1) Braskem implemented an in-house asset management MVP to monitor automation systems and identify opportunities to reduce maintenance costs and failures. 2) A pilot project using the MVP in a polyethylene plant identified issues to address. Braskem then decided to implement Yokogawa's Maintenance Support System for improved predictive maintenance across its sites. 3) The MSS will be deployed at Braskem's Camaçari site in Brazil within 6 months and rolled out to other plants in 2021, with the goals of increasing availability, reducing management hours and field activities, and saving an estimated $150k per year.

1. Fabio Magalhaes
Senior Automation Engineer
Braskem
November 12, 2020
A New Digital Maintenance
Platform to Identify,
Protect, Detect, Respond
and Recover More
Effectively

2. Agenda
1. In-house Asset Management Solution
(MVP)
2. Motivation to Implement Asset
Management Solution
3. Go Into MVP Details
4. Pilot Project in a Polyethylene Plant
5. Maintenance Support System
6. What is coming next?
Sincere thanks to my co-authors: Mr. Anderson Paim and Ms. Ananda Teixeira

3. In-house Asset Management
Solution (MVP)

4. Automation Systems
DCS/PLC/SIS…
Other sources (PIMS/PI
databases/spread
sheets/manual inputs…)
MVP for Automation Asset Management
• Internal initiative handled by
Braskem’s automation engineers
(Mr. Anderson Paim and Ms.
Ananda Texeira) with startup
company, HCN
• Applicable at the Camaçari
Complex, Bahia state, Brazil
• Digital transformation and
industry 4.0 concepts,
methodology and tools
Connection driver,
Gateway and codes
Database
Dashboards,
Reports, trends,
treemaps …
MVP – Automation
Asset Management

5. Motivation to Implement Asset
Management Solution

6. Motivation to Implement New Solution
• Online monitoring, FUP of MTBF, life cycle, spare points, prescriptive
and predictive maintenance, optimized maintenance plan, control tower
with specialized personnel
To capture opportunities:
• High cost of maintenance (several systems and vendors, contracts,
turnover, high MTTR, preventive maintenance plan)
• Increase in DCS hardware failure in last three years
To solve problems:

7. 3507 t
1916 t
Motivation to Implement New Solution

8. MVP Definition

9. MVP – Functional Design Specification
Control tower (WEB layout)
Plant view: drill down
• Plant, systems, devices, channels: inventory, life cycle, diagnostics
Automation System KPIs
• Availability, integrity, MTBF, MTTR, failure rate, OEE, n of failure by model or
vendor, % of spare points, % of free licenses, no. of downloads, loss of production
due to automation device failure
Connection and Access
• Good quality and user-friendly interface
Outputs
• Dashboards, maintenance reports, management reports, trends, search tools
Codes
• Open, user-friendly tools, easy to edit and maintain
Warnings
• Emails, text messages: in case of failure or low performance
Integration
• PLC, DCS, SIS, subsystems, ERP, maintenance management software, PIMS/PI,
databases, spread sheets, manual inputs
Cyber Security
• Access control, user level, cyber policies

10. MVP – Logical Architecture
Web
(Braskem Intranet)
Dashboards
(Asset Management
Layout)
Warnings
SMS/e-mails
Logical
Architecture
Server Digital
Solutions
(Virtual Server)
DCS 🡪 OPC
(Emerson/Yokogawa/
Rockwell/etc…)
PI IP21
(PE1/PE2/PE3
Q1/CS1/PVC1)
Database
(Text/SQL/XLS/PDF)
Human
(WEB HMI)
System Integration
(SAP/SAGI/Process Guard/
Guardian)
Data
Acquisition

11. MVP – Physical Architecture

12. Pilot Project in Polyethylene Plant

13. Pilot Project in PE-3
System spec:
• Delta V v12.3.1 software license version
• DeltaV MD/MD Controller (VE3005)
• AI Card, 8 Ch., 4-20 mA, HART (KJ3002X1-BA1)/ AI Card, 8 Ch., 1-5 VDC (KJ3002X1-BD1)/ AO Card, 8 Ch., 4-20 mA, HART
(KJ3002X1-BE1)/ DI Card, 32 Ch., High Density (KJ3001X1-CA1)/ Discrete Out Card, 32, ch, 24 Vdc, High Side. (KJ3001X1-BJ1)/
RTD Card, 8 Ch., (KJ3002X1-BF1)/ Prog. Serial Card, 2 Ports, RS232/RS485 (KJ3003X1-BA1)/ Mynah MIM-4207
Data
Acquisition

15. Summary of plant automation asset status according to subject

16. Pilot Project Tools and Codes
• Python 2.7: OPC connection driver to Delta V,
gateway to MySQL and code editor
• Sublime Text 3: Used to edit and maintain Python
codes. Three main routines:
• 1 minute update routines (processors, controllers and
workstations)
• 5 minutes update routines (DCS channels)
• 1 hour update routines (calcs: KPI (availability, integrity), MTBF,
MTTR, life cycle)
• OPC Remote and OPCWatchit: Used to do data
monitoring (data quality analysis)
• MySQL Workbench 6.3: Database. It is used by
Power BI
• WEB interface to allow manual inputs of MySQL
foreign keys
• No routine nor scripts running in Power BI platform
Calcs and treatment for MySQL Python OpenOPC library
MySQL connection

17. Maintenance Support System (MSS)

18. Predictive Tool – Yokogawa MSS
Motivation
• Braskem boosting industry 4.0 themes and predictive maintenance initiatives
• Benchmark Shell and Yokogawa in Europe
• Good results and usedness of PE-3 MVP
• An opportunity that came up during Yokogawa contract renewal
What is MSS?
• Maintenance Support System: Yokogawa solution based on predictive tool as a digital platform to perform asset management
• Maintenance solution using Industry 4.0 concepts
Features
• Online monitoring of layers 1 and 2 devices of industrial networks architecture
• Getting data from automation tools, databases and manual inputs (spread sheets, etc)
• Sort events, data modeling and data science analysis
• Provide warnings, logs, text messages, e-mails with the event information and mitigation plan
Coverage/ Rangeability
• Large amount of application: OS, networks, data bases, IoT devices, DCS, SIS, PLC, OT systems, local or virtual interfaces
• Multi vendor
Deliverables/ Expected results
• Automatic warnings and register of occurrences in order to accomplish the main workflow of OT passive monitoring solutions: identify, protect,
detect, respond and recover
• Asset management through dash boards: OT monitoring issues, asset management and alarms view

19. Predictive Tool – Yokogawa MSS
To be implemented in Camaçari
site within 6 months

20. Challenges of Implementation
Integration of MSS Site Server (level
3.5, DMZ Zone) and MSS Center
Server (level 4, Office Domain Zone)
Deal with old systems at level 1 layer.
Specially those ones without Ethernet
interfaces

21. Expected Results
Deliver highest
predictable
availability at
lowest cost
Capture new opportunities:
• Better decisions, faster – provide information and
understanding directly to decision makers to make
improvements – via e-mail or text messages
Solve problems:
• Reduction of c. US$ 150K this year due to new
contract basis including online asset passive
monitoring tool.
Reduce management hours to generate KPI
reports, preventive routines and some activities in
the field to get troubleshooting information.
Applicable at the Camaçari Complex, Bahia state,
Brazil
• Reduction of 30+% man-hours. Some field activities
replaced by MSS automatic outputs.

22. What’s Coming Next?

23. Next Steps
MSS to be implemented in Camaçari site within 6 months
Roll out to remaining plants in Northeast Brazil in 2021
OT monitoring as a complementary solution in 2021, 2022
• 3G and MQTT/AMQP/OPC-UA
• WEB server with HTML-5 interface as a supervisory
• CODESYS and IEC-61131 edition
• Embed VPN and firewall
• 64GB SD memory: allow implementation of MySQL databases, Excell applications and HTML-5 pages
Technology prospecting: PLC to specific applications

24. The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders.
Thought
“Restlessness is discontent and
discontent is the first necessity of
progress. Show me a thoroughly
satisfied man and I will show you
a failure.”
Thomas Alva Edison