pTec by Indalyz AG A predictive maintenance software solution for - - PowerPoint PPT Presentation

A predictive maintenance software solution for effective asset management

pTec

by Indalyz AG

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Why predictive maintenance?

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First, we must understand what solutions exist in the market today: All three solutions are common in the market today. However, lets ask

• urselves….

Condition-based Reactive-based Time-based Maintenance occurs based on current state of equipment Maintenance occurs after an event of failure or damage Maintenance occurs at fixed periods regardless of state

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Operational downtime Topline performance Maintenance Capex What if you could predict a component failure? What if you could ensure maintenance is performed exactly when its needed? What if you could efficiently monitor and control maintenance costs, downtime and inventory in the long term? What if an asset can warn in advance when repair is needed?

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pTec The Premier Predictive Maintenance Solution To All Major Industries

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pTec in comparison to other maintenance strategies

Predictive Maintenance Reactive Maintenance

• Monitoring of machine and processing
• f data to predict state of equipment
• Visible long-term maintenance planning
• Reduction of downtime
• Reduction in costs
• Replacement of parts or the whole

machine after a failure has occurred

• “Run until it breaks“
• Inevitable downtime

Time-based Maintenance Condition-based Maintenance

• Maintenance according to timed

manufacturer specifications

• “Fix it regardless”
• Costly and labor-intensive
• Frequent maintenance-related

downtime

• Monitoring of the current machine

condition

• Maintenance only after reaching the

critical machine condition

• Often spontaneous machine shutdown
• Unpredictable maintenance planning

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Operability Reduction in downtime Cost Reactive Time-based pTec Predictive Condition-based

• Complete malfunction
• Absolute downtime
• High replacement cost
• Inevitable downtime
• Minimal visibility of

actual maintenance cost

• Unnecessary costs
• No visibility of actual

wear & tear

• Minimal downtime
• Clear visibility on state of

equipment

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pTec Product Presentation

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pTec is an innovative software solution predicting failures before they

• ccur based on historical and current sensor data as well as other

available technical information. pTec serves as an early warning system helping to avoid severe damage and loss of production. pTec is a self-learning forecasting technology applying state-of-the-art artificial intelligence algorithms, robust filter techniques and projection formalism.

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With pTec it takes past data, current data, all data possible through both manual data entry and sensor systems attached to machinery. Data is then processed through special proprietary software to present forecasts of machinery integrity.

pTec

Sensors attached to object Manual data entry of historical and present data Sensors attached to environment (e.g. weather stations, water flow, etc.)

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Data Input Data Processing Data Output Data processing flow

Sensor systems collect condition data from technical equipment about the wear of individual components. Routines on local hardware analyze the sensor signals and send relevant condition information to central data bases. Routines on central servers compute from current and historical condition information and additional environment information the future evolution of the technical state of all components. Expert systems compare the future evolution with technical basic data of the components to determine break downs and arrange an

• ptimal maintenance

schedule.

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DELIVERABLES Technical equipment components will be used until the ‘effective’ rather than the ‘expected’ life time. Minimization of unexpected machinery breakdown and consequent interruption of the business. Minimization of downtime caused by maintenance intervention avoidance of additional collateral damages following the breakdown of a component. Improved customer service as failures are minimized. Reduce OPEX & Increase ROA

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ADVANTAGES Proven and reliable data-driven forecasting technology (three years of testing) allowing an high accuracy of forecasting. High quality of concluded maintenance suggestions. Forecasting technology combines the advantages of fleet learning as well as an individual and component-related detailed analysis. pTec provides information about how a failure of an individual component affects other components/asset.

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pTec is highly sophisticated having multiple facets and solution processes to provide the most accurate forecast possible.

Process

historical & current

data Uses

artificial intelligence

algorithms Able to process by

parts or masses

without compromise Robust

filtering & projection

formalization techniques Multiple

time horizons

in forecasting Forecasting of

future probability

• f defaults

Recommendation on

• ptimal conditions

Customized condition

Monitoring

• f machine status

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Selected Areas Of Application

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Some of the pTec applications in the real world. STATIC DYNAMIC

Already applied Under development ü Wind ü Pipelines & pump stations

• Railways
• Hydro plants
• Refineries

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Case Study 800 Wind Turbines

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TRIAL SETUP Forecast of technical state of 800 wind turbines over 3 years ① Computer-based processing of historical and current condition monitoring data ① Sensor data: approx. 2,000 technical parameters ① Data processing of over 1.6 million time series ① Forecast period: one week to 12 months

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PROCESS

Vector database SQL-database Local application

Sensor system & weather station Data compression

Collective prognosis system & dynamic expert system Continuous data collection

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RESULTS

• Forecast of technical condition of 800 wind turbines over 3 years
• Computer-based processing of historical condition monitoring data
• Sensor data: approx. 2,000 technical parameters
• Data processing of over 1.6 million time series
• Forecast period: 3 - 6 months
• First-time pro-active maintenance planning
• High accuracy of forecasting improves profitability
• Calculation of residual term of partially damaged components

Results over 6 month period

Damaging event prognosticated Damaging event NOT prognosticated Alarm signal 94.83 % 4.65 % No alarm signal 0.52 %

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INTERPRETATION OF TEST RESULTS

• Figure: historical parameter (gray) and forecast parameters (magenta)
• Forecast horizon from one week to 12 months

Day of prognosis: March 24, 2013

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QUALIFIED SAVINGS Cost savings of pTec compared to preventive condition-based & time- based maintenance -

100.000 200.000 300.000 400.000 500.000

timely error detection Reduction of maintenance costs Reduction of scheduled down time Reduction of unscheduled down time Postponement of down time

preventive condition- based maintenance preventive time-based maintenance

(cost savings potential in EUR)

Time-based maintenance Condition-based maintenance One-time reduction of mean electricity production costs 0.362 ct/kWh $0.00234/kWh Payback 6 months 1 year

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Case Study Refinery

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TRIAL SETUP ① Similar as for wind energy turbines. ① Current situation: most refineries perform reactive maintenance or preventive time-based maintenance. ① Application of pTec in various components like pumps, compressors, mills, rotary kilns, converters, conveyor belts, mixers, stirrers. ① Combination of pTec with localized and central control units.

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EARLY LEAKAGE DETECTION SYSTEM Short time detection of leaks in pipes by analysing turbulence signals (IM&P product together with MLU Halle) Support and improvement by using pTec-data

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RESULTS & ALERT PARAMETERS

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ADVANTAGES

• Technicians can access all predicted component and assess

information.

• Ranking of critical assets.
• Reasons for component failures are easily comprehensible.
• Reduction in the backlog of maintenance work.
• Reducing refinery downtime.
• Asset availability greater than 98%.
• Avoid unplanned environmental, health and safety (EHS) events.

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Our Services

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pTec ec

Customization of Graphical User Interface (GUI) Software updates Operation & Maintenance Customization of maintenance software Planning (sensor and hardware system) Staff training Installation Analysis and report

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A predictive maintenance software solution as integral part of Industry 4.0 solving the Big Data issue.

pTec

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INDALYZ AG Software Development Sales & Distribution Logistics Tel.: +41 41 743 07 28 Fax.: +41 41 743 07 33 email: getinfo@indalyz.com Web: www.indalyz.com Riedstrasse 7 CH-6330 Cham

CONTACT