Transition to online AMS reduces maintenance costs and improves operations
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The transition to online Asset Management System (AMS) during the DeltaV upgrade improved maintenance efficiency and reduced costs for a utility department by shifting from scheduled to predictive maintenance. This shift allowed for quicker diagnoses and resolutions of maintenance issues using smart device technology, ultimately resulting in significant savings and improved reliability for equipment. The presentation highlights the history, challenges, and business results of this transition, revealing an estimated total savings of $75,000 to $100,000 since the implementation of online AMS diagnostics.
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Transition to online AMS reduces maintenance costs and improves operations
- 1. Transition to online AMS reduces maintenance costs and improves operations Workshop 1A-2942
- 2. Presenters David Rabon Control Systems Specialist Mike Ruhle Account Manager
- 3. Introduction Summary : Utility department’s evolution to smart devices and transition from offline to online AMS during DeltaV upgrade helps reduce maintenance costs and improve operations Agenda History of smart devices and AMS at the Site DeltaV Upgrade project Work Process Changes Challenges Business Results Summary
- 4. History of Smart Devices and AMS Field Devices and Vision Original install - Boiler upgrade in 1994/95 Used as opportunity to establish a vision Investment made in Rosemount smart transmitters, DVC5000 with advanced diagnostics, and Valvelink Software Interface was point to point – offline to start Immediate return during start up and commissioning of new equipment Faster loop checks Easier Field calibration of valves
- 5. History of Smart Devices and AMS Evolution of Diagnostic use and integration Began using technology to improve boiler overhauls Improved calibration efficiencies for I&C group Champion used Valvelink Diagnostics to validate valves re-assembled correctly after open/inspect Optimized instrument calibration list. Reduced frequency of calibration based on performance history Gradual evolution from scheduled maintenance to predictive Went from open/inspect all to some depending on diagnostics Started integrating smart data Provox Alerts - travel deviation & temperature Difficult to decipher but some value
- 6. History of Smart Devices and AMS Delta V installed in 2001 Integration much easier HART IO Cards Developed face plates with actual valve travel for operators Rosemount 3095MV transmitters Continued to look for opportunities to move to online AMS Take advantage of advanced diagnostics
- 7. Going online – DeltaV v9.3 upgrade V9.3 upgrade Good opportunity to get the AMS infrastructure installed AMS – Intelligent Device manager and Valvelink snap on installed as part of upgrade to support future FF devices and Pfizer’s online vision Originally installed on Pro-plus A number of projects also in the works WW upgrade to DeltaV Boiler upgrade from Provox to DeltaV New CTG/HRSG with FF devices Majority of smart devices would now be wired direct to DeltaV HART IO
- 8. Pfizer Groton DeltaV & AMS System Overview Foundation Fieldbus, HART I/O & Field Devices DeltaV Engineering & AMS Server - AMS Client – Device alerts routed to Maintenance station I&C Shop DeltaV Controller and I/O System Control Room- Pro Plus Operator Stations – Process alerts and Device feedback only. No device alerts configured. DeltaV Network AMS Communications
- 9. Going online – After the upgrade Transition from installed software to optimized tool Champion assigned to own system Leveraged additional licensing from plant Configured system Installed Maintenance station in I&C Shop Set up Plant Web Alerts Installed a DeltaV Operate graphic for PW Alerts Did FF and AMS training for Champion and technicians Set up quarterly mentoring visits as part of local support contract Ongoing Training and optimizing configuration
- 10. Going online – After the upgrade
- 11. Work Process changes Maintenance station critical to success Convenient for technician Operator not burdened by device alarms Allowed for EASY change in work process Needed to get buy in from Maintenance and Operations No need to do schedule only based maintenance Believe in the data Maintenance set up Work order for Champion to do a Daily PM Reviews any device related alerts Does further troubleshooting If issue sets up a work order to fix equipment
- 12. Overall Challenges Continuous improvement of skills to keep up with technology Leveraged local DeltaV service contract Continuous reinforcement with complementary groups within the Organization Maintenance- Develop trust in the diagnostic data. Reliability- Integrate diagnostic data into overall reliability program. Operations- Understand new architecture - techs will be responding to alarms operators do not see. Projects- Continue to invest in the SMART technologies.
- 13. Business Results Achieved Increased Maintenance efficiency and costs Triage allows for right tools for job and less time Example : Replacement sensor in pH probe Trusting in the data Open/inspect ALL valves on an as needed basis versus time Use data to plan maintenance Avoided Unplanned outages Find valve and instruments problems before they become process issues Self scheduling: I&C shop now writing corrective work orders based on data from the daily review of AMS. These WO’s resolve problems before they are operational issues.
- 14. Example- EQ-02 pH Probe Diagnostic evaluation revealed an “Offset Error” Warning and the Help files assisted in correcting error. Saved replacement of the probe. Reduced troubleshooting time. Savings- $2,500.00 Unneeded part replacement Reduction in troubleshooting time Quicker release back to production
- 15. Example – XTCCHW-100-01 Before
- 16. Example - XTCCHW-100-01 After
- 17. Example - XTCCHW-100-01 Summary Chiller 100 Flow Control valve not working properly Found a PD online/in-service alert record PD alert simplified troubleshooting Corrected relay issue before high demand months Savings- $940.00 Reduction in energy – more efficient chiller Air consumption savings
- 18. Examples – XPCVBFP-12-1 Before
- 19. Examples – XPCVBFP-12-1 After
- 20. Examples – XPCVBFP-12-1 Summary Call in to fix valve issue Visually found travel feedback arm disconnected Mechanical interference with Travel feedback arm Used Diagnostics to find additional issues Pneumatic lock in last valve not tubed to supply Found the right root cause and faster Fixed the issues on both valves before a trip required switchover to other feedpumps Savings- $2,904.00 Reduction in troubleshooting time and potential mech. maint. Avoided switchover to redundant pump
- 21. Examples - Effluent mag meter EQ02-1-2 is a magnetic flow meter associated with the discharge of the effluent. It was locked into an over-ranged PV condition thereby rendering it useless to operations. Utilizing AMS, I was able to troubleshoot and correct the issue at the Maintenance station This flow meter electronics box is located in B-192 and has a very cumbersome user interface. AMS made working with it more efficient Reduced maintenance cost and reduced time without effluent data Savings- $972.00 Reduction in maintenance/troubleshooting costs
- 24. Example- XFVB-5-5 Summary Boiler # 5 Feed reg valve operating erratically Used diagnostics to prove positioner issue versus mechanical issue and prevented unnecessary opening of valve. 6 weeks until diagnostics findings were accepted. Reduced Maintenance cost by not assuming mechanical issue and unnecessarily opening valve After resolution - Improved control and allowed for run on #5 on high load days Savings- $7,980.00 Avoided mechanical maintenance Able to run more efficient boiler
- 25. Financial Benefits Since 2009, we have analyzed 11 issues, where AMS played a prominent role, and have calculated the following savings. Avoided Maintenance time $11,760 Avoided Downtime $5,668 One time Costs $8,700 Switching equipment, Un-required spare parts used These 11 examples represent about 30% of all issues addressed with AMS. Total Extrapolated savings: ~$75-$100K Also avoided an average impact to the I&C group schedule of 4.8% per event. I&C Team self scheduling work based on data from the daily AMS review.
- 26. Summary We have presented the history of implementing the on-line AMS diagnostics in a maintenance group to assist the transition from reactive maintenance to a reliability based model. We have shown the benefits of implementing on-line AMS diagnostics. More efficient maintenance process Increased equipment availability and reliability. We would appreciate any feedback you have on the presentation Are there any questions?
- 27. Questions? Contact Information: [email_address] [email_address]
Editor's Notes
- #5: Vision : The project team had a short term vision to use the technology to execute the project more effectively. The plant team began figure out a long term vision on how use the technology long term to improve their maintenance.
- #6: Timeline: Boiler upgrade, Began using diagnostics to validate rebuild, Began using alerts online, Making PM recommendations based on diagnostics, Optimized calibration list based on real data versus time, AMS online, Maintenance station and alerts in shop, Using AMS as first look tool . Provox Integration: Alerts reported back a A,B or C level diagnostic errors that had to be researched through the Provox diagnostic tool.
- #8: Upgrade notes: Challenge with AMS on proplus. More convenient for the technicians when installed on a maintenance station in the tech’s shop. Projects: We used the projects to leverage the expansion of the DeltaV AMS to other systems. Hart devices that were isolated, became connected to the shop via AMS.
- #9: Emphasize the Maintenance Station. Not whole system, just representation of AMS centric areas
- #10: -We had proven the value to the point where we could make some Organizational changes (Champion recognized) -At that point in our knowledge, we recognized the assistance of our local integrator could move us ahead much faster. NEC knew the options we had, Champion had sufficient understanding to make informed decisions about the options. -Mentoring visits allowed Pfizer to explore options and get advice from experience as well.
- #11: Display maintenance techs checks. Shows device errors. This is a standard DeltaV Alarm Summary display filtered for Field Device and DeltaV Hardware Alerts only, then saved as a new graphic called Device Alerts Summary.
- #12: Challenge was to build trust in the data from AMS.
- #15: EQ-02 Discharge pH Probe Diagnostic evaluation revealed an “Offset Error” warning and the Help files assisted in my correcting it. This saved replacement of the probe, fairly expensive for that SS type, which would most likely have been the course of action (Pre-AMS) upon it’s not being able to hold a calibration. Reduced troubleshooting time. Saved a good part from being changed. System returned to operation sooner. Offset error appeared as a device alert (Rosemount Analytical 5081 HART pH analyzer). Help indicated Possible Causes and Checks: 1. Zero offset errors can indicate poisoning of the reference electrode, which requires it to be replaced. 2. A false error can result from trying to erroneously standardize a pH reading more than 1 pH unit. If the cause is Item 2. above, a new standardization (calibration) will solve the problem. Savings Avoided cost of new probe Reduction in troubleshooting time Unit back to operation sooner
- #16: Air mass flow indicated a air issue. Further investigation found that both the instrument air regulator was damaged by corrosion and not working and the relay and i/p was not working properly. Issue found in winter and could do work when demand not critical. If summer could have caused issues. Chiller 100 Flow Control valve not working properly Found a PD online/in-service alert record PD alert simplified troubleshooting Corrected issue before high demand months POINT OUT SCALE 140 to 220 SCFH versus 4-12 SCFH Air flow
- #17: Point out difference in air flow in the 2 graphs.
- #18: Add categories for savings: Avoided downtime Reduction in energy. Calculations are only for (4) months. If gone longer without finding – savings would have been $2100/year
- #19: Two issues were found on 12 valve one on 11 valve. First the instrument air tubing on 12 was found to interfere with the valve travel not allowing full travel of valve and caused calibration to fail. Second, both valves had pneumatic lock up valves installed that allow it to fail last upon loss of air pressure. These lock up valves were not installed correctly, not allowing valve to function properly. 12 valve would not function at all, 11 valve functioned however, not optimally and could have locked up during operation Call in to fix valve issue Visually found travel feedback arm disconnected- could not calibrate or use diagnostics. This graph is after mechanical interference fixed. Used Diagnostics to find additional issue (lock in last valve) Two issues found Mechanical interference with Travel feedback arm Pneumatic lock in last valve not tubed to supply Found the right root causes and faster Fixed the real issues on both valves before a trip required switchover to other feedpumps Might now have noticed the issue with a standard calibration
- #21: Savings details Avoided troubleshooting and maintenance hours. If not redundant pumps, and boilers, this downtime would have been more costly.
- #22: Effluent Discharge mag flow meter EQ02-1-2 is a mag flow meter associated with the discharge of the effluent. It was locked into an over-ranged PV condition thereby rendering it useless to operations. Utilizing AMS, I was able to troubleshoot and correct the issue at the Maintenance station. This flow meter electronics box is located in B-192 and has a very cumbersome user interface. AMS made working with it extremely more user friendly. Reduced maintenance cost and reduced time without effluent data DeltaV alert – call from operations. This was during start-up of some equipment that was moved from another system to DeltaV. The 4-20mA range in the instrument had been configured incorrectly and didn’t match the range in DeltaV. AMS helped figure this out quickly. Reduction in maintenance costs. Up in air, so getting to device is challenge and takes extra time. High lift or staging.
- #23: Used diagnostics to prove positioner issue versus mechanical issue and prevented unecessary opening of valve. Found that positioner had similar problem to #1 oil valve. Had to put boiler in manual for 6 weeks until diagnostics findings were accepted. The feedsystem and DA loops were unstable during that time. Boiler # 5 Feed reg valve operating erratically Boiler had to be put in manual Reduced Maintenance cost by not assuming mechanical issue and unnecessarily opening valve After resolution - Improved control and allowed for run on #5 on high load days NOTE THAT THIS IS POT ISSUE DUE TO UNOBTAINABLE TRAVELS
- #25: Savings details: Reduction in maintenance costs by not opening valve (mechanical work). Ability to use #5 boiler on high load day. Savings in cost to run this boiler more efficiently.
- #26: Avoided downtime minimal because of equipment redundancy. Finding issues before they are operations issue.