Plant Services - July 2008 - (Page 26)

Condition Monitoring CBM in the bull’s-eye RELIABILITY been,” says Wil Chin, director of field have been adapted for industrial use, Y FORECAST MANA ABILIT GEM CAP ENT systems for ARC, citing both ends and computing intelligence has been EN OPEN OP MAI of the DCS, from smarter sensors distributed down to the lowest levels NTE NA CALIBRATION T NC & CONFIG. EN and transmitters to more capable so that motors and pumps – any OEM REACTIVE M EM MGMT. MODEL MAINGE A RELIABILITY DCS software. “They not only asset with a microchip – can TENANCE INFO PREVENRCM can tell you what the process be put to work in a CBM TIVE PRE-PLANNED ANALYSIS MAINWORK PACKAGES INFO is doing, but how well the environment. Management MODEL TENANCE Open Capability Forecast WORK ORDER DATABASE TRACKING performance of the meaROOT So it’s no surprise that COMPONENT CAUSE MRO MATERIALS TRACKING CONDITIONANALYSIS surement is relative to a automation engineers have BASED INFO MRO LABOR GEO-SPATIAL MAINgiven standard.” In the been broadening their soSpare part TRACKING OPEN TENANCE MRO TOOLS OBJECT SPARE FAILURE integrated DCS environlutionsanalysisinclude mainto info PART REGISTRY HISTORIES ANALYSIS MGMT. ment, maintenance pertenance modules. For exINFO SE sonnel “no longer have ample, GE Fanuc (www. R NS OR REGIS T LE to wait until regular PM gefanuc.com) in April anDYN MP A SA AT DAT . D A rounds,” because the system nounced the addition of a A D AG LARM ATA MANIPULATION TION will track deviations from Maintenance Gateway modT EN & EV EC EN IN TD ENT STATE DET TE IAG SSM ENT preset limits based on historic ule to its Proficy automaLL NOS SSE IGE IN TIC HEALTH A SSM N NT TE SSE trends to provide health status tion software suite. The system AGE LL TIO NT PROGNOSTIC A IGE RA NT ENE and trigger alarms in real time. can reside on the plant floor, in G AGEN T O&M ADVISORY OP EN C NT In general, PAMs don’t offer a the maintenance department or in ONDITION MANAGEME unified environment to directly inboth places. “It doesn’t matter,” says tegrate plant and site assets. The Pi Mike Yost, Proficy product marketFigure 1. The MIMOSA architecture supports enterprise historian and suite of reing manager, adding that “the same CBM by facilitating integration of reliability, lated products from OSIsoft (www. performance OEE [overall equipment maintenance and condition management. osisoft.com) is a pervasive solution effectiveness] number is seen across the for integrating real-time data, typigrating with and sending messages to entire platform” for quicker identificacally in process-industry applications the EAM/CMMS. Invensys, whose tion and correction of problems. that trend maintenance data. The core Wonderware plant automation softSimilarly, major distributed control function of this product is to manage ware and Foxboro DCS business units system (DCS) suppliers, including process data such as analog and digital both offer maintenance add-ons, ofEmerson, Honeywell and ABB on the readings; product, material and batch fers arguably the broadest and deepest process side, offer what tech-analyst information; quality information inplatform for integration, particularly firm ARC Advisory Group (www. cluding upper and lower limits; and because it also owns the Avantis EAM arc-web.com) calls a “plant asset man120 aggregated process-variable averages. system. But integration partnerships agement” (PAM) system. PAM soft100 80 Some established condition-moniabound for those who wish to operate ware is part of the DCS and directly 60 Gas Index 40 toring suppliers have been acquired by in a CBM environment. OEE communicates with sensors to predict 20 0 companies also involved in real-time “There’s a lot more intelligence in failures, alerting the plant users to control, such as Rockwell Automathe field [device] than there ever has equipment problems as well as inteYM AN A NT ME GE NA OPEN REL IAB ILIT Percentage Mohawk keeps tabs on paper A paper machine is roughly the size of a football field and houses a “microcosm of hundreds of different machines and controls working in unison,” says Paul Stamas, vice president of information technology at Mohawk Fine Paper, Cohoes, N.Y. Across five plants and additional converting facilities, the company tracks as many as 20,000 data points. A mix of discrete, batch and continuous process operations call upon real-time controls and software from ABB, Rockwell Automation and GE Fanuc. An OSIsoft Pi process historian serves as a “giant octopus” that connects once-disparate data, and now trends and correlates time and events such as paper machine speed, ambient temperature and energy usage. “Our plan is to feed condition-based data from the factory floor into Pi, and then into the Infor EAM system,” Stamas says, going live in June. He says that Mohawk, with revenues under $400 million, is the second-largest producer of wind power in U.S. manufacturing (behind much-larger Johnson & Johnson). “For both economic and socioeconomic reasons,” he says, the company is considering adding Infor’s new Asset Sustainability Edition. 26 Headline 01/2006 01/2006 01/2006 02/2006 02/2006 02/2006 03/2006 03/2006 03/2006 04/2006 04/2006 05/2006 05/2006 05/2006 06/2006 06/2006 06/2006 07/2006 07/2006 07/2006 08/2006 08/2006 08/2006 09/2006 09/2006 10/2006 10/2006 10/2006 11/2006 11/2006 11/2006 12/2006 12/2006 12/2006 01/2007 01/2007 02 /2007 02 /2007 02 /2007 03 /2007 03 /2007 03 /2007 04 /2007 04 /2007 04 /2007 Actual usage (KWH): Design usage (kwH): 1,048,112 933,510 Actual cost: Design Cost: Profit or loss: $86,530 $77,066 (9,434) www.PLANTSERVICES.com BIN DA ARY TA . OPTA DA Y July 2008 http://www.gefanuc.com http://www.gefanuc.com http://www.osisoft.com http://www.osisoft.com http://www.arc-web.com http://www.arc-web.com http://www.PLANTSERVICES.com

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Plant Services - July 2008 Contents From the Editor Letters The PS Files Up and Running Crisis Corner Asset Manager Technology Toolbox Cover Story Compressors Power Transmission Flooring Web Hunter In the Trenches Product Picks Classifieds Energy Expert

Plant Services - July 2008

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