FIABILIDAD: Consultoria, Tecnologías y Aplicaciones · condición en una Planta Típica Hasta...
Transcript of FIABILIDAD: Consultoria, Tecnologías y Aplicaciones · condición en una Planta Típica Hasta...
FIABILIDAD:Consultoria, Tecnologíasy AplicacionesFrancisco Grela/Antonio Fuentes
Consultoría de FiabilidadFrancisco GrelaSoluciones de FiabilidadDirector de Ventas, Sur de Europa
4 de Febrero de 2016
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 3
What is Reliability?What is Reliability?
AvailabilitySafety
Profitability
Predictability
Corrosion
OPEXAsset Management
ConsistencyThro
ughp
ut Protection
Risk
Hea
lth
SHEVibration
Mai
nten
ance
Assets
Wear
Perf
orm
ance
IntegrityCondition
Sustainable
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 4
Reliability is …Reliability is …Availability Safety Profitability
Eliminate Unplanned Shutdowns / Slowdowns
Effective Maintenance Plan
Reliability Index
Incidents affecting people
Recordable environmental incidents
Protection of Assets
Sustain or Increase Throughput
Manage OPEX
Effective Turnarounds
Underperformance of Assets and Plant
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 5
Compelling FactsCompelling Facts
46%MECHANICAL FAILUREis the single greatest cause of process interruption (source: Marsh & McLennan Protection Consultants)
5%PRODUCTION CAPACITY LOSTProduction capacity is lost to as much as 5% every year as a result of unplanned shutdowns (source: Asdza Nadleehe, ‘‘Engineering & Maintenance: Prevention Is Better Than Cure,” Oil & Gas IQ, October 2011)
50%SAFETY INCIDENTSA typical refining facility will spend less than 10% of its time in transient operations. However, 50% of all process safety incidents occur during this time (source: Tame Your Transient Operations, Chemical Processing June 2010)
50%MORE REPAIR COSTSIt costs approximately 50% more to repair a failed asset than if the problem had been addressed prior to failure (source: U.S. National Response Center)
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 6
Emerson’s Reliability PortfolioEmerson’s Reliability PortfolioMachinery Health Management• Machinery protection and diagnostics• Vibration monitoring, analysis and prediction• Online, wireless, and portables solutions
Plant Asset Management• Integrated equipment health monitoring and performance
analysis• Asset Performance Management services• Smart field sensor and control element management
Lifecycle Services• Asset monitoring and performance improvement services• System maintenance and optimization• Training, repair and field services
Reliability Consulting• Maintenance and reliability consulting• Reliability engineering and project delivery• Foundational data services and management
Machinery Health Management• Machinery protection and diagnostics• Vibration monitoring, analysis and prediction• Online, wireless, and portables solutions
Plant Asset Management• Integrated equipment health monitoring and performance analysis• Asset Performance Management services• Smart field sensor and control element management
Lifecycle Services• Asset monitoring and performance improvement services• System maintenance and optimization• Training, repair and field services Pr
ojec
t Ser
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[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 7
■ Taxonomy■ Asset Records■ Inventory Records■ Bills of Material■ Standardized Content
■ Maintenance & Reliability –Training & Mentoring
■ Business Transformation■ Business Process Design■ Organization Design■ Program Management■ Change Management■ Enterprise Playbooks
■ PdM Products & Services –Vib, IR, US, Oil, MCE
■ Catapult Data Development■ AMS Suite – Integrated
Monitoring & Analysis■ Remote Monitoring
■ Program Standardization■ Criticality Analysis■ Reliability Strategy Development■ RCM/FMEA■ PdM Application■ Engineering Process Design
Maintenance and Reliability ServicesMaintenance and Reliability Services
DATAINTEGRITY
MAINTENANCE & RELIABILITYCONSULTING
ENABLINGTECHNOLOGIES
RELIABILITYENGINEERING
EAM Booster Packs
ReliabilityConsulting
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 8
$100
$346
$159
$219
Top Performers Hold a Huge Business AdvantageTop Performers Hold a Huge Business AdvantageReliability Business ImpactNormalized to First Quartile Performance
Based on 2013 Solomon RAM Study, Solomon Associates LLC
Com
para
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Mai
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Cos
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0
100
200
300
400
Mechanical Availability Index
6
7
8
9
101010
8.68.6
9.59.5
9.89.8
Fourth Quartile Third Quartile Second Quartile First Quartile
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 9
QUARTILE MAINT$(% RAV)
STORES$ (% RAV)
% VIBRATION % IR MECH % IR ELEC % OILANALYSIS
% OTHER NDT % ON PM % ON BOM
12 Industry TypesTop 1st 0.9% 0.3% 91.8% 71.0% 100.0% 38.1% 63.9% 21.0% 75.0%
Middle 1st 2.5% 0.6% 82.5% 60.9% 92.0% 35.7% 55.9% 23.0% 69.0%
Top 2nd 3.5% 0.7% 69.5% 51.7% 88.1% 29.8% 49.9% 25.0% 61.0%
Middle 2nd 5.0% 1.6% 56.1% 41.2% 85.1% 24.3% 41.0% 27.0% 57.0%
Top 3rd 6.5% 2.8% 42.8% 34.6% 79.8% 19.8% 35.9% 29.0% 55.0%
Middle 3rd 7.8% 3.9% 35.2% 21.2% 74.5% 15.4% 28.9% 32.0% 49.0%
Top 4th 9.1% 4.7% 26.1% 15.0% 68.7% 10.8% 22.1% 34.0% 46.0%
Middle 4th 13.7% 6.7% 13.2% 3.6% 60.9% 5.1% 15.9% 35.0% 39.0%
Bottom 4th 16.2% 10.2% 5.1% 0.0% 52.1% 1.0% 9.8% 39.0% 33.0%
Better maintenance performersdepend on
more asset health information
Benchmarks for Monitoring Asset HealthBenchmarks for Monitoring Asset Health
Source: Management Resources Group
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 10
Top Performer CharacteristicsTop Performer Characteristics• Predictive Maintenance (PdM) Technologies and Preventive
Maintenance (PM) drive about 80% of daily work– Over 50% daily work order hours are related to PdM– About 30% of daily work orders are related to PM
• Less than 5% of daily work orders are initiated via traditional work requests from equipment operators
• Objective and early work identification begins the chain of events:• Enough Time to Plan Work• Higher Schedule Compliance• Increased Wrench Time (>50% vs. US Average of 28%!)• Reduced Costs (Less Labor, Materials, Collateral Damage, DT) • Precision Repairs• Higher Reliability• More Production
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 11
Disconnected Silos Typical in 3rd and 4th Quartile PerformersDisconnected Silos Typical in 3rd and 4th Quartile Performers
supplychain
management
assetmaster data
planning,scheduling,
workexecution
maintenanceprocedures
processparameters
workidentification
conditionindicators
asset healthanalysis
Consulting & integrated technologies help clients connect silos of capabilities
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 12
Disconnected Silos Typical in 3rd and 4th Quartile PerformersDisconnected Silos Typical in 3rd and 4th Quartile Performers
Consulting & integrated technologies help clients connect silos of capabilities
assetmaster data
maintenanceprocedures
processparameters
conditionindicators
asset healthanalysis
workidentification
planning,scheduling,
workexecution
supplychain
management
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 13
Consulting & integrated technologies help clients connect silos of capabilities
Connected Integrated Elements Typical in 1st and 2nd Quartile PerformersConnected Integrated Elements Typical in 1st and 2nd Quartile Performers
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 14
The Reliability Value ChainThe Reliability Value Chain
Top performers have optimized elements and a fully connected value chain
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 15
Phased approach to improve your Reliability StrategyPhased approach to improve your Reliability Strategy
CLEAN YOUR DATA HOUSE
STEP UP YOUR INFORMATION
PUT IT ALL TOGETHER TO CREATE KNOWLEDGE
TAKE THE RIGHT ACTIONS AT THE RIGHT TIME
1234
Reliability Value Chain
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 16
“With Emerson ...”“With Emerson ...”Availability Safety Profitability
Move to proactive maintenance and ensure equipment is always available
Focus on the right assets by having insight into equipment health
Reduce Risk – Mitigate unplanned shutdowns
Gain insight into the comprehensive health of assets to avoid HSE risks
Maximise asset operation and performance
Minimise the duration and cost of a planned shutdown
Expertise, Technology & Services Improve financial and business performance through effective Enterprise Asset Management Provide expertise, resources and methodology
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 17
Questions?Questions?
Tecnologías para la Gestión de Activos y FiabilidadFrancisco GrelaAntonio Fuentes
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 19
Emerson’s Reliability PortfolioEmerson’s Reliability PortfolioMachinery Health Management• Machinery protection and diagnostics• Vibration monitoring, analysis and prediction• Online, wireless, and portables solutions
Plant Asset Management• Integrated equipment health monitoring and performance
analysis• Asset Performance Management services• Smart field sensor and control element management
Lifecycle Services• Asset monitoring and performance improvement services• System maintenance and optimization• Training, repair and field services
Reliability Consulting• Maintenance and reliability consulting• Reliability engineering and project delivery• Foundational data services and management
Machinery Health Management• Machinery protection and diagnostics• Vibration monitoring, analysis and prediction• Online, wireless, and portables solutions
Plant Asset Management• Integrated equipment health monitoring and performance analysis• Asset Performance Management services• Smart field sensor and control element management
Lifecycle Services• Asset monitoring and performance improvement services• System maintenance and optimization• Training, repair and field services Pr
ojec
t Ser
vice
s
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 20
Energy Management System
Operations
• DCS
Asset Management
FIELD ASSETS
Field Device DiagnosticsData Historian
• Device Configuration
Plant Wide Reliability SolutionsPlant Wide Reliability Solutions
Performance Monitoring
• Prediction integrated to existing Protection
CRITICAL ASSETS
• Prediction / Protection
Machinery Health Diagnostics
• Accelerometers / Velocity sensors / Displacement Probes
ESSENTIAL ASSETS
• Wireless vibration analysis
• Vibration analysis
Essential Asset Monitoring
CMMS
• Work Orders• Maintenance Actions
BALANCE OF PLANT ASSETS
• Data collection / vibration analysis (alignment, balancing)
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 21
Gestión de Instrumentos y VálvulasGestión de Instrumentos y Válvulas
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 22
AMS Suite: Intelligent Device ManagerAMS Suite: Intelligent Device Manager
Complete management of instruments and valves– Predictive diagnostics– Configuration– Documentation– Calibration management
SNAP-ON applications deliver additional capabilities
Based on open standards– HART, FOUNDATION Fieldbus,
PROFIBUS DP, OPC, XML, Web Services, WirelessHART
Scalable, with full client / server Supporting devices from all vendors
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 23
Gestión de Activos rotativos Gestión de Activos rotativos
Blowers/Fans Pumps
Compressors
Fin Fans Cooling Towers MotorsPumps
TurbinesGearboxes
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 24
Portable and Online Predictive Machinery Health™ Management SolutionsPortable and Online Predictive Machinery Health™ Management Solutions
CSI2140
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 25
Clasificación de Máquinas y tipo de monitorización de sucondición en una Planta TípicaClasificación de Máquinas y tipo de monitorización de sucondición en una Planta Típica
Hasta fallo
RO
I par
are
gist
roau
tom
átic
ode
da
tos
RO
I par
are
gist
rope
riód
ico
de
dato
s
TurbinasCompresores Calderas
Ventiladores MotoresEngranajesBombas
Generadores
Instrumentos portátiles
Transmisores
Soluciones en línea
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 26
Activos críticos (Protección –API670- y Predicción)Activos críticos (Protección –API670- y Predicción)
Reciprocating Compressors
Centrifugal Compressors
Pumps, MotorsGearboxes
Turbines
CSI 6500 familyCSI 6500 family
Advanced Diagnostics
Protection & Adv. Diagnostics Protection
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 27
Qué son Activos “esenciales”?Qué son Activos “esenciales”?• Cualquier activo cuyo fallo puede causar una perturbación importante en el
proceso o una parada o un retardo en la operación• No se consideran lo suficientemente críticos como para tener un sistema de
monitorización cableado• Tiene una instrumentación limitada para realizar una monitorización en
tiempo real• Sus fallos pueden ser considerados como de baja probabilidad y alto impacto
Fired Heaters
Pipes
VesselsBlowers/Fans
PumpsHeat Exchangers
CompressorsFin Fans Cooling Towers
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 28
Heat Exchangers
Cooling Towers
Blowers
CompressorsAir-Cooled Exchangers
Pumps
Essential Asset Monitoring Suite
Preconfigured applications built on AMS Asset Graphics software which combines process and asset data obtained from the field to report Overall Asset Health
Extensive use of WirelessHART technology
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 29
• CSI 2140 Analizador Portátil de Vibración• CSI 5200 Análisis de Aceites• CSI 9830 Termografía Infraroja
BALANCE OF PLANT (Route based monitoring)BALANCE OF PLANT (Route based monitoring)
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 30
AMS™ Suite: Machinery Health ManagerAMS™ Suite: Machinery Health Manager• Proporciona gestión de información de análisis
de vibraciones online y basado en rutas• Incluye datos de múltiples tecnologías de
diagnóstico predictivo• Análisis de Lubricantes• Termografía Infraroja• Ultrasonidos …
• Aconseja acciones y prioriza las actividades de mantenimiento
• Análisis automático que indica la naturaleza y severidad de la condición
• Analiza la causa raiz con información gráfica de los resultados
Diagnósticos Predictivos
Se integra con el sistema de control• Ovation, DeltaV y compatible con AMS Suite
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 312/3/201631
AMS Machinery Manager DiferenciadorHerramientas de Diagnóstico AvanzadoAMS Machinery Manager DiferenciadorHerramientas de Diagnóstico Avanzado• Orbitas• Centrado de Eje• Diagramas de Bode/Nyquist• Superposición de Gráficos• Cascadas en color• AnálisisTransient• Coherencias• Forma de onda circular• Cursor horizontal en plano• Funciones de respuesta en frecuencia
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 32
Comprehensive Approach to Machinery MonitoringComprehensive Approach to Machinery Monitoring
Reciprocating Compressors
Centrifugal Compressors
Pumps, MotorsGearboxes
CSI 6500Machinery Health Monitor for Online Machinery Protection
and Prediction
Predictive Diagnostics with AMS Machinery Manager (existing)DCS Monitoring Other Predictive Technologies
• Thermography• Oil Analysis• Alignment• Balancing• Electric motor analysis
OPC, XML Web Services, Meridium/Maximo
Performance Analysis with AMS Performance Advisor
Wi-HART Communications
CSI 21XX forAdvanced Portable
Prediction(existing)
CSI 9420 Wireless Vibration
Rosemount Wi-HART
Transmitters
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 33
AMS™ Performance Advisor / MonitorAMS™ Performance Advisor / MonitorAMS Performance Monitor• Monitorización remota del Performance a través de un
servicio de consultoría• Basado en modelos termodinámicos (KPIs)AMS Performance Advisor• Monitorización del performance en tiempo real• Integrado con protección y diagnósticos predictivos• Modelos ASME / ISO Standard
• Valoración del Performance de acuerdo a las especificaciones de diseño del fabricante
• Planifica actividades de mantenimiento y hace un seguimiento de su efecto en el Performance
• Determina que equipo y que sección precisa mantenimiento• Vigila el coste económico de la degradación del Performance del equipo
Monitorización de Performance
Se integra con el sistema de control• Ovation, DeltaV y compatible con AMS Suite
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 34
DEC’15 JAN’16 FEB’16 MAR’16 APR’16 MAY’16 JUN’16 DEC’16 JAN’17 FEB’17
Reliability Solutions – New productReliability Solutions – New product
CSI 6500 ATG
ARES
Ovation MHMCSI 2140 ATEX
ASSAULTARES
CSI 2140 ASI
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 35
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 36
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 37
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 38
Monitorización Activos EsencialesFrancisco GrelaAntonio Fuentes
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 40
Intercambiadores
Torres de refrigeración
Soplantes
CompresoresEnfriadores
Bombas
Aplicaciones de la monitorización de activos esenciales de Emerson
Aplicaciones preconfiguradas en AMS Asset Graphics que combinan datosde proceso y de activos para controlar la Condición General del Activo
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 41
Visión general del estado del
activo
AMS Suite: Asset Graphics
Datos de proceso y de la condición para
proporcionar alertastempranas
Información detalladade ayuda al
diagnóstico de la causa raiz
Aplicaciones de la monitorización de activosesenciales de Emerson
AMS Suite: Machinery Health Monitor
Permite la identificación de problemasen activos utilizando diagnósticos
predictivos
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 42
Datos de ProcesoP en descarga/Aspiración
DP en filtroP/L en sellos de aceite
CaudalesT aire/proceso
Fugas
Datos del ActivoVibración/PeakVueTM
T rodamientoVelocidad, energíaPosición mecánicaParada/arranque
Configuración inicial
Algoritmo que analiza
Cambios estadísticossignificativos y límites
max/min
Algoritmo que analiza
Cambios estadísticossignificativos y límites
max/min
Indicador de la condición del activo
La solución de Emerson utiliza algoritmos que combinan datosdel equipo y del proceso para informar de la condición del activoLa solución de Emerson utiliza algoritmos que combinan datosdel equipo y del proceso para informar de la condición del activo
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 43
Monitorización Activos EsencialesSolucion 1 – Desarrolle su propia aplicaciónMonitorización Activos EsencialesSolucion 1 – Desarrolle su propia aplicación
Bombas Recipientes/tuberíasEnfriadoresCompresores
El cliente define las alertas y la condición
SoplantesTorres refrigeraciónIntercambiadores
OPC
Supervisión de planta(con algoritmos del cliente o de otros)
DCS /OPC Server
Mantenimiento
Smart Wireless Gateway
Nuevos datos inalámbricos
IEC 62591 standard
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 44
“Build your Own” is not Simple!“Build your Own” is not Simple!
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 45
Monitorización Activos Esenciales de Emerson Solucion 2 – Use la solución de Emerson – en cualquier DCSMonitorización Activos Esenciales de Emerson
Solucion 2 – Use la solución de Emerson – en cualquier DCS
Condición del activo y alertas
EAM SoftwareModulos
OPC
Supervisiónde planta
DCS /OPC Server/
Mantenimiento
Datos existentesDatos de condición
PC Planta
Nota: Si el DCS es DeltaV, ya dispone de los módulos de la solución incluidos
Bombas Recipientes/tuberíasEnfriadoresCompresores
SoplantesTorres refrigeraciónIntercambiadores
Smart Wireless GatewayIEC 62591 standard
Nuevos datos inalámbricos
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 46
Monitorización Activos Esenciales de Emerson Solucion 3 – Use de forma autónoma el EAM software y HMIMonitorización Activos Esenciales de Emerson Solucion 3 – Use de forma autónoma el EAM software y HMI
EAM SoftwareModulos
OPC
Supervisor de Planta
Plataforma AMS AssetGraphics
completa
Bombas Recipientes/tuberíasEnfriadoresCompresores
SoplantesTorres refrigeraciónIntercambiadores
Smart Wireless GatewayIEC 62591 standard
Nuevos datos inalámbricos
Datos existentes
Monitorización de ActivosEsenciales. Análisis de Medidasdisponibles y no disponibles
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 48
What is the EAM Missing Measurements Analysis?What is the EAM Missing Measurements Analysis?Goal:
– By providing service to quickly identify the existing AND missing measurements – And relative value to the customer by using EAM software
What is the service?– Quick turnaround service to review customer P&IDs and provide easy to
understand report including:• Easy to Read Missing Measurements Report• Bill of Materials (Recommendation of hardware, software, services part numbers and
preliminary pricing)
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 49
Example ReportsExample Reports
1. Send Customer P&IDs for Review* (PW = Proposed Wireless measurement) 2. EAM Expert to Analyze for Existing and Missing
Measurements and create Easy to Understand Report
3. Visualize how EAM software can use Measurements for new calculations and alarms 4. Final Bill of Material recommendation
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 50
Beneficios de la Monitorización de ActivosEsenciales, es valioso para Ud.?Beneficios de la Monitorización de ActivosEsenciales, es valioso para Ud.?
En una refinería típica de 250.000 b/d un programa de monitorización de activos esenciales puede ahorrar hasta un 14% de costes de mantenimiento, 1.2% de aumento en su capacidad productiva y un 2% de costes de energía de precalentamiento al año
EntradasCapacidad de refino en barriles día 250000Margen neto por barril refinado $5,00Gasto en mantenimiento annual excluyendo paradas $50,000,000Costes energéticos por MBTU $6Dias de operación al año 350Beneficios operativosCapacidad de producción perdida debido a activos esenciales 3.5%Recuperación de producción con diagnósticos predictivos 30%Mejora operativa anual $5,512,500Beneficios en MantenimientoCostes de mantenimiento en activos esenciales respecto al total 70%Mantenimiento annual de activos esenciales $35,000,000Reducción media en costes de reparación debido a mantenimiento predictivo 20%Reducción de costes anuales de mantenimiento $7,000,000Beneficios energéticosRecuperación de energía por la mejora de la monitorización 10%Pre‐heat fouling maximum 20%EficienciaFired heater efficiency 80%If heater limited, % time unit is at maximum capacity 25%Annual Energía Cost Reduction $2,200,000TOTAL ANNUAL PROFIT IMPROVEMENT $14,712,500
Source: InTech, 2012. Improve reliability with essential asset monitoring
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 51
En resumen… Los retos críticos del negocio son todos interdependientes. Una única parada no programada
o retraso puede tener un efecto en cascada en su planta. Si la fiabilidad se ve afectada, así lo será su rendimiento, los costes, los márgenes,…
Solo siete clases de activos acumulan una media del 3,5% en pérdidas de producción y el 76% en gastos de mantenimiento.
Una mala fiabilidad puede provocar incidentes de seguridad y medio ambientales.
Comience en pequeños proyectos, pruebe el concepto – usted puede pilotar la monitorizaciónde sus activos esenciales y ampliar la cobertura a otros equipos a su criterio.
No sería mejor si Ud puediera de una forma eficaz… Recuperar pérdidas de producción causadas por paradas o retrasos no programados. Utilizar diagnósticos predictivos para reducir sus costes de mantenimiento.
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 53
BackupBackup
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 54
MRO Catalog (>7 Million Parts)Manufacturers List (>70,000)Equipment Templates (6,200)Equipment TaxonomyFMEA Templates (500+)Failure HierarchiesBOM TemplatesPdM BaselinePM Template
CONTENT LIBRARIES
Project Management StandardsStrategy Session ProceduresRCM/FMEA ProceduresBOM ProceduresPMO StandardsPM Procedures
STANDARDS
Catapult® SoftwareWebRUSL® SoftwareWork ManagementCriticality RankingReliability StrategyEquipment Master Data & Hierarchy
TOOLS
ACE™ Change Management ToolkitReadiness for Change SurveyIACET Certified Training Courses
CHANGE MANAGEMENT
Standards based approach.....drives scalability and consistencyStandards based approach.....drives scalability and consistency
150,000 MAN HOURSintellectual property
Assessments & Planning Data Configuration
Reliability EngineeringMaintenance Process Improvement
Inventory StandardisationBusiness Consulting
Training
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 55
H - RCM
Crit
ical
M - FMEA L - Template No Scheduled MaintenanceFMEA - Failure Mode
Effect Analysis is a systematic technique for failure analysis of equipment.
Templates – Generic maintenance strategies No scheduled maintenance is a
strategy that is often adopted when the consequence or impact of failure is considered negligible
Essential
RCM – Reliability Centred Maintenance is a process to ensure that systems continue to do what their users require in their present operating context
Criticality Use: Priority BandingCriticality Use: Priority Banding
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 56
Inventory ProcessOptimization
Storeroom Design & Kitting Integration
MRO Stock Optimization
CMMS / EAMEnhanced Master Data
ChangeManagementReadiness
KPIDevelopment
BusinessProcessDesign
WorkFlowDevelopment
Skills NeedsAnalysis
SkillAssessments
Training Plan& Schedule
ConductTraining
MROStrategy
EquipmentStrategy
EquipmentCriticality Strategy Session
StandardizedMRO Content
Master Equipment List Development
Equipment CriticalityDevelopment
RCFAMOM
ReliabilityStrategyDevelopment
BOMStrategy RCM PdM
Application
PdM Baselines BOMDevelopment FMEA PM
Development
Business Case Workshop& Calculator
Reliability Gap Analysis/ Foundational Data Assessment
Implementation, Planning & Strategy Sessions
Emerson’s Reliability Consulting Standards Emerson’s Reliability Consulting Standards
BUSINESSPROCEDURES
TRAINING
FOUNDATIONALELEMENTS
INVENTORYMATERIALSMANAGEMENT
RELIABILITY
SustainabilityAudits
Mentoring
InventoryMaintenance
OngoingMeasurement& Analysis
EnhancedReliabilityProgram
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 57
Energy Management System
Operations
• DCS
Asset Management
FIELD ASSETS
Field Device DiagnosticsData Historian
• Device Configuration
Plant Wide Reliability SolutionsPlant Wide Reliability Solutions
Performance Monitoring
• Prediction integrated to existing Protection
CRITICAL ASSETS
• Prediction / Protection
Machinery Health Diagnostics
• Accelerometers / Velocity sensors / Displacement Probes
ESSENTIAL ASSETS
• Wireless vibration analysis
• Vibration analysis
Essential Asset Monitoring
CMMS
• Work Orders• Maintenance Actions
BALANCE OF PLANT ASSETS
• Data collection / vibration analysis (alignment, balancing)
Emerson Confidential • 58Emerson Confidential • Slide 58
CSI Hardware SystemsCSI Hardware SystemsAdvanced
DiagnosticsProtection & Adv.
Diagnostics Protection
Up to 48 Prediction Channels
Up to 24 Protection and Prediction Channels
11 2-Channel Signal or 4-Channel Temp/Process Card
4-Channel Machinery Health Analyzer
Emerson Confidential • 59Emerson Confidential • Slide 59
Emerson Sensors and AccessoriesEmerson Sensors and Accessories• Accelerometers• Eddy Current Displacement Probes• Dynamic Pressure Transducers• Sensor Housings• Cables• Rosemount Temperature, Pressure