opex advantages asset optimization - fieldbus · additional key improvements centralized tooling...

© 1999 – 2007 Fieldbus Foundation

EMEA 2009

OpEx Advantages+

Asset Optimization

Francois Ichtertz / Dominik BrandManager FOUNDATION Fieldbus

Endress+Hauser Process Solutions AG.

Panos GiannakouliasCertified FF Systems Manager

Endress+Hauser II AG Middle East Support Center


EMEA 2009

CapEx / OpEx savings and life cycle phases

�Use of an open standard technology�Reduction in cost for wiring, barrier,marshalling rack and Junction box�Reduction in cost for control system -I/O interface�Reduction in cost for power supply unitand number of cabinets�Reduction in control room size�Engineering and documentation�Fast commissioning, lower start-upcosts

FAT,SAT,Commissioning

RenewalOperation

MaintenanceInstallationDesign

OPEX SavingsCAPEX Savings

�Use of an open standard technology�Increased information for betteroperation, accuracy of measurement &control�Enhancement in control function andthe performance�Improved throughput�On-line diagnosis enables truepreventive maintenance�Improved trouble shooting


EMEA 2009

Increase Plant Availability


EMEA 2009

Where are the OpEx savings ?

Operation and Production Costs

Additional production time by:� Improved maintenance for:

� Fewer process upsets� High availability

� Easier and faster incremental expansion

Improved throughput by:� Improved quality and productivity� Improved Alert capabilities for better operation� Improved accuracy of measurement and control� Data access for Business Intelligence


EMEA 2009

Where are the OpEx savings ?

Maintenance Costs

“Right time” or proactive maintenance to:� Reduce unnecessary trip to plant� Avoid failure instead of solve failure� Reduce time to repair� Root cause identification and elimination� Reduce inventory cost

Infrastructure with:� Centralized maintenance� Centralized tooling and data management


EMEA 2009

Operation and Production Costs


EMEA 2009

Control In the Field – Performance Benefits

� CIF provides superior reaction todeterministic disturbance in the process� Possible to synchronize data sampling and control� Possible to reduces Latency effect in the control chain

� CIF provides enhanced process integrity


EMEA 2009

Reduced VariabilityP

roce

ss O

utpu

t (%

)

Time (s)

56

58

60

62

10 20 30 40 50


EMEA 2009

Tighter Loop ControlControl Limit

Manual

Digital

Digital

Analog

Analog

Pneumatic

Pneumatic

Manual

For fast process application:

�Improvements in response timeof between 10% and 30 %

�Improvements in disturbancerejection of up to 20%


EMEA 2009

Migrate CIF progressively …. maximizing ROA !

Ethernet

FieldController

FF - H1

Pure CIF

Hybrid CIF

MAX

ASSETS

UTILIZATION

DCSAdvanced Control


EMEA 2009

Maintenance Costs


EMEA 2009

Potential for improvements

Potential for Predictive Maintenance with Pressure Transmitters

0%

5%

10%

15%

20%

25%

30%

35%

Routinecheck

NoProblem

Calibrationshift

Zero Off Pluggedlines

Failed

35%

28%

20%

6% 6% 4%

Shell GlobalSolutions

63% of instrument maintenance labor results in no action taken-> waste of resources


EMEA 2009

Potential for improvements

Maintenance today:

�65% of work orders generated for transmitters areunnecessary either no problem or problem with otherequipment�75% of control valves removed from process lines didnot require removal�50% of instrument tech’s time is spent on paperwork


EMEA 2009

Role Based Diagnostics

1

Asset ManagementMaintenance Station

Process ControlEngineering Station

Control Network

H1

Plant operators

Plant maintenance engineering


EMEA 2009

Maintenance Urgency – Wear Reserve


EMEA 2009

Maintenance Urgency – Wear Reserve

Warning

Alarm

Prediction of timeBefore affectingthe process

wear reserve


EMEA 2009

Equipment Monitoring in the PlantProcess Condition Monitoring• Devices• Functions• Sub-processes• Other key performance indicators

Quality

Machine Condition Monitoring• Condition Monitoring• Runnability Monitoring• Oil lubrication Monitoring

Field Device Performance Monitoring• Field Devices on different fieldbuses

Ft

FC

Ff

FC

LC

It is all about Diagnostic Information !


EMEA 2009

Device Performance Monitoring (DPM)

DPM

Performance Monitoring

Database

Webreporter

E-Mailer ODBCNotifier

SoftwareApplication

H1

TravelDeviation High

Alarm

FF


EMEA 2009

Increase Maintenance Efficiency

� Less trip to the plant� Improve general efficiency� Improve security

� Work is scheduled and proactive for a betterquality and less unplanned shutdowns� Stop reactive firefighter actions and anticipate

problems� Intensify collaboration between Operation

and Maintenance

But it is all about People Mindset !


EMEA 2009

Additional Key Improvements

� Centralized Tooling and Configuration data� Easy back-up of the configuration data� Easy audit trail and data management� Easy update and migration of the Tooling

� Basis and fundament for real AssetManagement� Better Calibration Management� Improved Management of the Installed Basis


EMEA 2009

Asset Optimization

inductive energy transmission

inductive signal transmission

Control Network

1 0 0 1 0 0 1

��

Asset Management Softwareuses fieldbus

for Asset OptimizationSolutions

Digital Communicationfrom Sensor to Asset Management


EMEA 2009

Asset Optimization – Asset Data Access

Control Network

1 0 0 1 0 0 1

�� Parameter access

via fieldbus for bothTransmitter and Sensorto enable:•Configuration•Diagnostic


EMEA 2009

Asset Optimization – Calibration Mngt.

Control Network

1 0 0 1 0 0 1

��

•Manage complete lifecycle of a sensor

•Trace the calibrationand adjustment history

•Customized calibrationprotocols are generatedautomatically


EMEA 2009

Asset Optimization – Link to CMMS Level

Control Network

1 0 0 1 0 0 1

��

Internet

W@Mportal

CMMS


EMEA 2009

Business Intelligence - Managing Data


EMEA 2009

Questions ?

opex advantages asset optimization - fieldbus · additional key improvements centralized tooling...

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