Rockwell_subbed.qxp 1/4/09 12:26 Page 48
Asset Performance Management Systems Boost Reliability and Profitability
Figure 1: Production Manager’s Report
Gelsenkirchen
Plant production Plant constraints
Total capacity 69.26
(tons/hour)
Total opportunity 1.17
71
March 2008
Total production 70
Sun Mon Tues Wed Thur Fri Sat 69
Production
PPS: silence
1 Opportunity
68 Delta production 75.11%
2 345678
9 101112131415
67
Per cent: 75.11%
16 17 18 19 20 21 22
66
23 24 25 26 27 28 29
30 31 68.1
0
04/03/2008
Line production Line production Line production
(tons/hour) (tons/hour) (tons/hour)
18.4 10.8 43
18.2
10.6 42
18 Production
10.4
Production
41
Production
17.8
Opportunity
10.2
Opportunity
40
Opportunity
17.6
17.4
10 39
17.2
9.8 38
0 9.6 37
PPF23 PPF24 PP5
17.5 10.3 40.3
One ton = 907kg. PPF = polypropylene; PP5 = polypropylene line 5.
common lesson drawn from four projects indicates that one may who, what, where, why and how. Considering these questions will
utilise the electrical contractor for cable installation in terms of the drive the design team to determine what data are needed, where
cable scheduling, but one should rely on technical specialists to they are needed and how they will be utilised for project success.
terminate the network cabling throughout the facility.
Consideration must be given as to whether to implement a
An effective network strategy will evolve from the selection of centralised or federated data model. Given the size of systems today,
intelligent protection devices, selection of controlling methods, a centralised data model has the potential to grow to an
operation and maintenance methods and the agreed degree of unmanageable size that is difficult to maintain. It does have common
interface with the DCS. While this is often a cause of dissention in rules and simplifies tag tracking, but factors such as price and system
project ranks, the growing size of databases should lead one to performance should be considered. While answering these
consider a federated data model consolidated by a designated questions, timing of systems and what operators are required to see
historian. Developing a network strategy will first evolve from a should be evaluated. A load-shedding system will need to respond in
thorough understanding of the data, what networks are required and 150ms; a benchmark of 10 seconds elapsing while the system builds
who needs to look at the data. Working the network strategy must a record for the operators to see what happened is probably
be accomplished in concert with development of a data strategy. acceptable. Needing a pump to start to head off a shutdown that,
Once the data strategy is finalised, the network strategy should be consequently, takes 15 seconds to occur because the system is
revised to ensure that all data moving requirements are met. bogged down with data is not likely to be acceptable.
Once it is determined where the data are being generated from, In this case, a federated data model may be considered where data
where the information needs to go should be considered. Production consolidation occurs with historians and Internet-based visualisation
operations will need to understand which system is running and at tools versus consolidating at the DCS. The performance gained does
what levels. They will require a view of breaker status and motor have the downside of enforced vigilance in name-tag usage and
starter status. More in-depth data will be required of the electrical methods, but it allows each responsible party to manage the data
system operators and a slightly deeper layer of data will be required required to execute a piece of the overall operation for success.
for maintenance and asset management personnel. This must all be
defined, as well as the locations of the people who require the data. Next, consider who needs the data and in what time-frame the data
This will determine where the wider area network must reach to are required. It is too time-intensive and requires too many resources
drive maximum system effectiveness. The full schematic of the to allow full data exchange among all systems. Role-based
network and a written specification describing the strategy becomes visualisation streamlines data movement and helps fine-tune
the documentation for the overall network strategy. It defines network strategies. Determine who needs the data and the timing of
performance parameters, people affected and how the network is the particular requirement and document it. In the case of a refinery
implemented. It also should define network security methods. in the Mid-West, fast tasks such as load shedding occurred without
visualisation and happened in 150ms. Visualisation for control and
Next, Develop a Data Strategy control functions occurred in a two-second cycle. Remotely located
Optimum APM requires not only developing a network strategy, but rotating asset experts needed to see trends over time. The system
also creating a data strategy. This comes back to simple questions of provided these data over a 12-hour cycle with one-second resolution
48
EXPLORATION & PRODUCTION – VOLUME 7 ISSUE 1
Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64  |  Page 65  |  Page 66  |  Page 67  |  Page 68  |  Page 69  |  Page 70  |  Page 71  |  Page 72  |  Page 73  |  Page 74  |  Page 75  |  Page 76  |  Page 77  |  Page 78  |  Page 79  |  Page 80  |  Page 81  |  Page 82  |  Page 83  |  Page 84  |  Page 85  |  Page 86  |  Page 87  |  Page 88  |  Page 89  |  Page 90  |  Page 91  |  Page 92  |  Page 93  |  Page 94  |  Page 95  |  Page 96  |  Page 97  |  Page 98  |  Page 99  |  Page 100  |  Page 101  |  Page 102  |  Page 103  |  Page 104  |  Page 105  |  Page 106  |  Page 107  |  Page 108  |  Page 109  |  Page 110  |  Page 111  |  Page 112  |  Page 113  |  Page 114  |  Page 115  |  Page 116  |  Page 117  |  Page 118  |  Page 119  |  Page 120  |  Page 121  |  Page 122  |  Page 123  |  Page 124  |  Page 125  |  Page 126  |  Page 127  |  Page 128  |  Page 129  |  Page 130  |  Page 131  |  Page 132  |  Page 133  |  Page 134  |  Page 135  |  Page 136  |  Page 137  |  Page 138  |  Page 139  |  Page 140  |  Page 141  |  Page 142  |  Page 143  |  Page 144  |  Page 145  |  Page 146  |  Page 147  |  Page 148  |  Page 149  |  Page 150  |  Page 151  |  Page 152  |  Page 153  |  Page 154  |  Page 155  |  Page 156