EXTERNAL — INDUSTRIAL AUTOMATION | ENERGY INDUSTRIES ABB Ability ™ Asset Performance Management Improving production availability through predictive analytics
— Asset reliability challenges facing energy customers Higher asset reliability is a key contributor to production availability, process speed and product quality Market drivers Energy businesses spend : > 30% of opex on unplanned maintenance 40% of opex Aging assets on scheduled and Loss of experience Market pressures Margin pressures Asset complexity unscheduled maintenance, And slimmer capital means less on-site drive the need for force producers to Increases as budgets drive which only covers skill and expertise as higher production continuously find components 20% of their assets. producers to find knowledgeable availability, which opportunities to become more new ways to extend reliability and drives the need for reduce maintenance digital, driving a maintenance maximum asset and operational the life of existing need for higher assets. resources retire. availability. expenditures. knowledge levels. According to a recent ARC survey, companies have been losing between 3-5% of their production to unplanned downtime . The need to maximize asset reliability has never been greater Slide 2 July 31, 2020
— Maintenance strategies need to be aligned with desired asset performance Preventive Maintenance (PM): Appropriate for Just 18 Percent of Assets > Yet this has been the focus for most plant maintenance strategies - Doing PM on the other 82 percent can also cause failures! Autonomous Description: Equipment specific algorithms or machine issue and Prescriptive what to do for repair Asset attribute: Complex assets requiring advanced skills Predictive Description: Equipment specific algorithms or machine issue and what to do for repair (PdM) Asset attribute: Critical assets where unplanned downtime has business impact Condition Description: Alerts for bad trends or other rules-based logic using a single data value monitoring Asset attribute: Assets where a component failure cascades into big $ losses Description: Service in a fixed time or cycle interval Preventive Asset attribute: Probability of failure increases with asset use of time Description: Run to failure Reactive Asset attribute: Failure is unlikely, easily fixed/replaced, or non-critical Run to failure Slide 3 July 31, 2020 ARC: - https://www.arcweb.com/technologies/asset-performance-management)
— Driving savings through earlier and better equipment performance visibility When can failures be detected or predicted? What we need – A fault condition that is detectable: allows detection with sufficient time to allow corrective action to be taken – Sufficient instrumentation to allow parameters to be observed – Information about fault progression, measured data to form a sufficiently accurate “digital twin”, to assess equipment condition. – A maintenance strategy and procedures that can take advantage of this information Slide 4 July 31, 2020
— Introducing ABB Ability ™ Asset Performance Management
— What is it? Solutions set that combines deep energy experience with predictive analytics to help energy businesses predict, prioritize and reduce risk – from asset to enterprise ABB Asset Performance Compare Management building blocks Compare actual fleet, plant, equipment and component performance with expected performance Predict Uncover potential failures, their associated probability and predicted time to failure Optimize Monitor, analyze, plan and act for optimized maintenance and operation of critical plant equipment Slide 6 July 31, 2020
— Solution 1: ABB Ability™ Edge Insight IT/OT integration Enables better asset visibility and decisions by integrating disparate data into one common platform What & Why Key features Deployment Secure streaming of high-resolution Fast, scalable connection – correct data Quickly deploy; accommodate for • • • data on-premise to cloud storage, local to correct people and systems digital business models with small storage or office distribution. The upfront investment Vendor agnostic • service connects to industrial field Subscription-based lease of software, • Connects to any industrial field • device protocols and translates the interfaces and services protocol, translates to OPC UA or AMQP data distributes it through a safe, one- Based on standard connectivity • way transfer of data. (OT-IT) Designed with “field plugs” – install only • interfaces, further expansion possible what you need Save up to 75% of the data normally sent through control system databases Buffer storage to minimize loss of • equipment data An enabler for condition monitoring – • move up to 97% from site to office Access to high-resolution process and • device data in order to support value- Flexibility – retaining data ownership, • added insights choose what to do with it, open system with no proprietary lock-ins Ensures accurate and complete • information to make better decisions Slide 7 July 31, 2020
— Solution 2: ABB Ability™ Condition Monitoring Sensors Smart Sensor for hazardous and non-hazardous environments What & Why Key features Deployment Uncomplicated implementation – WiMon tracks vibration and • Stand-alone • • enables simple, wireless installation, temperature data to enable condition- Third Party / DCS Integration • easy commissioning and intuitive based maintenance of motors, fans, Platform independent solution • configuration pumps and other rotating machines. Trouble-free operation – features long- • WiMon Data Manager life batteries, low maintenance sensors Makes condition monitoring data available and easy-to-use software to decision makers, so they can determine ABB Ability ™ Reliable signal transmission – • the right time for maintenance and reduce communicates consistently, through a or eliminate unnecessary service. robust and redundant meshed network Early prediction of faults (reduced • to prevent signal interruption, unplanned outages) Compliance – employs vibration • Reduced frequency of spurious repair • monitoring based on ISO 10816 Gateway trips guidelines Provides data for remote diagnostics • and lifetime predictions Slide 8 July 31, 2020
— Solution 3: ABB Ability™ Asset Insight Integrating condition monitoring data from underlying systems to visualize anywhere What & Why Key Features Gathers and presents real-time condition Gives users instant and secure access to data from different systems into one the asset data they need to make decisions dashboard so users can reduce time to Asset monitor library for monitoring of • action by having equipment health data electrical equipment, rotating and operational insights available in one machines, control and safety systems. place. It is typically a customised solution Enables integrated access to • for each deployment based on standard & maintenance advice (FMEA/RCM) new engineered models. Aggregated equipment health • overview, highlighting equipment with Easy access to asset health data, • degraded condition Remote Remote anywhere, anytime - directly in your Diagnostics Monitoring Worst performers list for key • browser Visualization and reporting parameters Can be deployed on the office network • Drill-down to equipment detail pages • or in the cloud Layout diagram for quick identification • Facilitates collaboration between • of location of fault customer and ABB domain experts Slide 9 July 31, 2020
— Solution 4: ABB Ability™ APM Asset Health For plant owners balancing competing priorities of cost, performance and risk, ABB’s Asset Health APM enables them to make more informed decisions related to their assets; preventing critical failures while optimizing reliability, availability and asset life cycle costs. Benefits Key features Sales enablement links Business model & deployment Monitor degradation / Comparison of actual fleet, Business model Presentation – LINK TBA eliminate failure to drive plant, equipment and Asset model (qrtly/yrly • operational efficiencies component performance vs. subscription). DEMO – LINK TBA expected performance. Demonstrable value and ROI Types ABC complexity (< 1 year) Expert system + Data science 1 off - Installation & • Brochure – LINK TBA Indications of potential commissioning failures, associated probability Reduced maintenance costs Paid pilot>Single • and predicted time to failure; +30% deployment>Enterprise Asset list – LINK TBA RCA and suggested action Reduced shutdown durations Operations: +20% Capability to monitor, analyze, Global execution in Q4 • Further sales and marketing plan and act for optimized Increased Turnaround Interval materials currently in progress COC Italy. • maintenance and operation of +30% for global product release. critical plant equipment Architecture: Improved production uptime Scalable deployment across On premise OR On cloud. • +10% plants and adding asset types Ability Platform (future) Slide 10 July 31, 2020
— APM Demonstration & Case Study
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