Transition to online AMS reduces maintenance costs and improves operations
•Download as PPT, PDF•
1 like•990 views
Presented by David Rabon and Mike Ruhle at the 2011 Emerson Exchange in Nashville. Abstract: The utilities department at Pfizer Inc. in Groton, CT has leveraged an investment in SMART technologies to move from a failure/preventative maintenance process to a reliability based process. With a DeltaV upgrade, online AMS and Valvelink snap-on were installed. The software along with training/mentoring and a change in work practices have improved maintenance efficiency and costs. In the past work was performed when operations identified a process related alert only. Now the technicians help identify issues, generate work orders and resolve them before they become process issues.
![Presenters ,[object Object],[object Object],[object Object],[object Object]](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)
Recommended
Recommended
More Related Content
What's hot
What's hot (20)
Similar to Transition to online AMS reduces maintenance costs and improves operations
Similar to Transition to online AMS reduces maintenance costs and improves operations (20)
More from Emerson Exchange
More from Emerson Exchange (16)
Recently uploaded
Recently uploaded (20)
Transition to online AMS reduces maintenance costs and improves operations
- 1. Transition to online AMS reduces maintenance costs and improves operations Workshop 1A-2942
- 8. Pfizer Groton DeltaV & AMS System Overview Foundation Fieldbus, HART I/O & Field Devices DeltaV Engineering & AMS Server - AMS Client – Device alerts routed to Maintenance station I&C Shop DeltaV Controller and I/O System Control Room- Pro Plus Operator Stations – Process alerts and Device feedback only. No device alerts configured. DeltaV Network AMS Communications
- 10. Going online – After the upgrade
- 15. Example – XTCCHW-100-01 Before
- 16. Example - XTCCHW-100-01 After
- 18. Examples – XPCVBFP-12-1 Before
- 19. Examples – XPCVBFP-12-1 After
Editor's Notes
- Vision : The project team had a short term vision to use the technology to execute the project more effectively. The plant team began figure out a long term vision on how use the technology long term to improve their maintenance.
- Timeline: Boiler upgrade, Began using diagnostics to validate rebuild, Began using alerts online, Making PM recommendations based on diagnostics, Optimized calibration list based on real data versus time, AMS online, Maintenance station and alerts in shop, Using AMS as first look tool . Provox Integration: Alerts reported back a A,B or C level diagnostic errors that had to be researched through the Provox diagnostic tool.
- Upgrade notes: Challenge with AMS on proplus. More convenient for the technicians when installed on a maintenance station in the tech’s shop. Projects: We used the projects to leverage the expansion of the DeltaV AMS to other systems. Hart devices that were isolated, became connected to the shop via AMS.
- Emphasize the Maintenance Station. Not whole system, just representation of AMS centric areas
- -We had proven the value to the point where we could make some Organizational changes (Champion recognized) -At that point in our knowledge, we recognized the assistance of our local integrator could move us ahead much faster. NEC knew the options we had, Champion had sufficient understanding to make informed decisions about the options. -Mentoring visits allowed Pfizer to explore options and get advice from experience as well.
- Display maintenance techs checks. Shows device errors. This is a standard DeltaV Alarm Summary display filtered for Field Device and DeltaV Hardware Alerts only, then saved as a new graphic called Device Alerts Summary.
- Challenge was to build trust in the data from AMS.
- EQ-02 Discharge pH Probe Diagnostic evaluation revealed an “Offset Error” warning and the Help files assisted in my correcting it. This saved replacement of the probe, fairly expensive for that SS type, which would most likely have been the course of action (Pre-AMS) upon it’s not being able to hold a calibration. Reduced troubleshooting time. Saved a good part from being changed. System returned to operation sooner. Offset error appeared as a device alert (Rosemount Analytical 5081 HART pH analyzer). Help indicated Possible Causes and Checks: 1. Zero offset errors can indicate poisoning of the reference electrode, which requires it to be replaced. 2. A false error can result from trying to erroneously standardize a pH reading more than 1 pH unit. If the cause is Item 2. above, a new standardization (calibration) will solve the problem. Savings Avoided cost of new probe Reduction in troubleshooting time Unit back to operation sooner
- Air mass flow indicated a air issue. Further investigation found that both the instrument air regulator was damaged by corrosion and not working and the relay and i/p was not working properly. Issue found in winter and could do work when demand not critical. If summer could have caused issues. Chiller 100 Flow Control valve not working properly Found a PD online/in-service alert record PD alert simplified troubleshooting Corrected issue before high demand months POINT OUT SCALE 140 to 220 SCFH versus 4-12 SCFH Air flow
- Point out difference in air flow in the 2 graphs.
- Add categories for savings: Avoided downtime Reduction in energy. Calculations are only for (4) months. If gone longer without finding – savings would have been $2100/year
- Two issues were found on 12 valve one on 11 valve. First the instrument air tubing on 12 was found to interfere with the valve travel not allowing full travel of valve and caused calibration to fail. Second, both valves had pneumatic lock up valves installed that allow it to fail last upon loss of air pressure. These lock up valves were not installed correctly, not allowing valve to function properly. 12 valve would not function at all, 11 valve functioned however, not optimally and could have locked up during operation Call in to fix valve issue Visually found travel feedback arm disconnected- could not calibrate or use diagnostics. This graph is after mechanical interference fixed. Used Diagnostics to find additional issue (lock in last valve) Two issues found Mechanical interference with Travel feedback arm Pneumatic lock in last valve not tubed to supply Found the right root causes and faster Fixed the real issues on both valves before a trip required switchover to other feedpumps Might now have noticed the issue with a standard calibration
- Savings details Avoided troubleshooting and maintenance hours. If not redundant pumps, and boilers, this downtime would have been more costly.
- Effluent Discharge mag flow meter EQ02-1-2 is a mag flow meter associated with the discharge of the effluent. It was locked into an over-ranged PV condition thereby rendering it useless to operations. Utilizing AMS, I was able to troubleshoot and correct the issue at the Maintenance station. This flow meter electronics box is located in B-192 and has a very cumbersome user interface. AMS made working with it extremely more user friendly. Reduced maintenance cost and reduced time without effluent data DeltaV alert – call from operations. This was during start-up of some equipment that was moved from another system to DeltaV. The 4-20mA range in the instrument had been configured incorrectly and didn’t match the range in DeltaV. AMS helped figure this out quickly. Reduction in maintenance costs. Up in air, so getting to device is challenge and takes extra time. High lift or staging.
- Used diagnostics to prove positioner issue versus mechanical issue and prevented unecessary opening of valve. Found that positioner had similar problem to #1 oil valve. Had to put boiler in manual for 6 weeks until diagnostics findings were accepted. The feedsystem and DA loops were unstable during that time. Boiler # 5 Feed reg valve operating erratically Boiler had to be put in manual Reduced Maintenance cost by not assuming mechanical issue and unnecessarily opening valve After resolution - Improved control and allowed for run on #5 on high load days NOTE THAT THIS IS POT ISSUE DUE TO UNOBTAINABLE TRAVELS
- Savings details: Reduction in maintenance costs by not opening valve (mechanical work). Ability to use #5 boiler on high load day. Savings in cost to run this boiler more efficiently.
- Avoided downtime minimal because of equipment redundancy. Finding issues before they are operations issue.