Honeywell.

com

2014 Honeywell Users Group Americas

8 Ways Process & Equipment Health Management Can

Increase Profitability

Bart Winters Asset Management Product Line

1
Document control number

Honeywell Proprietary

Agenda

Sample Problem
Asset Manager Solution
Positioning in Overall Reliability Ecosystem
8 Ways to Value
Case Studies

Problem Statement
Day in the life of plant/equipment engineer
Heat Exchanger problem
Where do you start

Instrument
Valve
Pump
Exchanger

Where am I at vs. where I should be?

What changed, when, how much?
Where get info???

Asset Manager Overview

Management
Reporting & KPIs

CMMS/ERP Integration

Asset Manager

Operator

Maintenance.
Reliability, & Engineering
Performance Calculations & Health
Assessment

DCS &
Historian

Asset
Data Sheets

Visual
Inspections

Smart
Instruments

Corrosion
Monitoring

Condition
Monitoring

Other
Applications

Unified Health Monitoring with Asset Manager

Unified Health Monitoring with Asset Manager

Control Valve
Health
Control Loop
Health
Heat
Exchanger
Health

Transmitter
Health

Pump Health
System
Health

Unified Health Monitoring with Asset Manager

Control Valve
Health
Control Loop
Health
Heat
Exchanger
Health

Transmitter
Health

Pump Health
System
Health

What Asset Manager Does

1. Integrates real-time information for
analysis and decision making
2. Applies Fault and Performance
models for asset health diagnosis
3. Automates Alerts and Actions for
proactive response to potential
failures

Information Integration
Integrate
information

Performance
Calculations

Event
Detection

Decision
Support

Define information in context of

Process and Equipment Assets
Equipment Model (templates &
instances)
Synchronize with other systems
SAP Hierarchy
Experion

Data Integration
OPC DA, HDA, A&E, etc

Links to Asset Information

Manuals
Repair history

Reporting &
Analysis

Asset Model
Define Equipment Model
Flexible
Multiple Levels
Built from library of asset
templates
Pre-defined Library of asset
templates
Template defines attributes for
each asset type

Templates
Plant Model

Performance Calculations / Monitoring

Integrate
information

Performance
Calculations

Event
Detection

Decision
Support

Reporting &
Analysis

Calculation Capability
Advanced Performance Library
(embedded)
Pump, Compressor, Turbine, Heat
Exchanger

Standard Performance Library

Boiler, column, condenser, blower

Thermo Calculation Package

UniSim Model
Excel Calculations
Data Driven & Scheduled

Example Feed Rate Calc.

UniSim Design Asset Manager Integration

Introduction
UniSim Design is a process simulation environment to create
rigorous steady state and dynamic models for plant design,
performance monitoring, troubleshooting, operational improvement,
business planning, and asset management

Standard Models
Heat Transfer Equipment, Rotating Equipment, Reactors, Vessels,
columns, Thermo dynamic package

Asset Manager - UniSim Design Interface

Map Field Data to UniSim Design Model Boundary Variables
(process data model for Input/Output) in Asset Manager
Manage Execution of models from Asset Manager interface

Event Detection
Integrate
information

Performance
Calculations

Event
Detection

Decision
Support

Reporting &
Analysis

Symptom / Fault Model

Rule logic for triggering event
Event Actions
OPC A&E Event
E-mail
CMMS (SAP or Maximo) work request

Define Fault Severity

Define Recommended Action
Minimize Chatter
Contextualized rule executes only
when context is true i.e. pump running
On-Delay & Off Delay

Simple & Complex Rules

Bearing Fault Example

Heat Exchanger Example

After Maintenance
HE Performance
Alert

HE Efficiency
Improved

Experion to Asset Mgr Fault Model

Experion Configuration

Mapping in Asset Mgr

Simplified Smart Instrument Monitoring

Define Template for device types ONCE
Organize diagnostic messages (per NAMUR)
Time delay to minimize chatter
Define Severity of fault
Define Action (OPC, Email, CMMS)
Corrective Action
Instances Auto Created
Define Criticality - (instrument on compressor vs back-up
pump) to calculate priority

Controller / Loop Performance

Combine device health with
control loop health

Control Performance Monitor

Asset Manager

Performance Index
(<.5 or >2) = FAULT
Valve Stiction
Oscillation Index
Bias / Drift / Frozen

Decision Support
Integrate
information

Performance
Calculations

Event
Detection

Decision
Support

Decision Support - Response

Tree-Map Overviews
Based on Fault Priority

View Graphics
Analyze Trends
View Events
Access Recommended Actions
Access Linked Information

Reporting &
Analysis

Decision Support: Graphics Displays

Baseline Model Data
@ current Operating
Condition

Current Model Data

@ current Operating
Condition

Fault Symptom Status Visualization

FMECA (Failure Mode
Effect & Control
Analysis) is used to
identify:
Failure (Faults)
Symptoms(Cause or
early warning for a
Failure)
Action to control or
repair
Who (Notify user
directly by e-Mail,
Operator console,
raise notification for
CMMS to generate
work order)

Reporting and Visualization

Integrate
information

Performance
Calculations

Event
Detection

Event Analysis
Bad Actors
MTBR, MTBF
Run-hours
Meter usage
Consumption
Energy Utilization
KPIs

Decision
Support

Reporting &
Analysis

Maintenance & Reliability Ecosystem

Process & Equip Health Mgt.

Maintenance

Health,
Condition &
Performance
Monitoring

Reliability

Ivara

Programs & Strategies

RCM/RBI
Asset Health Matrix
Maintenance Strategy
Reliability Analytics

Monitoring / Surveillance / Event Detection

For process and equipment assets providing
Prioritization, Alerting & Notifications
To enable pro-active actions by
Process and Reliability Engineers
To improve overall OEE

Monitoring

Process Health
Equipment Health
Corrosion Mon.
Smart Instruments
Loop & Control Perf.

Diagnostics

Models

Performance Models
Symptom Fault Models
Corrosion Models
Simulation Models
Statistical Models

Tracking

8 Ways to Increase Profitability

1. Improve asset uptime / OEE

Pro-active Maintenance, On-Condition, 1st Time Quality, Prevent unplanned and

overplanned

2. Reduce maintenance costs

Reactive work takes 3 times longer to complete and is 4 to 10 times more expensive
Predicting maintenance at the optimal time to avoid costly secondary damage

3. Improve operating performance

Minimize disruptions to Operations

Minimize mis-operation of equipment
Maintenance and Operations can collaborate to plan maintenance based on asset condition

4. Make Problems Visible

5.
6.
7.
8.

Connects the disparate Silos of information

Turns data into actionable information
Make maintenance decisions proactively

Increase Engineering Productivity

Extend Asset Life
Improve Energy Utilization
Improve Safety

8 WAYS TO INCREASE
PROFITABILITY

#1 Improve Uptime

Pro-active Maintenance
On-Condition Maintenance
1st Time Quality
Prevent unplanned and over-planned

#2 - Reduce Maintenance Costs

Reactive work takes 3 times longer to complete and is 4 to 10
times more expensive
Predicting maintenance at the optimal time to avoid costly
secondary damage

#3 - Improve Operating Performance

Minimize disruptions to Operations
Minimize mis-operation of equipment
Maintenance and Operations can collaborate to plan
maintenance based on asset condition

#4 - Make Problems Visible

Toyota Way Management Operating System
Connects the disparate Silos of information
Turns data into actionable information
Make maintenance decisions proactively

#5 Increase Engineering Productivity

Ready access to actionable information
Automatic monitoring and notification
Integrated information environment

#6 Extend Asset Life

Extend asset life through
Prevention of abusive operations (operator coaching)
Prevention of secondary damage
Understanding of true health

#7 Improve Energy Utilization

Visibility into efficiency

Monitor efficiency
Take actions on energy usage
Detect performance degradation

# 8 Improve Safety
More reliable plants are safer

Success Story
Middle East Oil & Gas Processing Facility
Honeywell chosen to provide Equipment Condition Monitoring solution for large
Oil & Gas processing facility to provide the following benefits:
Monitor over 1200 process and equipment assets
Detect performance degradation as leading indicator of equipment health
Combine electrical, mechanical, and process performance data in single health
monitoring location
Measures equipment performance to improve energy utilization
Support predictive maintenance
Support smarter turn-around planning
Prevent mis-operation of equipment

Process changes have a significant impact on equipment behavior and

reliability, which in turn show up in the process data. We can now see how the
process parameters affect the asset performance. It is the missing link that
Asset Manager provides. In one case leading to 15MgW savings/year
Reliability Manager Middle East Oil & Gas Processor