AIM f M i t i & IAIM f M i t i & IAIM for Maintain & ImproveSupporting a Real-time PAM Strategy

AIM for Maintain & ImproveSupporting a Real-time PAM Strategy

Wil ChinResearch Director

ARC Advisory Groupwchin@ARCweb.comwchin@ARCweb.com

Plant Asset Management (PAM)Typical Scope of a PAM Strategy Plant Asset Management (PAM)Typical Scope of a PAM Strategy

RampUp

OperRdy

FuncAsset Rdy

PeakPerf

AssmAsset

Asset

Operate & Optimize

ModsSpec

Optimize

Mods

Proj

p

Design &Build

Maintain &Improve

Liab

CashDes

ProjPlan

Improve

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Cash

IdeaBasis

PAM Requirements for AIMA Broad Range of Information TypesPAM Requirements for AIMA Broad Range of Information Types

Real-time predictive asset health informationI t lli t l ti l t l t di t t ti lIntelligent analytical tools to predict potential asset issues Processes to mitigate risks and consequences ofProcesses to mitigate risks and consequences of asset failures Optimal maintenance and operations practicesAbility to focus resources on the most criticalissues B fit ll i t t t l iBenefits equally important as control in automationWorkers with tools to Monitor, Analyze &

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Workers with tools to Monitor, Analyze & Optimize Plant Assets

PAM Requirements for AIMTo Answer Many Different QuestionsPAM Requirements for AIMTo Answer Many Different Questions

Information Needed for PAM

• answers reasonable questions regarding the physical asset,

about asset DNA specification

VirtualHuman

• about asset DNA, specification, application, configuration, health, recommended actions, and more Physical

• for Maintenance & Operations,

• to enable better decisions

PAM Strategies Based upon AIM Empower the

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PAM Strategies Based upon AIM Empower the Workforce with Knowledge

PAM Requirements for AIMDelivered in Many Different WaysPAM Requirements for AIMDelivered in Many Different Ways

Easily accessibleP id d d tiProvide procedures and practicesCover all assetsAvailable from one sourceAvailable from one source Consider importance and relevanceReal time status informationReal time status informationSpecific Stakeholder views History and up-to-date y pReal-time information

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AIM for PAMDistributed Across a Large Area AIM for PAMDistributed Across a Large Area

Plant AssetsThousands of Assets Are Located Across the Plant

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AIM for PAMDisparate Assets with Diverse InformationAIM for PAMDisparate Assets with Diverse Information

WorkersFlowmeters ESD

Machinery

Analyzers

Field Devices

Workers

HeatExchanger

Turbine

UtilitiesAnalyzers

Utilities

Conveyors

Compressor

MechanicalEquipment

Valves

MotorsSwitchgear

Cooling Tower Distillation

Train

Wiring

MotorsSwitchgear

DrivesPackaging

Machine

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Example of the Many Assets in PlantsExample of the Many Assets in Plants

Automation Assets

Machinery & Production Assets

Field Devices

Motors, Rotating,

Reciprocating Equipment

AIM for PAM

Process & Mechanical Equipment

AnalyzersRemote

Equipment

Control Valves &

PositionersElectrical

Equipment

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Wiring NetworksRest of Plant

Complex Information ManagementRequire Technologies and Domain ExpertiseComplex Information ManagementRequire Technologies and Domain Expertise

Global

Complex Information Rich AssetsGlobal

Information Varied Workforce

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Information Must Be Appropriate for Experienced Workers

Information Must Be Appropriate for Experienced Workersfor Experienced Workersfor Experienced Workers

Typical Chemical Plant w/ 3,308workers

Typical Chemical Plant w/ 3,308workers

800

1000

1200workersworkers

400

600

800

0

200

0-20 21-30 31-40 41-50 51-60 60+

Age

However60-80% experienced operations and maintenance

However60-80% experienced operations and maintenance

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p pslated to retire in 5 years

p pslated to retire in 5 years

But Also Meet the Needs of Inexperienced Workers

But Also Meet the Needs of Inexperienced Workerspp

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Market Forces Demand High PerformanceCreate Opportunities and Challenges for Manufacturers Market Forces Demand High PerformanceCreate Opportunities and Challenges for Manufacturers

•Accelerating Demand for Commodities

•Increasing Global Competition

•Downward pressure on costs •24 x7 Operation

•Rising Energy Costs

•Excessive IT Support Costs

•Rising Energy Costs•More Distributed Operations

•Customer-Imposed Standards & Requirements

•Aging Workforce in Manufacturing

Market Pressures Are Driving Manufacturers to Become Real-time Enterprises:

i l i

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Manage Assets in Real-time

ARC Vision of a Collaborative Integrated PAM StrategyARC Vision of a Collaborative Integrated PAM Strategy

Workers

A l

Field DevicesMachinery

AnalyzersUtilities AIM

for PAM

MechanicalEquipment

Valves

M t

PAM

Wiring

MotorsSwitchgear

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Intelligent Information Enhances PAM Solutions in a Common View

Information Not Always Available Information Not Always Available

Asset Class Electrical Mechanical

Automation Assets

Pressure, Temperature, Flowmeters, Level Meters, Mi ll S

Control Valves, Positioners, and

Miscellaneous Sensors, Analytical, Switches

Positioners, and Associated Equipment

Turbines, Compressors,

Production Assets

Motors, Switchgear, Transformers, Drives, Wiring

, p ,Fans, Gear Boxes, Conveyors, Grinding Mills, Extruders, Dryers, Pumps, Pipes Heat ExchangersPipes, Heat Exchangers, Tanks, Boilers, Furnaces

Must Deploy Intelligence in

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Must Deploy Intelligence in Production Assets

Measurement Technologies ProvideReal-time InformationMeasurement Technologies ProvideReal-time Information

Production Asset Monitoring Methods Asset Applications

R t ti & R i ti E i t

Vibration

Rotating & Reciprocating Equipment, Turbines, Compressors, Fans, Pumps,Motors, Gear Boxes, Wind Generators , Bearings

InfraredHeat Exchangers, Bearings, Motors, Switchgear, Transformers, Circuit Breakers, Furnaces

Rotating & Reciprocating Equipment,

Ultrasonic

Rotating & Reciprocating Equipment, Turbines, Compressors, Fans, Pumps,Motors, Gear Boxes, Wind Generators, Valves,

Oil A l i E i G B T i iOil Analysis Engines, Gear Boxes, Transmissions,

CorrosionPipes, Heat Exchangers, Tanks, Pumps, Valves, Field Devices, Boilers, and virtually any process wetted equipment

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virtually any process wetted equipment

Modeling Can be applied to virtually anyequipment

Solutions Must Connect via Many Communication Technologies Solutions Must Connect via Many Communication Technologies

Interoperability

Supervisory

p y

Control PROFInetPROFInet

ORK

LEV

EL HSE

I/ODP, PAN

ETW

O

Device

TYPE OF CONTROL

H1

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Machinery ProcessTYPE OF CONTROL

RealityReality

Many solutionsOnline real-time and off-line solutionsOnline real time and off line solutions Rich solutions from field device & equipment suppliersSoftware modeling solutions complement PAMSuccessful niche solutions- asset centric Proprietary and open connectivityAd-hoc implementationsComplete enterprise wide solution require integration of multiple solutions

PAM Needs to be Integrated into the

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PAM Needs to be Integrated into the Organizations AIM Strategy

Thank You.Thank You.For more information, contact the author at

wchin@arcweb.com or visit our web pages atwww arcweb com

18© ARC Advisory Group

www.arcweb.com