FIABILIDAD:
Consultoria, Tecnologías
y Aplicaciones
Francisco Grela/Antonio Fuentes
Consultoría de Fiabilidad
Francisco Grela
Soluciones de Fiabilidad
Director de Ventas, Sur de Europa
4 de Febrero de 2016
Vibration
Integrity
Availability
Corrosion Assets
Safety
Protection
SHE
Sustainable
Consistency
Profitability
Asset Management
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 3
OPEX
Health
Predictability
Wear
Risk
Throughput
Condition
Performance
Maintenance
What is Reliability?
Reliability is …
Availability
Safety
Profitability
 Eliminate Unplanned Shutdowns
/ Slowdowns
 Incidents affecting people
 Sustain or Increase Throughput
 Manage OPEX
 Effective Maintenance Plan
 Recordable environmental
incidents
 Reliability Index
 Protection of Assets
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 4
 Effective Turnarounds
 Underperformance of Assets and
Plant
Compelling Facts
5%
46%
Production 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)
is the single greatest cause of process
interruption (source: Marsh & McLennan
Protection Consultants)
PRODUCTION
CAPACITY LOST
50%
SAFETY INCIDENTS
A 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)
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 5
MECHANICAL
FAILURE
50%
MORE REPAIR
COSTS
It 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)
Emerson’s Reliability Portfolio
Reliability
Consulting
Machinery
Health Management
•
•
•
•
•
Maintenance and reliability consulting
Machinery protection and diagnostics
Reliability engineering and project delivery
Vibration monitoring, analysis and prediction
Foundational data services and management
• Online, wireless, and portables solutions
• Machinery protection and diagnostics
Asset
Management
•Plant
Vibration
monitoring,
analysis and prediction
•• Online,
wireless,
and portables
solutions
Integrated
equipment
health
monitoring and performance
analysis
Plant
Asset
Management
• Asset
Performance
Management services
••
•
•
Integrated
equipment
monitoring
and performance
analysis
Smart field
sensor health
and control
element
management
Asset Performance Management services
Smart field sensor and control element management
Lifecycle Services
Lifecycle
Services
• Asset monitoring
and performance improvement services
System
maintenance
and optimization
•• Asset
monitoring
and performance
improvement services
•• System
maintenance
and
optimization
Training,
repair and
field
services
• Training, repair and field services
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 6
Project Services
Machinery Health Management
Maintenance and Reliability Services
■ Maintenance & Reliability –
Reliability
Consulting
■
■
■
■
■
■
MAINTENANCE
& RELIABILITY
CONSULTING
■
■
■
■
■
■
Program Standardization
Criticality Analysis
Reliability Strategy Development
RCM/FMEA
PdM Application
Engineering Process Design
RELIABILITY
ENGINEERING
EAM Booster Packs
Vib, IR, US, Oil, MCE
■ Catapult Data Development
■ AMS Suite – Integrated
Monitoring & Analysis
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 7
Program Management
Change Management
Enterprise Playbooks
DATA
INTEGRITY
■
■
■
■
■
■ PdM Products & Services –
■ Remote Monitoring
Training & Mentoring
Business Transformation
Business Process Design
Organization Design
ENABLING
TECHNOLOGIES
Taxonomy
Asset Records
Inventory Records
Bills of Material
Standardized Content
Top Performers Hold a Huge Business Advantage
Reliability Business Impact
Normalized to First Quartile Performance
400
$346
10
10
9.5
300
9
8.6
$219
200
8
$159
$100
100
0
7
6
Fourth Quartile
Third Quartile
Second Quartile First Quartile
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide Based
8
on 2013 Solomon RAM Study, Solomon Associates LLC
Mechanical Availability Index
Comparative Maintenance Cost
9.8
Benchmarks for Monitoring Asset Health
QUARTILE
MAINT$
(% RAV)
STORES$
(% RAV)
% VIBRATION
% IR MECH
% IR ELEC
% OIL
ANALYSIS
% OTHER NDT
% ON PM
% ON BOM
12 Industry Types
Top 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%
Source: Management Resources Group
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 9
Better maintenance performers
depend on
more asset health information
Top 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 10
Disconnected Silos Typical in 3rd and 4th Quartile Performers
asset health
analysis
work
identification
planning,
scheduling,
work
execution
asset
master data
process
parameters
maintenance
procedures
supply
chain
management
condition
indicators
Consulting & integrated technologies help clients connect silos of capabilities
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 11
Disconnected Silos Typical in 3rd and 4th Quartile Performers
supply
chain
management
asset
master data
planning,
scheduling,
work
execution
maintenance
procedures
process
parameters
work
identification
asset health
analysis
condition
indicators
Consulting & integrated technologies help clients connect silos of capabilities
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 12
Connected Integrated Elements
Typical in 1st and 2nd Quartile Performers
Consulting & integrated technologies help clients connect silos of capabilities
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 13
The Reliability Value Chain
Top performers have
optimized elements
and a fully connected
value chain
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 14
Phased approach to improve your Reliability Strategy
Reliability Value Chain
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 15
1
CLEAN YOUR DATA HOUSE
2
STEP UP YOUR INFORMATION
3
PUT IT ALL TOGETHER TO CREATE KNOWLEDGE
4
TAKE THE RIGHT ACTIONS AT THE RIGHT TIME
“With Emerson ...”
Availability
Safety
Profitability
 Move to proactive maintenance
and ensure equipment is always
available
 Reduce Risk – Mitigate
unplanned shutdowns
 Maximise asset operation and
performance
 Gain insight into the
comprehensive health of assets
to avoid HSE risks
 Minimise the duration and cost of
a planned shutdown
 Focus on the right assets by
having insight into equipment
health
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 16
Questions?
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 17
Tecnologías para la
Gestión de Activos y
Fiabilidad
Francisco Grela
Antonio Fuentes
Emerson’s Reliability Portfolio
Reliability
Consulting
Machinery
Health Management
•
•
•
•
•
Maintenance and reliability consulting
Machinery protection and diagnostics
Reliability engineering and project delivery
Vibration monitoring, analysis and prediction
Foundational data services and management
• Online, wireless, and portables solutions
• Machinery protection and diagnostics
Asset
Management
•Plant
Vibration
monitoring,
analysis and prediction
•• Online,
wireless,
and portables
solutions
Integrated
equipment
health
monitoring and performance
analysis
Plant
Asset
Management
• Asset
Performance
Management services
••
•
•
Integrated
equipment
monitoring
and performance
analysis
Smart field
sensor health
and control
element
management
Asset Performance Management services
Smart field sensor and control element management
Lifecycle Services
Lifecycle
Services
• Asset monitoring
and performance improvement services
System
maintenance
and optimization
•• Asset
monitoring
and performance
improvement services
•• System
maintenance
and
optimization
Training,
repair and
field
services
• Training, repair and field services
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 19
Project Services
Machinery Health Management
Plant Wide Reliability Solutions
Energy Management System
CMMS
Asset Management
• Work Orders
• Maintenance Actions
Data Historian
Performance
Monitoring
Machinery Health
Diagnostics
Field Device
Diagnostics
• DCS
• Prediction integrated
to existing Protection
Operations
• Vibration
analysis
Essential Asset
Monitoring
• Wireless
vibration
analysis
• Data collection /
vibration analysis
(alignment, balancing)
• Prediction /
Protection
• Accelerometers /
Velocity sensors /
Displacement Probes
CRITICAL
ASSETS
[File Name or Event] • Emerson Confidential
• 2/3/2016
• Slide 20
• Device
Configuration
FIELD ASSETS
ESSENTIAL
ASSETS
BALANCE OF
PLANT ASSETS
Gestión de Instrumentos y Válvulas
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 21
AMS Suite: Intelligent Device Manager





[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 22
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
Gestión de Activos rotativos
Blowers/Fans
Gearboxes
Fin Fans
Pumps
Turbines
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 23
Cooling Towers
Compressors
Motors
Pumps
Portable and Online Predictive
Machinery Health™ Management Solutions
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 24
CSI2140
ROI para registro periódico de ROI para registro automático de
datos
datos
Clasificación de Máquinas y tipo de monitorización de su
condición en una Planta Típica
Generadores
Soluciones en línea
Compresores
Turbinas
Calderas
Motores
Ventiladores
Bombas
Engranajes
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 25
Transmisores
Instrumentos portátiles
Hasta fallo
Activos críticos (Protección –API670- y Predicción)
Centrifugal
Compressors
Reciprocating
Compressors
Pumps, Motors
Gearboxes
Turbines
CSI 6500 family
Advanced
Diagnostics
Protection & Adv.
Diagnostics
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 26
Protection
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
Blowers/Fans
Pumps
Heat Exchangers
Fin Fans
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 27
Compressors
Vessels
Fired
Heaters
Cooling Towers
Pipes
Essential Asset Monitoring Suite
Extensive use of
WirelessHART technology
Pumps
Air-Cooled Exchangers
Heat Exchangers
Cooling Towers
Blowers
Compressors
Preconfigured applications built on AMS Asset Graphics software which
combines process and asset data obtained from the field to report Overall
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 28
Asset Health
BALANCE OF PLANT (Route based monitoring)
• CSI 2140 Analizador Portátil de Vibración
• CSI 5200 Análisis de Aceites
• CSI 9830 Termografía Infraroja
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 29
Diagnósticos Predictivos
™
AMS 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
Se integra con el sistema de control
• Ovation, DeltaV y compatible con AMS Suite
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 30
AMS Machinery Manager Diferenciador
Herramientas 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
31
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 31
2/3/2016
Comprehensive Approach to Machinery Monitoring
Performance Analysis with AMS
Performance Advisor
DCS Monitoring
Predictive Diagnostics with AMS
Machinery Manager (existing)
Other Predictive Technologies
• Thermography
• Oil Analysis
• Alignment
• Balancing
• Electric motor analysis
OPC, XML Web Services, Meridium/Maximo
CSI 6500
Machinery Health Monitor for
Online Machinery Protection
and Prediction
Wi-HART
Communications
CSI 9420 Wireless
Vibration
Rosemount WiHART
Transmitters
Centrifugal
Compressors
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 32
Reciprocating
Compressors
Pumps, Motors
Gearboxes
CSI 21XX for
Advanced
Portable
Prediction
(existing)
Monitorización de Performance
™
AMS Performance Advisor / Monitor
AMS 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
Se integra con el sistema de control
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 33
• Ovation, DeltaV y compatible con AMS Suite
Reliability Solutions – New product
CSI 6500 ATG
CSI 2140 ATEX
Ovation MHM
DEC’15
JAN’16
FEB’16
MAR’16
APR’16
ARES
ASSAULT
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 34
MAY’16
JUN’16
DEC’16
JAN’17
ARES
CSI 2140 ASI
FEB’17
[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
Esenciales
Francisco Grela
Antonio Fuentes
Aplicaciones de la monitorización de activos esenciales de
Emerson
Bombas
Enfriadores
Intercambiadores
Torres de refrigeración
Soplantes
Compresores
Aplicaciones preconfiguradas en AMS Asset Graphics que combinan datos
de proceso y de activos para controlar la Condición General del Activo
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 40
Aplicaciones de la monitorización de activos
esenciales de Emerson
AMS Suite: Asset Graphics
Visión general
del estado del
activo
AMS Suite: Machinery Health Monitor
Datos de proceso y de
la condición para
proporcionar alertas
tempranas
Permite la identificación de problemas
en activos utilizando diagnósticos
predictivos
Información detallada
de ayuda al
diagnóstico de la
causa raiz
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 41
La solución de Emerson utiliza algoritmos que combinan datos
del equipo y del proceso para informar de la condición del activo
Indicador de la condición del activo
Algoritmo que analiza
Datos de Proceso
P en descarga/Aspiración
DP en filtro
P/L en sellos de aceite
Caudales
T aire/proceso
Fugas
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 42
Cambios estadísticos
significativos y límites
max/min
Datos del Activo
Vibración/PeakVueTM
T rodamiento
Velocidad, energía
Posición mecánica
Parada/arranque
Configuración inicial
Monitorización Activos Esenciales
Solucion 1 – Desarrolle su propia aplicación
Bombas
Compresores
Intercambiadores
Enfriadores
Torres refrigeración
Recipientes/tuberías
Soplantes
Smart Wireless Gateway
IEC 62591 standard
OPC
Nuevos datos inalámbricos
El cliente define las alertas y la condición
DCS /
OPC Server
Mantenimiento
Supervisión de planta
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 43
(con algoritmos del cliente o de otros)
“Build your Own” is not Simple!
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 44
Monitorización Activos Esenciales de Emerson
Solucion 2 – Use la solución de Emerson – en cualquier DCS
Bombas
Compresores
Enfriadores
Torres refrigeración
Intercambiadores
Recipientes/tuberías
Soplantes
Smart Wireless Gateway
IEC 62591 standard
Nuevos datos inalámbricos
OPC
Datos existentes
Datos de condición
EAM
Software
Modulos
PC
Planta
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 45
Condición del activo y alertas
Supervisión
de planta
DCS /
OPC Server/
Mantenimiento
Nota: Si el DCS es DeltaV, ya dispone de los módulos de la solución incluidos
Monitorización Activos Esenciales de Emerson
Solucion 3 – Use de forma autónoma el EAM software y HMI
Bombas
Compresores
Intercambiadores
Enfriadores
Torres refrigeración
Recipientes/tuberías
Soplantes
Smart Wireless Gateway
IEC 62591 standard
Nuevos datos inalámbricos
OPC
Plataforma AMS
AssetGraphics
completa
Datos existentes
EAM
Software
Modulos
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 46
Supervisor
de Planta
Monitorización de Activos
Esenciales. Análisis de Medidas
disponibles y no disponibles
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 48
Example Reports
1. Send Customer P&IDs for Review
* (PW = Proposed Wireless measurement)
3. Visualize how EAM software can use
Measurements
for new •calculations
[File Name
or Event] • Emerson Confidential
2/3/2016 • Slide 49and alarms
2. EAM Expert to Analyze for Existing and Missing
Measurements and create Easy to Understand Report
4. Final Bill of Material recommendation
Beneficios de la Monitorización de Activos
Esenciales, 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
Entradas
Capacidad de refino en barriles día
Margen neto por barril refinado
Gasto en mantenimiento annual excluyendo paradas
Costes energéticos por MBTU
Dias de operación al año
Beneficios operativos
Capacidad de producción perdida debido a activos esenciales
Recuperación de producción con diagnósticos predictivos
Mejora operativa anual
Beneficios en Mantenimiento
Costes de mantenimiento en activos esenciales respecto al total
Mantenimiento annual de activos esenciales
Reducción media en costes de reparación debido a mantenimiento predictivo
Reducción de costes anuales de mantenimiento
Beneficios energéticos
Recuperación de energía por la mejora de la monitorización
Pre‐heat fouling maximum
EficienciaFired heater efficiency
If heater limited, % time unit is at maximum capacity
Annual Energía Cost Reduction
TOTAL ANNUAL PROFIT IMPROVEMENT
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 50
Source: InTech, 2012. Improve reliability with essential asset monitoring
250000
$5,00
$50,000,000
$6
350
3.5%
30%
$5,512,500
70%
$35,000,000
20%
$7,000,000
10%
20%
80%
25%
$2,200,000
$14,712,500
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 monitorización
de 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 51
Backup
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 53
Standards based approach..
...drives scalability and consistency
150,000 MAN HOURS
intellectual property
Assessments & Planning
Data Configuration
Reliability Engineering
Maintenance Process Improvement
Inventory Standardisation
Business Consulting
Training
CONTENT LIBRARIES
MRO Catalog (>7 Million Parts)
Manufacturers List (>70,000)
Equipment Templates (6,200)
Equipment Taxonomy
FMEA Templates (500+)
Failure Hierarchies
BOM Templates
PdM Baseline
PM Template
STANDARDS
Project Management Standards
Strategy Session Procedures
RCM/FMEA Procedures
BOM Procedures
PMO Standards
PM Procedures
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 54
TOOLS
Catapult® Software
WebRUSL® Software
Work Management
Criticality Ranking
Reliability Strategy
Equipment Master Data & Hierarchy
CHANGE MANAGEMENT
ACE™ Change Management Toolkit
Readiness for Change Survey
IACET Certified Training Courses
Criticality Use: Priority Banding
H - RCM
M - FMEA
Critical
FMEA - Failure Mode
Effect Analysis is a
systematic technique
for failure analysis of
equipment.
Essential
RCM – Reliability Centred Maintenance is a
process to ensure that systems continue to do
what their users require in their present
operating
context
[File Name
or Event]
• Emerson Confidential • 2/3/2016 • Slide 55
L - Template
Templates – Generic
maintenance strategies
No Scheduled
Maintenance
No scheduled maintenance is a
strategy that is often adopted when
the consequence or impact of
failure is considered negligible
Emerson’s Reliability Consulting Standards
BUSINESS
PROCEDURES
Change
Management
Readiness
KPI
Development
Business
Process
Design
Work
Flow
Development
Sustainability
Audits
TRAINING
Skills Needs
Analysis
Skill
Assessments
Training Plan
& Schedule
Conduct
Training
Mentoring
Business Case Workshop
& Calculator
Reliability Gap Analysis
/ Foundational Data
Assessment
Implementation, Planning
& Strategy Sessions
MRO
Strategy
Equipment
Strategy
FOUNDATIONAL
ELEMENTS
INVENTORY
MATERIALS
MANAGEMENT
Equipment
Criticality
Strategy Session
Standardized
MRO Content
Master Equipment
List Development
Equipment
Criticality
Development
Inventory
Process
Optimization
Storeroom
Design &
Kitting Integration
MRO Stock
Optimization
Reliability
Strategy
Development
BOM
Strategy
RCM
Enhanced
Inventory Reliability
MaintenanceProgram
Ongoing
Measurement
& Analysis
PdM
Application
MOM
RELIABILITY
PdM Baselines
BOM
Development
[File Name or Event] • Emerson Confidential • 2/3/2016 • Slide 56
FMEA
PM
Development
RCFA
CMMS / EAM
Enhanced Master Data
Plant Wide Reliability Solutions
Energy Management System
CMMS
Asset Management
• Work Orders
• Maintenance Actions
Data Historian
Performance
Monitoring
Machinery Health
Diagnostics
Field Device
Diagnostics
• DCS
• Prediction integrated
to existing Protection
Operations
• Vibration
analysis
Essential Asset
Monitoring
• Wireless
vibration
analysis
• Data collection /
vibration analysis
(alignment, balancing)
• Prediction /
Protection
• Accelerometers /
Velocity sensors /
Displacement Probes
CRITICAL
ASSETS
[File Name or Event] • Emerson Confidential
• 2/3/2016
• Slide 57
• Device
Configuration
FIELD ASSETS
ESSENTIAL
ASSETS
BALANCE OF
PLANT ASSETS
CSI Hardware Systems
Advanced
Diagnostics
Up to 48 Prediction
Channels
Protection & Adv.
Diagnostics
Up to 24 Protection and
Prediction Channels
4-Channel Machinery Health
Analyzer
Emerson Confidential • 58
Emerson Confidential • Slide 58
Protection
11 2-Channel Signal or 4Channel Temp/Process Card
Emerson Sensors and Accessories
• Accelerometers
• Eddy Current Displacement Probes
• Dynamic Pressure Transducers
• Sensor Housings
• Cables
• Rosemount Temperature, Pressure
Emerson Confidential • 59
Emerson Confidential • Slide 59