value of asset management strategies

Value of Asset Management Strategies

“I need to insure that my facility is operating the way I built it to run!”

Common Water Supply & Water Treatment System Objectives

reduce risk to service reduce risk to service outagesoutages

reduce risk to service reduce risk to service outagesoutages

improved site improved site securitysecurity


improve maintenance staff improve maintenance staff effectivenesseffectiveness


reducing commissioning time & reducing commissioning time & costcost


keeping employees safekeeping employees safekeeping employees safekeeping employees safe

disaster disaster recoveryrecoverydisaster disaster recoveryrecovery

complying with regulationscomplying with regulationscomplying with regulationscomplying with regulations

monitor & protect monitor & protect systemssystems


Water Supply & Water Treatment System Benefits• Reduction in long term operating & maintenance costs and

lowering the risks to the community served by… – Improve maintenance staff effectiveness

• Root cause analysis & locked door device analysis automatically• Monitor & protect systems

– Monitor devices on networks for abnormal operation including degradation or failure

– Automatic integrated condition monitoring including notification• Automatic tracking of versions with security on all production intellectual

property• Messaging (email) appropriate personnel• Facilitate more migration from reactive & preventive maintenance to

predictive & reactive maintenance models – Increase site security for device access

• Creating audit trails for asset configuration changes, detect unwanted changes

• Back up asset intellectual property to a secure system for disaster recovery

• Store every version of asset configurations in a secure system for archival and retrieval

• Automatic verification of some device configurations against controlled masters

– Extend service life of equipment through verification, condition monitoring & security

Assets’ Influence on Objectives

Even the smallest Even the smallest change can affect operations!change can affect operations!

Each asset no matter how largeEach asset no matter how largeor small is linked to the next asset.or small is linked to the next asset.

RSMACC Systems

• RSMACC Systems consist of an architecture that includes at least one core function.

• That RSMACC System can be added to, creating a much more comprehensive solution.

• The 4 core functions are:– Change Management, CM– Network Health, NH– Enterprise Online, EOL– Automated Asset Manager, AAM

• You can purchase CM alone and add AAM at anytime

• Or you can purchase a NH System and add EOL, etc…

Typical Device Configuration Scenario

• User starts RSLogix program– User locates the RSLogix controller

program– User connects to the controller– Downloads or makes online

changes, saves program on local disk drive, floppy or somewhere else

– What version of the program is in your controller and where did the program come from & where did it go after the change?

Change Management

ArchiveArchiveArchiveArchive

AuditAuditAuditAudit

Verification/RecoveryVerification/RecoveryVerification/RecoveryVerification/Recovery

ReportingReportingReportingReporting

Access ControlAccess ControlAccess ControlAccess Control

AuthenticationAuthenticationAuthenticationAuthentication

ReconciliationReconciliation

DetectionDetection

AccountabilityAccountability

ControlControl

PreventionPrevention

The Value is greatest when applied proactively rather than after the fact!

The stream of managing change starts with “Prevention” and flows

through “Reconciliation”.

Change Management

• User starts RSLogix program – RSMACC security system ask your

domain controller to authenticate the user

– Regardless of results, RSMACC records workstation and user launching RSLogix

– RSMACC security applies the defined security permissions

Change Management

– User retrieves application program from RSMACC archive using RSLogix 5 or 500 file open or the RSMACC client using the RSMACC security system to verify permissions

– RSMACC records who retrieved the application program & where it went

Any type of file can be stored in this Archive system!Any type of file can be stored in this Archive system!

Change Management

– File management system• Holds any kind of

document

– Manage user folder rights

– Supports• Pinning/ mastering• Sharing• Branching

Change Management

– User connects to the controller• RSMACC records device connection

– User makes online modifications to control program

• RSMACC records each user change as it occurs

Change Management

Change Management

• Secure operator changes from RSView SE or PanelView Plus during production– Set-point change (Tag

write)– Command

• Alarm acknowledgement

– Recipe download

• Signature required before operation occurs

• Generates compliance enabling 21 CFR Part 11 audit trail

Change Management

• Documenting Configuration Changes – Supports self-

documenting Change Management procedure

• Ability to prove scope of change is limited to approved change

• Contains information necessary to enable FDA 21 CFR Part 11 compliance

– Date/Time of audit event

– Source (Application)– Location (Workstation)– Username (Domain ID,

and Full Name from Domain Id)

– Automatically generated description of change with old and new value

Change Management

– User returns the application program to the RSMACC archive system

• RSMACC archive compares the files and increments the version if it is different regardless of the type of program

Change Management

– RSMACC verifies automatically at the prescribed periodicity that the controller program matches the master program and version in archive

• A message can notify that the function ran correctly or not, and differences were found or not.

• A report of the differences found is saved.

Brief Overview, Managing Device Configuration

CM

24vdc

509 -BOD

RSLogix™ 5 or 500 Standard v6.10…RSLogix 5 or 500 Professional v5.50…

RSLogix 5000 (English) v10.03...

Security for:Archived filesRSMACC functionsRSLogix 5 v4.00.00 or greater RSLogix 500 v4.00.00 …RSLogix 5000 v11.00 … RSMACC Client v1.00.00 …RSMACC Change Management v1.00.00…RSLinx v2.20.01 …More products are coming as… FactoryTalk Security is integrated!

FlexLogixFlexLogixENetENetCNetCNetDH+DH+

MicroLogixMicroLogixDH485DH485DF1DF1

CompactLogixCompactLogixENetENetCNetCNetDH+DH+

PLC3PLC3DH+DH+

PLC2PLC2DH+DH+

PLC5PLC5DH+DH+ENetENetCNetCNetDF1DF1

PanelView StandardPanelView StandardEnet, CNet, DNet, RIO, DH+, DH485, DF1 Enet, CNet, DNet, RIO, DH+, DH485, DF1

(Enhanced on RIO only)(Enhanced on RIO only)

ControlLogixControlLogixDriveLogixDriveLogix

ENetENetCNetCNetDH+DH+

SLC*SLC*ENetENetDH+DH+DH485DH485DF1DF1

PanleView PlusPanleView PlusENet, CNet, DH+, DH485ENet, CNet, DH+, DH485

Verification for:All devices shown below… files on computers… and some robots

Archive for:Virtually any form or type of file

Audit:RSLogix editors listedRSViewSE & ME, RSBatch… (some integration)More products are coming as… FactoryTalk Audit is integrated!

RSMACC Systems






Typical Device Status Events

• Event– Radio message or alarm

~75~75%%

Automatic Device Health Status

• Periodically the Diagnostic Scheduler Service, running on a local computer, scans the health of DeviceNet, ControlNet, and Ethernet/IP network devices and reports on their status to the RSMACC system.– Smart devices, when prompted,

will identify their health status by responding with a coded number

– Comparing that number to the type of device using the network configuration file allows us to automatically generate information about the failure

DiagnosticDiagnosticSchedulerSchedulerServicesServices


– That number corresponds to a real problem for the device at that node.

– These are automatically logged to the centralized RSMACC Diagnostics and Health log database



– RSMACC log message includes a link to root cause and solution information from distributed RSMACC Clients

– RSMACC requires no additional code or configuration to recognize a device code and communicate the device status to the system and subsequently the appropriate personnel


RSMACC Systems






Traditional Condition Monitoring

• Machinery in the plant might malfunction so we must do our preventive maintenance periodically regardless of real indicators like cycles, revolutions, temperature, vibration, level or viscosity. – This requires a person to take local

readings and then analyze those readings typically back at their desk.

• In several industries this may even require travel

• In all, it is extremely time consuming

Automatic/Integrated Condition Monitoring

• Our integrated and automatic protection systems are designed to provide continuous monitoring and protection to machinery – RSMACC system provides a live

connection to sensor data from the XM modules

• Vibration Analysis • Process Parameters

– Temperature, Pressure, and Flow

• Turbine Supervisory Instrumentation (TSI)

– Thrust, Differential and Case Expansion, Valve position, and Eccentricity

• No more traveling to the location or climbing on machines to take readings!


– RSMACC Client combines digital images of your plant equipment with monitored data for simple asset monitoring and alarm annunciation

– EnWatch data can be combined with the XM data on the live monitor


– Online remote configuration capability


– Live Time data display from any XM channel

• Trend, Spectrum, Waveform, Waterfall, Polar, Orbit, Shaft-Centerline


– Historical data can be added to real-time using our Emonitor systems

• Emonitor Enshare– Data Storage, Alarming, Frequency

Analysis, & Connectivity

• Emonitor Odyssey Deluxe– Data Storage, Alarming, &

Frequency Analysis

• Emonitor Odyssey– Data Storage & Alarming

RSMACC Systems






Automatic Messaging

• RSMACC binds process information from intelligent assets and RSMACC internal systems & messaging to MAXIMO to facilitate WORK ORDER generation and tracking

– Predictive Interaction• Process data like…

– N:7:0 > desired level» A work order for checking/calibrating the

thermocouples should be issued– Operator interface sends signal requesting

maintenance on machinery based on a reading or operator input

– Reactive Interaction• An intelligent sensor or device is malfunctioning

– Photo eye signal is degrading, work order issued to clean

• RSMACC detects that an assets configuration does not match the master on file

– Work order created to asses the situation a

• RSMACC detects a security violation– Message sent to IT or Security to investigate issue

• Process data – B120/12 not 0

» A work order for fixing a leaking valve should be issued

• RSView SE Interface for Work Order generation/messaging

– Track status of work orders & data• Plan for work based on status & changes• Adjust schedules and priorities of planned work

MAXIMOMAXIMO

(Automatic) Work (Automatic) Work Order Generation Order Generation

Automatic Messaging

• A lot of plants are struggling with the increased work load including increased complexity of systems. – Consequently plants have moved to

more of a run-to-failure, RTF, mode for some maintenance

• This is as expensive in some cases as hiring more people and doing preventive maintenance

• A balanced approach is more appropriate based on individual requirements

– This type of system is deigned to help in the balance between RTF and total PMS

• Moving some appropriate systems to Reactive models

– Compensates for not having time to do PMS

– Facilitates better time management– Facilitates a more appropriate cost

model for maintenance

MAXIMOMAXIMO

(Automatic) Work (Automatic) Work Order Generation Order Generation

RSMACC Systems

• RSMACC Systems architecture includes some basic functions like– Reporting

• Both manual ad-hoc and automatic

– Security– Service Monitoring– Archive

Manual & Automatic Reporting

• RSMACC can be configured to generate automatic reports for changes to machines and their respective assets. – For instance, a maintenance

manager might want a report for changes that occurred over the weekend or during the past evening.

Manual & Automatic Reporting

• Other Uses For Reporting – Generate a morning report for

Maintenance/ Engineering Manager review showing ALL changes to PLC programs during 2nd and 3rd shift

• Forces• Empty branches• Changes to rungs, ignoring value

modifications• All employees that made

modifications

– Generate a weekly report for the Plant Manager showing all programmable assets that have been modified by name

– Generate a report monitoring critical applications (e.g., pasteurization process) that have not been changed

System Planning & ArchitectureCommon Architecture with Plug-In Functions

– RSMACC Server & RSMACC Client common to all applications– Plug-In Functions

• RSMACC Network Health– Monitor, report, and diagnose device and network health

• RSMACC Automated Asset Manager– Automate preventive, predictive, and reactive maintenance

• RSMACC Enterprise Online Condition Monitor– Integrated automation condition monitoring

• RSMACC Change Management– Authenticate, audit, archive, and verify device configuration

System Planning & Architecture

RSMACC Server(s)• Windows 2003

Server• Windows 2000

Server w/SP4• Pentium 4, 2GHz

or more• 1GB RAM• 1.5GB free on

system volume• 20GB shared

volume, RAID-5 capable

– Only if hosting Microsoft SQL 2000 Server

RSMACC Client• Windows 2000

w/SP4 or XP Pro SP1

– DO NOT USE XP SP2

• Pentium III, 500MHz

• 256MB RAM• 1GB free on

system volume

Recommended Platform Requirements:

System Planning & Architecture

RSMACC Client

`

Windows 2000 Server PDC

RSMACC ServerRSMACC ServerService MonitorSecurity ServerAdministration UtilitiesVerification

PLC5SLC500ControlLogixPanelViewReporting

RSLogix 5RSLogix 500RSLogix 5000

RSMACC ClientSecurity clientArchive client RSLogix 5RSLogix 500RSLogix 5000

SQL Server 2000Profile dBEvent & Audit dBArchive dBTablesStored procedures

Ethernet TCP/IP / Microsoft Windows Domain

Assets’ Influence on Objectives

Even the smallest Even the smallest change can affect operations!change can affect operations!

Each asset no matter how largeEach asset no matter how largeor small is linked to the next asset.or small is linked to the next asset.

Common System Objectives

reduce risk to productionreduce risk to productionreduce risk to productionreduce risk to production







keeping employees safekeeping employees safekeeping employees safekeeping employees safe

disaster disaster recoveryrecoverydisaster disaster recoveryrecovery

complying with regulationscomplying with regulationscomplying with regulationscomplying with regulations



Water Supply & Water Treatment System Benefits• Reduction in long term operating & maintenance costs and

lowering the risks to the community served by… – Improve maintenance staff effectiveness

• Root cause analysis & locked door device analysis automatically• Monitor & protect systems

– Monitor devices on networks for abnormal operation including degradation or failure

– Automatic integrated condition monitoring including notification• Automatic tracking of versions with security on all production intellectual

property• Messaging (email) appropriate personnel• Facilitate more migration from reactive & preventive maintenance to

predictive & reactive maintenance models – Increase site security for device access

• Creating audit trails for asset configuration changes, detect unwanted changes

• Back up asset intellectual property to a secure system for disaster recovery

• Store every version of asset configurations in a secure system for archival and retrieval

• Automatic verification of some device configurations against controlled masters

– Extend service life of equipment through verification, condition monitoring & security

What’s next…

• Action…

value of asset management strategies

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