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© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. AV-09 Leveraging RCM Techniques to Address Today’s Challenges Presented at Avantis User Group 2012 Jason Vick Manager, Mobility Technical Sales Consultants

Slide 3 Introduction Reliability based initiatives are nothing new to our industry. Traditionally these initiatives have focused on: – Condition Directed Activities Tasks target preventing failures at the component level. – Time Directed Activities Tasks target preventing failures at the component level. –Failure Finding Activities Tasks target identification of failed components before a plant consequence. To achieve the goals of the Reliability Initiative it will take help from everyone at the plant. Success will also depend on your ability to enforce Procedures and create visibility to the data collected.

Slide 4 Agenda RCM Overview The IntelaTrac Solution Operations Maintenance Engineering Bad Actor Identification KPIs & ROIs

Slide 5 1 RCM Overview

Slide 6 Reliability Centered Maintenance (RCM) The RCM process was adapted from a program developed by the Airline industry in the 1960’s when they found it too cost prohibitive to upkeep the new larger planes that were being developed. The objective of the program is to develop a proactive maintenance plan to maintain continuous operation and maximize Plant throughput by maintaining target rates in a safe and environmentally responsible manner. To achieve this, a reliability-based maintenance, monitoring and testing program, and RCM process training for personnel responsible for implementing the recommendations needed to be implemented.

Slide 7 RCM Principles The initial RCM process begins with a three-step process that is performed in the Initial System Analysis (ISA). This process is a joint venture involving several groups including representatives from Operations, Instrument technicians, Inspection (Rotating and Pressure vessel groups) Electrical, and Machinery Maintenance. Identify the units objectives and specific operational functions required to achieve those objectives Evaluate the equipment, determine the dominate failure cause and the effect of that failure Identify the optimal task list to prevent that failure –Failure Finding –Failure Prevention/Postponement

Slide 8 Task Definition Workflow Example IntelaTrac Can Directly Impact These Areas

Slide 9 Organizational Challenges While RCM and other like initiatives offer huge benefits to many organizations, there are a host of challenges that prevent most people from achieving the highest levels of reliability. 1.Top down organizational support. 2.Employee Ownership. 3.Task Selection/Frequency. 4.Many PMs exist outside of CMMS (Data Visibility). 5.Deficient training (initial and ongoing). 6.Lack of Procedural Enforcement. 7.Misaligned Roles or lack of expertise.

Slide 10 Industry Challenges Example of Challenges in Process Industries: ●Over 50% of maintenance cost are directly related to improper operation of equipment. ●89% of all components fail randomly. These failures are most often caused by neglecting the basic care of equipment. ●Secondary equipment failures and production slowdowns are 8-10 times more costly than primary equipment failures. These failures are often caused by Reassembly Errors, Part Defects, Installation Errors, and Improper Operation. The front line workforce has the opportunity to radically improve plant reliability and operational profitability. Relying just on Maintenance does not allow us to drastically reduce failures.

Slide 11 2 The IntelaTrac Mobile Solution

Slide 12 Alarms & Events Startup/Shutdown Procedures Compliance IntelaTrac’s Mobile Platform Addresses Industry Challenges Field Worker Training Process Data Product Changeover Field Worker Rounds Logbook Lock Out / Tag Out Manual Maintenance

Slide 13 IntelaTrac Product Suite Procedure Builder– advanced procedure configuration Auditor Plus– work process and procedure review Mobile / Workstation IntelaTrac– procedure execution Web Reports – configurable reports, ing Schedule Manager– advanced scheduling & workload balancing

Slide 14 Procedure Builder Drag & Drop Configuration Procedure Items -basic building blocks Integrations to External Systems Peripheral Integration Conditions define follow- up Actions Single and Multiple Actions Decisions for Advanced Workflow

Slide 15 Leveraging Decisions Decisions allow a procedure to be configured in a way that enables the end user to execute Tasks in a true dynamic fashion. Examples of how Decisions can be used are: Scheduling Tasks either time based or condition based within a Procedure that will have its own schedule. Changing Tasks, Limits, and Actions based upon variable conditions Triggering of Rechecks or Revalidations For tasks that would trigger based on a single variable we typically just assign the “Conditional” Task to an actual Condition. PM Task Frequency must be as efficient and effective as possible. Thus PM Tasks must have the capability to be dynamic.

Slide 16 Integrations Integrations allows for data to be pushed/pulled to 3 rd party systems. Additionally, new integrations can be added to IntelaTrac to accomplish custom functions or communicate to 3 rd party software that is not currently supported. Some examples of Integrations are: Supported OSI PI Honeywell PHD AspenTech IP21 Wonderware Historian Wonderware Galaxy Custom Schedule Modifier Tietonator EC Bentley System One IntelaTrac Tag Just like an organization working together is critical for success of a Reliability Program, the different software used for the program must also easily work together.

Slide 17 Schedule Manager Calendar view of scheduled procedures. Ideal for PM Tasks that are outside of CMMS. Look Ahead (Current or Future Scheduled) Look Behind (Completed, Overdue or Missed) Drag & Drop Scheduling

Slide 18 Mobilizing Third-Party Systems Database Server Synchronization Server Configuration Scheduling Execution Storage Examples of Third Party Systems IntelaTrac SDK IntelaTrac Web Server

Slide 19 Mobile – Rounds & Procedures Operator is presented with a list of Tasks –Using Defined Pick Lists –Device / Virtual Keyboard –Peripheral Devices

Slide 20 Mobile – Free Text Notes & Logbook Free Text notes may be added at any time Or…triggered by an Action Enter free text or select a default note Default Notes can be edited Note is also available as a Log Entry

Slide 21 Mobile – Historical Readings History –Includes Notes –History Details –Historical Trends –Pan & Zoom

Slide 22 Mobile Trend Graphs Select one or more tags to view OPC-HDA Trends are transferred to the computer automatically Some trends are always available Zoom In / Zoom Out

Slide 23 Take Action ! Take Action ! Mobile-Focused Advice and Escalations Message Text can be calculated. Could be delivered from an external system at run time.

Slide 24 Mobile- Attached Documents Attached Documents provide a method to include additional information (usually reference material), in the form of a PDF, graphic, or spreadsheet, with a Procedure.

Slide 25 Images on the Mobile Mobile IntelaTrac users can attach images to Task Notes The Note and Image are stored together The user can add additional Notes and Images

Slide 26 Mobile – Procedure Sign-off

Slide 27 Auditor Plus Desktop application for Supervision Pre Configured Reports –Business Process Compliance –Exception –Administrative Drill down to the specific Procedure instance –Details –Graphing

Slide 28 Web Reports Creating Data Visibility through Scheduled and Ad Hoc Web-based Reporting.

Slide 29 3 Defect Identification

Slide 30 Defect Identification Defect Identification is the key to identifying and understanding the Root Cause of your Bad Actors? What causes a Bad Actor? –Deficient PMs –PM Task Frequency Incorrect –PM Not Performed As Scheduled –Procedural Enforcement –Parts Availability –Design Change Needed

Slide 31 As found during Operator Routine Duty Tasks Defect Identification: Seal Issues

Slide 32 Defect Identification: ENV Issues As found during Operator Commitment Tasks

Slide 33 Defect Identification: Vibration Issues Found as a result of extending current CM program with Operator collected vibration data via IntelaTrac

Slide 34 4 KPIs & ROI

Slide 35 KPIs & ROI Identifying Key Performance Indicators (KPIs) and ensuring your Return On Investment (ROI) are critical for any project executed at your plant. Now the questions are: –What do I track? –How do I track it?

Slide 36 KPIs Daily KPIs –Daily KPIs should be tracked for round completion percentages, approval percentages, and exceedences reported. ROI KPIs –Equipment Failure saves. –Work Orders written based off of IntelaTrac findings –Work order cost reductions Post-IntelaTrac versus Pre-IntelaTrac. –ENV Compliance –F&S Compliance Reliability Based KPIs –Unit Utilization Pre/Post IntelaTrac –PM Schedule Attainment –Equipment MTBF

Slide 37 Pump Reliability and Average Repair Cost – Refining Customer

Slide 38 % of Pumps Worked vs. Availability- Energy Customer Your Plant is Running At 98%...Is it Reliable?

Slide 39 ODR Driven Rotating Equipment Repair Cost Reduction - Valero Ardmore

Slide 40 Summary IntelaTrac manages the processes and procedures used to ensure that organizations consistently execute all field tasks required to achieve reliable operations IntelaTrac provides an extensible Task Management and Performance Monitoring System that fosters stewardship and accountability. IntelaTrac mobile applications provide contextual information and user guidance to help drive reliability and improve performance IntelaTrac tightly couples enterprise applications with field workers and actionable tools to implement and sustain reliable operations in a wide range of industries

Slide 41 Questions & Answers Contact Information: Jason Vick (m) +1 (302)