary failures
Partial shut-down

Throughput

Lost opportunity
Plant upset

overtime costs

Startup

Shut-down

Leads to fire fighting mentality

Time

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Preventative Maintenance
Maintain on a schedule basis
12%-18% savings over Reactive Maintenance Avoid catastrophic failures Extend life of assets Wastes Resources by performing maintenance that may not yet be required Risk of inducing failures while maintaining a healthy asset Often requires more maintenance staff
Throughput

Lost opportunity
Plant upset Partial shut-down Startup Shut-down

Time

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Predictive Maintenance
Maintain on Condition
30%-40% savings over Reactive Maintenance 8%-12% savings over Preventative Maintenance Extend life of assets Preemptive Safer May require investment in condition monitoring equipment
Throughput

Lost opportunity
Plant upset Partial shut-down Startup Shut-down

Time

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Reliability Centered Maintenance (RCM)

Focus on criticality of equipment
Apply the technique that is appropriate based on the criticality of the equipment
BEP
Throughput

Lost opportunity
Plant upset Partial shut-down Startup Shut-down

Blend of maintenance techniques

Typical Reactive ~55% World Class <10% 25%-35% 45%-55%

Time

Preventative ~31% Predictive ~12%

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Traditional Operation and Maintenance

OCS
CMMS / Calibration Systems

Operations

Maintenance

In a typical day, maintenance will spend an additional 40% of its time investigating root cause of problems

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Real-Time Plant Asset Management (PAM) system

OCS Asset Condition Reporting System
CMMS / Calibration Systems

Operations Operations

Maintenance Maintenance

Extended Automation System 800xA

Advanced Process Performance Assessment

Field Devices

Asset Health Assessment

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Asset Optimization
Complete asset optimization for:
automation devices plant infrastructure plant equipment production processes

Real-time monitoring of asset health facilitate fast, reliable implementation of corrective measures Reporting and analysis visualization tools support root cause determination

Asset Monitoring and Reporting DMS Calibration Integration CMMS connectivity Remote access via web technology

Integrates a into single application view:

CMMS data Calibration system data Condition monitoring system data Control system data

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Asset Optimization
Incorporates industry standard evaluation processes
Key Performance Indicators (KPI)
Asset Monitors identify degrading performance before failure occurs

Root Cause Analysis (RCA)

Identifies performance problem and source

Supports Continuous Improvement Initiatives

Real-Time Performance Management (RPM) Total Productive Maintenance (TPM) Measurement, analysis, and improvement of business and maintenance practices to achieve full production potential

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Asset Monitoring and Reporting

The Advantage

Continuous Health Condition Monitoring for all all kinds kinds of of Plant Assets Assetsin inone onesystem system with root cause detection capabilities reported into single User Interface Interface.
Event driven reporting reduces preventive maintenance effort Same functionality for all assets reduces amount of different procedures Faster and precise fault detection reduces downtime Cost reduction due to improved maintenance tools

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Asset Monitoring and Reporting

The ABB Advantage
Oops! BAD! OK!

Scheduled Monitoring of Asset Health Status Smart and detailed Condition reporting Message distribution Electronic Record based fault report submitting
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Main Features
PC based application Scheduled execution of Asset Monitor Applications Analysis of Asset specific data according to implemented business rule Event driven generation of asset conditions
Reported into 800xA Alarm and Event System Animated System Structure View reports most severe Maintenance Condition Capability of condition forwarding to remote locations or paging devices Capability of electronic fault condition reporting into CMMS

Libraries with Asset Monitors for

Basic Asset functions Field Devices (HART, ProfiBus, Foundation Fieldbus) Electronic equipment PC and Network Equipment SDK for project and plant specific Assets

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What is an Asset Monitor?

Field Device Data ERP Data Production Personnel Data Automation System Data Real-time A$$et Information

Asset Monitor

Asset specific function block that verifies asset related input data according implemented maintenance and diagnostic rules Use real-time production and control data Keep score for the asset performance Correlation of data in asset context Provide visibility to big picture Transmit the information to those able to act
Other personnel Other systems
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Maintenance Workplace
Organizes and arranges asset information for maintenance personnel
Asset Group alarm bands

Maintenance personnel filters Asset Structure

Selected asset available aspects

Selected aspect viewing area

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Asset Viewer
Asset Tree provides quick identification of maintenance conditions Most severe problems are propagated up the tree

Asset Monitors identify severity of asset performance degradation

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Asset Reporter
Asset Reporter is a detailed view of all asset monitor conditions for a given asset

Condition details are available by rightclicking on the item of interest

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Electronic Fault Report Submittal

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Asset View and Report Remote Access (Thin Client)

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Remote Alarming to Key Plant Personnel

800xA messenging service sends messages with alarm information to preconfigured pagers, email accounts, and SMS/GSM devices Configurable user groups assign messages to specific individuals or groups Message handler allows specification of source and destination, time to wait for acknowledgement before resending, and number of attempts before changing destination Message scheduling allows configuration of times that each user receives message

01 ce i V-1 LC Serv f to Ou

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Asset Reports
Asset Reports give maintenance engineers comprehensive information to aid in every day decision making Play vital role in definition of proactive maintenance strategy AO standard reports include:
Asset Condition History Calibration Overview reports Running Time reports

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Asset Reports Asset Condition History

Lists all maintenance conditions for every asset in a given time period Counts the number of faults per condition Helps to identifies repeating offenders Highlights critical assets with high failure rates Helps define proactive maintenance strategy

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Asset Reports Calibration Overview

Lists all calibration events per device for a given time period Shows the current calibration state on top of the list Identifies the current calibration state for every device

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Asset Reports Running Time

Lists all assets in a structure with a Runtime Asset Monitor For a give time period, report will show:
Configured runtime limit Hours of operation Active limit Data of last asset monitor reset Calculate the remaining days of operation based on the current calculated average runtime rate
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CMMS Connectivity - Main Features

Combines Maintenance and Process Automation Provides Maintenance specific information for plant equipment on a Process Automation object Reduces paperwork and allows manual work order creation in process automation context Generates fault specific work orders in conjunction with Asset Monitoring

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CMMS Connectivity

The ABB Advantage

Increased operational efficiency, reduced time to repair: DCS
Streamlined work processes Paperwork elimination Single, electronic audit trail

Maximo
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CMMS Data Views

Active work orders Work order history Equipment status Preventive maintenance Spare parts Fault report submitter

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Portal to Native Maximo Environment

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View Active Work Orders

For a particular asset, an aspect summarizes all active work orders submitted in the Maximo system Work Order Number provides a link to the Maximo system work order details

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View Work Order History

For a particular asset, an aspect summarizes the work order history available from the Maximo system Work Order Number provides link to the Maximo system work order details

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View Equipment Status

For a particular asset, an aspect summarizes the equipment status available from the Maximo system

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View Preventive Maintenance Schedule

For a particular asset, this aspect summarizes the maintenance schedule information in the Maximo system.

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View Spare Parts

For a particular asset, this aspect summarizes the equipments spare parts information from the Maximo system.

Item number links to the Maximo systems spare parts availability data.

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Generate and Submit Fault Report

For a particular asset problem, this aspect makes it possible to generate and submit a fault report to the Maximo system.

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Reduced Time to Repair

Corrective action taken. Operator notified asset problem corrected Problem identified by Asset Monitor

n e e w t e e c b n n a o te n i t c n a i r a e t m n i d s n s a e l s n m o a i e t S era op
Work order automatically added and scheduled in Maximo (If calibration required, work order is forwarded to DMS Action List) Is Maximo aware of problem? Has maintenance been scheduled?

Submit fault report to Maximo

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