Asset Effectiveness Solutions Experion PKS Asset Effectiveness Solutions Industrial process management systems generate large volumes of data and standard systems translate this, to some extent, into information. An example would be the process control system generating alarms which inform the operator of the potential need for action. The people in your business process use their knowledge to interpret this information to make a decision on whether or not action is required. The value of this decision making process is immense as it is our major opportunity to vary plant production parameters to achieve reliable, sustainable production rates that provide us the greatest net margin between our cost of operation and volume/quality of product produced. If the decisions made are poor, ill-informed or untimely the result will something less than optimal production. The Experion PKS Process Knowledge System provides the functionality to improve information creation, management and delivery to facilitate the application of knowledge for improved decision quality. It also provides the capability to embed best practice knowledge into the tools used to assist decision making to reduce the variability in response to abnormal process operation and equipment performance. This allows sustainable performance improvement and mitigates against the loss of expertise and the need to re-learn knowledge on how best to operate the process and care for production assets. Experion PKS provides process knowledge tools and technologies that reach every level of your organisation. They will help you tap into, sustain and leverage the knowledge level within your organisation so staff are working on higher-level decision making functions and not data and information processing. Whilst Experion PKS includes many of the systems and interfaces that you regularly rely on and use to keep your plant operating, it integrates and packages data, information and knowledge to get the right information to the right person in a recognisable format as soon as it becomes available. This key differentiator distinguishes Experion PKS from traditional automation systems allowing users to leverage expert knowledge to achieve untapped performance results. The RCM methodology provides an excellent basis for the methodical and reviewable establishment of a planned maintenance regime with justifiable application of predictive and preventive techniques. To do this, it is based around an elegantly simple analysis process to determine what is important, how it can be adversely affected, how that might be detected and what mitigation action should be taken. This paper explores the application of the RCM methodology to systems, such as those controlled by Honeywell’s Experion PKS, rather than directly to equipment and their components and looks at the ways several leading industrial organisations are using their pro-active maintenance programs to assist management of production performance. Specific examples will be discussed on the application to this approach at Australian industrial sites. Real-time RCM

Asset Effectiveness & RCM Problem: RCM frequently used to rationalise PM only Maintenance policy is established and the RCM logic is ‘archived’ Condition Maintenance (secondary actions) are segregated into specialist tasks the relationship to the parent modes of failure is ‘lost’ Limited use of automated data capture and decision support tools Resolving the huge quantity of equipment condition indicators and what they mean to modes of failure is ‘non-trivial’ RCM is all about managing equipment by modes of failure – not just setting up a maintenance program based on failure modes

The Proposed Solution The core of the asset effectiveness solution proposed by Honeywell is the Alert Manager decision support tool environment. The Alert Manager interacts with condition monitoring activities (on-line, periodic or tour based static records, process control systems etc) to provide a knowledge base that translates basic symptoms through diagnostic stages to maintenance actions. Combining all sources of equipment condition information for critical equipment unifies existing asset condition information and makes it accessible and visible to all stakeholders. The tree map view shown on this slide provides the ability to show the condition of the whole plant at a glance. It is highly filterable to allow equipment to be group as it needs to be seen (such as by equipment of a certain type or by equipment associated with each process for example). Each small block represents the hierarchical collection of equipment against which we collect condition information (perhaps a pump, a heat exchanger of a flotation cell). The size of the block is a normalised rating of its criticality to the production process and its colour indicates its current performance. Large red blocks warrant attention as they represent the greatest risk to plant performance.

The Alert Manager based solution also allows assets and their condition to be reviewed in a hierarchical structure more familiar to the maintenance workforce and replicating the structure established in the maintenance management system. From the hierarchical view you are able to directly access: Diagnostic Folders providing: visibility of the currently present symptoms , when they were reported and by whom visibility of the currently present faults, when they were reported and by whom currently recommended actions to address symptom/fault conditions history of symptoms, faults and close-out actions Information Folders access to information relevant to equipment performance, condition and reliability

The Alert Manager collects condition monitoring data from any source The Alert Manager collects condition monitoring data from any source. It can accept fault diagnosis from condition monitoring systems, and can automatically run spread sheet tools for analysis of data. Symptoms that are not avaiable through electronic detection are a ble to be entered manually. The system has a fault-symptom tree, so, based on the symptoms seen, the Alert Manager can also prompt the maintenance personnel to run further tests to aid in fault diagnosis if required, and finally diagnose the problem. Once a fault diagnosis is made, the Alert Manager can provide notification of the recommendation to initiate an appropriate response action. Maintenance recognition of equipment condition/performance issues then takes place in an automated environment allowing the earliest possible action to be initiated to lower the risk of equipment failure. Maintenance supervision can then be focused on detailed planing, ensuring that the resources, materials and equipment are available for people to perform their work in a fast, efficient, and accurate manner. With the Alert Manager, maintenance can be initiated based on the actual performance of assets and the measured deviation from expected performance. This allows unnecessary interference with equipment to be minimised. Alert Manager effectively links equipment condition data sources with the maintenance execution system increasing the ability to initiate valuable work that is really needed. This very practical method of asset condition management allows direct monitoring of the occurrence of equipment faults which are the specific source parameters around which your preventive maintenance programs should be based. Now that we are able to manage equipment health by managing the occurrence of faults we have a sound basis for establishing optimum maintenance frequencies, thereby minimising preventive maintenance costs. What we typically see is equipment failing periodically so that we can get a feel for the failure rate, often expressed as the mean time between failures. Because we capture the fault history directly in Alert Manager, we then have the periodicity data we need to optimise the preventive maintenance interval.

Asset Effectiveness Solutions Experion PKS Asset Effectiveness Solutions Industrial process management systems generate large volumes of data and standard systems translate this, to some extent, into information. An example would be the process control system generating alarms which inform the operator of the potential need for action. The people in your business process use their knowledge to interpret this information to make a decision on whether or not action is required. The value of this decision making process is immense as it is our major opportunity to vary plant production parameters to achieve reliable, sustainable production rates that provide us the greatest net margin between our cost of operation and volume/quality of product produced. If the decisions made are poor, ill-informed or untimely the result will something less than optimal production. The Experion PKS Process Knowledge System provides the functionality to improve information creation, management and delivery to facilitate the application of knowledge for improved decision quality. It also provides the capability to embed best practice knowledge into the tools used to assist decision making to reduce the variability in response to abnormal process operation and equipment performance. This allows sustainable performance improvement and mitigates against the loss of expertise and the need to re-learn knowledge on how best to operate the process and care for production assets. Experion PKS provides process knowledge tools and technologies that reach every level of your organisation. They will help you tap into, sustain and leverage the knowledge level within your organisation so staff are working on higher-level decision making functions and not data and information processing. Whilst Experion PKS includes many of the systems and interfaces that you regularly rely on and use to keep your plant operating, it integrates and packages data, information and knowledge to get the right information to the right person in a recognisable format as soon as it becomes available. This key differentiator distinguishes Experion PKS from traditional automation systems allowing users to leverage expert knowledge to achieve untapped performance results. The RCM methodology provides an excellent basis for the methodical and reviewable establishment of a planned maintenance regime with justifiable application of predictive and preventive techniques. To do this, it is based around an elegantly simple analysis process to determine what is important, how it can be adversely affected, how that might be detected and what mitigation action should be taken. This paper explores the application of the RCM methodology to systems, such as those controlled by Honeywell’s Experion PKS, rather than directly to equipment and their components and looks at the ways several leading industrial organisations are using their pro-active maintenance programs to assist management of production performance. Specific examples will be discussed on the application to this approach at Australian industrial sites. Real-time RCM