Optimisation of Maintenance

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1 Integrated Engineering Workshop 3: Integrated Maintenance Management Optimisation of Maintenance Dr. Thomas Müller-Heinzerling, Manager Technological Concepts, Siemens Karlsruhe siemens.com/answers

2 Workshop 3 - Optimisation of Maintenance Dr. Thomas Müller-Heinzerling Professional experience 1982 Diploma in experimental physics: Mößbauer spectroskopy 1985 Ph.D. in experimental physics: Superconductors from 1985 Siemens AG Product management for the distributed control system TELEPERM M from 1988 Focus on Batch Management, Project lead for BATCH X from 1991 Member of ISA SP88 and DKE AK931 Batch Control from 1992 German technical expert in IEC SC 65 TC65A WG11 Batch Control (now IEC MT61512) from 1995 Focus on Life Sciences and Validation; member of NAMUR/ GMA working group on validation from 2005 Project lead for Asset Management for mechanical plant components Manager Technological Concepts Siemens Karlsruhe Seite 2

3 The situation today Maintenance strategies The classical forms of maintenance strategies are: reactive / failure-driven or preventive (i.e. cyclical). These forms still prevail in todays process plants. Predictive (i.e. condition-based, forward-looking) maintenance is not in common use. Seite 4

4 The situation today Many involved systems with separate data repositories?? ERP system (Enterprise Resource Planning) Plant design tool(s)? EAM system (Enterprise Asset Management) Engineering data Online data DCS (Distributed Control System) Seite 5

5 The situation today Systems with separate data repositories example flow measurement?? Plant design tool(s)? Engineering data Online data ERP system (Enterprise Resource Planning) EAM system (Enterprise Asset Management) DCS (Distributed Control System) Seite 6

6 The situation today Systems with separate data repositories example pump?? ERP system (Enterprise Resource Planning) Plant design tool(s)? EAM system (Enterprise Asset Management) Engineering data Online data X X DCS (Distributed Control System) Seite 7

7 The situation today Manual Condition Monitoring, Maintenance orders on paper Condition Monitoring / Health checks of the assets: Simple checks (noise, oil level, ) in conjunction with plant inspections More thorough checks (vibration spectra, thermal imaging, ) only: for very few assets / in larger intervals / by specialists Consideration of construction or design data (e.g. maximum number of operating cycles, maximum number of operating hours) à manually / on paper Maintenance: Reactive and cyclical execution Maintenance orders are printed out Additional information (wiring diagrams, exploded views, ) on paper à need to be found and possibly be carried on-site Seite 8

8 Our expectations for the future Change of the mix of maintenance strategies, better diagnostics Decrease of the classical forms: reactive resp. preventive Increase of predictive maintenance: Seite 9

9 Our vision for the future Connected systems with shared data repositories ERP system (Enterprise Resource Planning) Plant design tool(s) COMOS COMOS EAM system (Enterprise Asset Management) Engineering data Online data DCS (Distributed Control System) Seite 10

10 Our vision for the future Integrated Condition Monitoring, paperless maintenance orders Condition Monitoring / Health-Checks der Assets: Increase of on-line condition monitoring Support through more intelligent devices with self-diagnostics and by diagnostic functions in DCS or MES (Manufacturing Execution System) More thorough checks (vibration spectra, thermal imaging, ) continue to be used for some assets / in larger intervals / not only by specialists Consideration of construction or design data (e.g. maximum number of operating cycles, maximum number of operating hours) à through automatic / system supported data exchange Maintenance: reactive, cyclical and, where possible and beneficial, event-driven execution Maintenance orders are handled electronically Additional information (wiring diagrams, exploded views, ) are available electronically Seite 11

11 Live demo at the Siemens booth Five examples for improvements of maintenance Example 1: Avoidance of maintenance through Condition Monitoring: Recognition and correction of an unhealthy operating state: beginning cavitation of a pump Early warning regime Current NPSH value NPSH characteristic Cavitation regime Result: Endangered asset saved, plant disturbance and unnecessary maintenance prevented! Seite 12

12 Live demo at the Siemens booth Five examples for improvements of maintenance Example 2: Optimal reactive maintenance through fast recognition and repair of a failure: Wire break at the Coriolis flowmeter FC430 Result: Asset with sudden failure repaired in optimum time using design data with automatic documentation! Seite 13

13 Live demo at the Siemens booth Five examples for improvements of maintenance Example 3: Predictive maintenance through early detection of arising maintenance demand: Operation of control system bus is deteriorating Result: Asset with creeping deterioration detected in time, repaired, disturbance prevented! Seite 14

14 Live demo at the Siemens booth Five examples for improvements of maintenance Example 4: Predictive maintenance through evaluation of process data for mechanical assets: Sporadically operated electric motor approaches operating hour limit Result: Asset with approaching maint. demand recognized, maintenance planned for appropriate point in time and spare parts ordered just-in-time. Extrapolation in MRO à Prediction of remaining life-time Seite 15

15 Live demo at the Siemens booth Five examples for improvements of maintenance Example 5: Plant performance improvement, energy savings and predictive maintenance: Recognition of bad performance and maintenance demand of a pump with large efficiency loss Efficiency loss through non-optimal operating point Efficiency characteristic Efficiency loss through wear Power demand characteristic Result: Asset with bad performance identified, possibly furnished with an inverter J, maintained in time, energy saved! Seite 16

16 Live demo at the Siemens booth Invitation Floor plan of the Siemens booth in the Mezzanine: Maintenance Result: Feedback, exchange of ideas, inspiration for both sides J Seite 17

17 Thank you! Integrated Engineering Dr. Thomas Müller-Heinzerling Vertical Sector Sales Chemical Industry Concepts and Technology Siemens AG Karlsruhe Industry Sector Karlsruhe and Nürnberg siemens.com/answers Seite 18

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