advanced condition based maintenance - emerson …€¦ · · 2013-12-06advanced condition based...

Advanced Condition Based Maintenance

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Why Focus On Maintenance?

• Maintenance Impact on Financials

– Maintenance Typically Accounts for ~3% of OpEx at ~$100-250k/store

– Effectively Every $1 Spent = ~$50 In Lost Sales

• Economy Still Tough

• Potential Impact:

– A 2% Reduction in Maint. & Energy = 1.3% Increase in Profits

– For a 1,000 Store Chain = $4M Increase Profits

Typical Equipment Failure Impact

$0

$1,000

$2,000

$3,000

$4,000

$5,000

$6,000

$7,000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Co

st Im

pac

t

Time

Consequences of Traditional Maintenance Practices During Equipment Failure

Product Impact

-Lost Product -Lost Sales-DissatisfiedCustomers-Food Quality Perception-Store Personel Time

Maintenance

-Equipment Repair/ReplaceCosts-Emergency or Overtime Service Costs-Out of Contract Charges e.g. refrigerant

Energy Impact-Higher Energy Usage Related to Equipment Degraded Performance, Efficiency

Normal Wear & Tear

Regular PM's

-No Issues

Early Equipment Operation Degradation

Regular PM's, T&M, Call-outs Maintenance

-Performed But Not For Undetected Early Equipment Operation Problems

Complete Equipment

Failure

Emergency Call-out

Maintenance Challenges

• Chain Consolidation and Maintenance Outsourcing

– Positives:

• Increased Buying Power = Lower Cost

• Contractor Economies of Scale

– Negatives:

• Lower Visibility of Actual Maintenance Quality

– Repair what needs repairing while there and before it breaks and becomes an emergency call-out at overtime rates

– Good Faith? Do The Right Thing?

• Increase in Out of Contract Charges (e.g. After-hours Emergency Call-outs)

• Higher Energy Costs

• Adversarial Relationship

– “if fan was dirty and failed, isn’t that your fault for not cleaning during PM?”

What‘s Optimal?

• Best Practices = Maintenance Contracts with Well Defined PM’s

– Typically Best Quality but May Have Short-term Higher Cost

– Low Visibility…”did they actually clean the coils”

Source: Cadick Corp.

What is Condition Based Maintenance?

Source: OnStar

What is Condition Based Maintenance? • Maintenance Performed Based On Equipment Condition i.e. Before It Has

Deteriorated To Point Where It May Fail If Not Serviced

• Similar To Today’s Automotive Diagnostics Systems ODB-II Messages and

Fault Codes :

• “Time For Oil Change”

• “Air Filter Replacement”

• “Low Tire Pressure”

• Mechanics Advised of Faulty Part Without Having to Perform Diagnostics Enables Timely and Cost Effective Maintenance

• Similarly CBM for HVAC/R Utilizes Equipment Sensor Data To “Learn” Equipment Expected Behavior and Compares Against Actual To Detect Anomalies

• Condition Anomalies or Exceptions Triaged for Optimized Dispatching

CB Maintenance Graphical Status

Typical Equipment Failure Impact

$0

$1,000

$2,000

$3,000

$4,000

$5,000

$6,000

$7,000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Co

st Im

pac

t

Time

Consequences of Traditional Maintenance Practices During Equipment Failure

Product Impact

-Lost Product -Lost Sales-DissatisfiedCustomers-Food Quality Perception-Store Personel Time

Maintenance

-Equipment Repair/ReplaceCosts-Emergency or Overtime Service Costs-Out of Contract Charges e.g. refrigerant

Energy Impact-Higher Energy Usage Related to Equipment Degraded Performance, Efficiency

Normal Wear & Tear

Regular PM's

-No Issues

Early Equipment Operation Degradation

Regular PM's, T&M, Call-outs Maintenance

-Performed But Not For Undetected Early Equipment Operation Problems

Complete Equipment

Failure

Emergency Call-out

With CB Maintenance Advisories

CBM

Notice

Advisory

CBM

Warning

Advisory

CBM

Alarm

Advisory

• Notice Advisory: Service

Next Visit ~30 Days

• Warning Advisory:

Service Soon Next 3-7

• Alarm Advisory: Service

Immediately

Maintenance is Optimized and Costs are Reduced

Equipment Requirements for CB Maint.

Suction

Discharge

Condenser

Ta

Pc Pd

Ts Ps

Lr

T Temperature

Sensor

P Pressure Sensor

Installed

Standard

CoreSense™

Diagnostics

E2 RX/BX

Controller

CB Maintenance Application For Supermarkets

Service Request Root Cause CB Maintenance Support

Case High Temp 1. Frosted evap. caused by failed fan

2. High/Low superheat caused by blocked or stuck TXV

Superheat Monitoring

3. Low refrigerant Slow Leak Detection

High Suction Pressure

1. Compressor trip on oil, phase loss, welded contactor

CoreSense™ Protection & Diagnostics

2. Compressor trip on high discharge pressure, temperature

Condenser Performance Monitoring & Superheat Monitoring

High Discharge Pressure

1. Condenser airflow blocked/fouled Condenser Performance Monitoring

2. Condenser fan fail Condenser Performance Monitoring

Top System Failure Modes

CoreSense™ Support

CBM Available Applications and Benefits

CBM Feature Asset / Maint.

Savings

Refrigerant

• Detect Slow Leaks

• Record Refrigerant

Additions/Losses

Reduce Leak Rate

10-20%

Track Leaks and

Additions for

Compliance

Condensers

• Control Strategy

Optimization Monitoring

• Condenser TD Performance

Monitoring

Fouled Coil Can

Increase Energy

Use 5-10%

Lower Condensing

Pressures Reduces

Comp. Wear and

Failure Rate

Cond. Cleaning

Based on Severity of

Fouling

Compressors

• Refrig. and A/C Compressor

Cycling Monitoring

• Performance Monitoring

with CoreSense™ Diagnostics

• Return Gas Monitoring

High Cycling Can

Increase Energy

Use +10%

High Superheat

Decreases

System Efficiency

Faster, Accurate

Diagnosis and

Failure Prevention

Extends Life

Optimize Dispatching

with Severity Based

Advisories

A 50% Refrigerant

Loss Can Reduce

System Efficiency

5-10% (Source:

EPA)

Energy

Savings

Optimized

Control Strategy

and Setpoint

How Does CB Maint. Work?

Refrigerant Slow Leak Detection

The Problem:

• Slow Leaks Hard to Identify Due to Normal Fluctuations In Level

• May Be Viewed As Tolerable

• Unresolved Leaks Means More Refrigerant Charges

Test Store Receiver Level

How Does CB Maint. Work? cont.


• Good Modeling Enables Early Detection and Potential Resolution

• Action Can Save Refrigerant, Equipment, Product, Labor Time



• In This Example ~30% of Refrigerant Was Lost and Recharged


Refrigerant Slow Leak Detection Process

Equ

ipm

ent

Sen

sor

Dat

a Ambient Temperature

Discharge Pressure

Liq. Level

Time of Day

Lear

nin

g M

ach

ine

Soft

war

e

Tests and Builds Models for Normal Liquid Level Behavior

Stores Multiple Models for Varying Operating Envelopes

CB

M E

xcep

tio

n G

en

erat

ion

Best Model for Given Operating Envelope Compared to Actual Level Over Time

If Increasing Difference Leak Advisory Generated

CB Maintenance Field Test Results

Incidence of CB Maint. Advisories Against WO’s

CB Maintenance Advisories Distributed Across The Year

CB Maintenance Field Test Results cont.

Incidence of CB Maint. Refrigerant Advisories Across Year

Slow Leaks Detected Proportionally To Fill Events


47% Normal Leakage and Catastrophic Leaks

Detected Slow Leaks24%

Non-Preventable

(Catastrophic

Leaks)11%

Non-Preventable

(Normal Leaks)

36%

Preventable (Difficult to

Predict/Model)

29%

Indentified Leak Types


$1,100

$500

$375

$1,168

$2,482

$440

$0 $500 $1,000 $1,500 $2,000 $2,500 $3,000


Condenser Performance

Compressor Cycle Count Exceeded

Compressor Cycle Rate Exceeded

High Suction Superheat

Low Suction Superheat

Est. Value per Site/Yr

Estimated Potential Maintenance & Energy Savings of $6,064

Note: Any potential cost of works to correct CBM issue or any savings from reduced PM's not included.

Summary of Benefits of CBM Practices Maintenance

• Typical Equipment Maintenance Savings of 18% to 40% Compared to PM or Run-

to-Failure Source: US Plant Maintenance Survey

• Reduce Expensive Major Failures “Fires” Occurring at Worst Time

• Reduce Shorten Equipment Life Caused by Compromised Operation

• Optimize Maintenance Dispatching Right Technician Skill Level for Right Problem

At the Right Time

Energy

• Reduce Energy Waste Caused By Low System Efficiency Conditions Like:

– High Condensing Pressures, Excessive Compressor Cycling, High Return Gas Temperature

– Low Refrigerant Levels

Product

• Reduce Product Loss Occurrences Caused By Preventable Major Equipment

Failure

• Improve Food Quality Reputation

Back up slides

CBM Software and Service Architecture

Hosted CBM Servers Data Acquisition and

Algorithm Processing

ProAct Portal - CB

Maintenance Dashboard

LAN or Web Access

Customer vLAN VPN

P T

Store E2

Liq. Level,

Press., Temp.

Sensors

Lv P T

Store E2

Liq. Level,

Press., Temp.

Sensors

Lv P T

Store E2

Liq. Level,

Press., Temp.

Sensors

Lv

ProAct Site Manager -

CB Maintenance

CBM Service Process • FAQ…

ProAct Portal CBM

NOTICE: Need for Routine

Maintenance Detected & Required

WARNING: Urgent Near Term Service

or Maintenance Required

ALARM: Component or System

Requires Emergency Service

Monitoring Technician is Able to Triage

Alarms and Dispatch Service

Technicians to Handle Critical issues

First

Benefits of CBM

CB Maintenance Feature Feature Description and Benefit

Energy

Customer

Value

Asset

Optimization

Customer

Value

Maintenace

Customer

Value

Compliance

Customer

Value

Total

Customer

Value *Savings Assumptions and Basis

Refrigeration compressor

faults and performance

monitoring via

CoreSense Diagnostics

Compressor mounted Copeland CoreSense Diagnostics

refrigeration diagnostics monitor compressor operation and

provide advanced protection and diagnostics alerts, making it

easier to accurately diagnose and prevent refrigeration

system failures.

$800 $2,300 $3,100

see Copeland CoreSense value proposition

literature

Refrigerant Slow Leaks

and Additions Monitoring

Refrigerant slow leaks detection across full system, aiding in

refrigerant loss prevention and reducing equipment failure,

system downtime, and product losses. Refrigerant additions

dedection aids costs tracking and audits.

$1,625 $1,000 $2,625

Industry avg of 4,000lbs/store with 25% leak

rate reduced by 25%. Refrigerant leaks lead

to product losses 5% Source:

http://w w w .epa.gov/greenchill/dow nloads/bureauaffai

rs.pdf

Refrigeration System

High and Low Return

Suction Gas Superheat

Monitoring

Detects refrigeration high and low suction superheat

conditions that can lead to compressor failure. Common

examples include, faulty TXV's, uninsulated suction lines,

cases not properly isolated during defrost.

$438 $800 $1,238

15% of systems operate at high or low

superheat due to incorrect TXV setting,

clogged screen, fan coil fail, or missing

insulation 3% savings

Compressor On/Off High

Daily Cycling and Total

Cycles Monitoring

Detects high compressor cycling and total cycles which can

result in a shorten compressor life and increased energy

usage, as well as effecting food quality.

$200 $385 $585

Customer data shows 3% of compressors

high cycle shorten life by 50% and increase

energy usage of 2%

Condenser Performance

(TD) and Control

Monitoring

Detects condenser low performance (high TD) due to debris

on the condenser coil (fouling), fan failure, or incorrect

control, all of which can lead to decreased system efficiency

and possible system failure.

$825 $200 $200 $1,225

Energy savings based on 25% of condensers

operate 20% below mfr ratings due to fouling

with 5-10% increased energy use. Savings

on equipment life of 10%. Reduce Comp

wear

*Estimates for annual energy savings derived from the annual primary energy use for commercial buildings data found in the DOE funded study “Energy Savings Potential and R&D Opportunities for Commercial Refrigeration” (Navigant

Consulting, Inc., 2009) and Emerson Retail Solution's customer testing.

CBM Provides Insight To Action Workflow

Proactive Insights

Reactive Insights

• Hi Temp Alarm • Tripped

Compressor • Board Offline

• Slow Refrigerant Leak Detected

• Excessive Comp Cycling Detected

• High or Low Rack Superheat

• High Condenser TD • CoreSense

Diagnostics

• Dispatch Contractor • Notify Store Manager • Act Immediately • Ignore As Noise

Fault

Info. Type

Fault

Condition

Fault

Analysis

Action

• Verify Condition • Smart Dispatch

Workflow (IP) • Verify Resolution

• Analyze Related Parameters or Conditions

• Compare To Normal Operation via Algorithm

• Identify Sites/ Equipment with Specific Condition

• Implement CBM Workflow (IP)

• Enterprise Wide Condition Based Maintenance

• Deficiency List For Enterprise For Proactive maintenance

• Facility Health Metric

• Notify Maintenance Manager

CBM Algo’s

Equipment

Alarms

Equipment

Performance

Data

CBM

Advisories

1

Service Use Cases

Upon Seeing A High Cycling Condition A Technician Will Investigate Potential Root Cause (eg. Incorrect Control Strategy, Component Failure etc) And Determine Resolution:

(1) Remotely Change E2 Setting To Correct Problem (eg. Fix Control Strategy)

(2) Suggest On-Site Investigation In PM Schedule

(3) Provide A Weekly Report Of All Compressors, Sites With High Cycling Problems To Customer Maintenance Team

Compressor High Cycles Incidence ~ 16 Out Of 480 In Test Case ~

3% Of All Supermarket Compressors Is Our Estimate

(1) Many Maint. Providers Don’t Know When Condition Exists

(2) No Action Being Taken Until Failure In Majority Of Incidences

(3) When Action Is Taken It Is In Response To Other Alarm

Today

With CB

CB Maintenance = Predictive Maintenance

• Which Of My Refrigeration Systems

Are Operating Improperly or

Inefficiently?

- Compressor CoreSense

Diagnostics

- Condenser Performance

- Compressor Cycling

- Rack Superheat Monitoring

• Which Of My Refrigeration Systems

Are Leaking Refrigerant?

• How Can I Implement A Better

Maintenance Scheme or Optimize

Maintenance Dispatches?

• Where Should I Focus My

Maintenance $$?

Questions CBM Can Answer Nature Of CBM

Refrigeration

Leak

High

Cycling

• Not Urgent But Important Equipment

Performance Degradation Monitoring

• Conventional Alarms Point To

Current Problems But CBM Points To

Conditions That Will Lead To

Potential Big Problems

ProAct CBM Service Summary

Availability

• Beta Customer Sign-up in May 2012

• Service “Go Live” July 2012

Future Features

• Smart Dispatch Integration Fall 2012

• Extended HVAC Support

• Cases and Walk-ins Diagnostics Support

37 Emerson Confidential

Complexity Increases With Every SubSystem That Makes Up A Retail Facility

Sensory Data

•Discharge Press. & Temp.

•Suction Press. & Temp.

•Ambient Temp.

•Condenser TD

•Refrigerant Level

•Suction Gas Superheat

•Condenser Setpoint

•System Voltage

•Rack Current

•Modulation Status

•System Overall Health

•Developing Problems

•When To Perform Maint

•Contactor Remaining Life

•Compressor Cycling

•Condenser Efficiency

•Remote Diagnostics

•High Cycling

Insights

•System Uptime

•Efficiency

•Product Quality

•Maint. Cost Savings

Customer Value

38 Emerson Confidential

Simple Component Level Information Can Drive Big Savings Value

•Asset Information

•Compressor Proofing

•Power Consumption

•Run & Fault History

•Remote Diagnostics

•High Cycling

•Compressor Protection

•Energy Efficiency

•Cost Savings

Sensory Data Insights

Customer Value

•Ambient Temp.

•Discharge Temp.

•Motor Tem.

•Contactor Status

•Unloader Status

•Power Voltage

•Control Circuit Voltage

•Current

•Demand Signal

•Oil Press.

•Low/ High Pressure Cut-Out

•Digital Modulation Status

advanced condition based maintenance - emerson …€¦ · · 2013-12-06advanced condition based...

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