pTec by Indalyz AG A predictive maintenance software solution for effective asset management
Why predictive maintenance? 2 Predictive Maintenance Solutions by Indalyz AG
First, we must understand what solutions exist in the market today: Condition-based Maintenance occurs based on current state of equipment Reactive-based Maintenance occurs after an event of failure or damage Time-based Maintenance occurs at fixed periods regardless of state All three solutions are common in the market today. However, lets ask ourselves…. 3 Predictive Maintenance Solutions by Indalyz AG
What if you could predict a component failure? What if an asset can warn in advance when repair is needed? 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? Topline performance Maintenance Capex Operational downtime 4 Predictive Maintenance Solutions by Indalyz AG
pTec The Premier Predictive Maintenance Solution To All Major Industries 5 Predictive Maintenance Solutions by Indalyz AG
pTec in comparison to other maintenance strategies Predictive Maintenance Reactive Maintenance • Monitoring of machine and processing • Replacement of parts or the whole of data to predict state of equipment machine after a failure has occurred • Visible long-term maintenance planning • “Run until it breaks“ • Reduction of downtime • Inevitable downtime • Reduction in costs Time-based Maintenance Condition-based Maintenance • Maintenance according to timed • Monitoring of the current machine manufacturer specifications condition • “Fix it regardless” • Maintenance only after reaching the • Costly and labor-intensive critical machine condition • Frequent maintenance-related • Often spontaneous machine shutdown downtime • Unpredictable maintenance planning 6 Predictive Maintenance Solutions by Indalyz AG
pTec Reactive Time-based Condition-based Predictive • Complete malfunction • Unnecessary costs • Inevitable downtime • Minimal downtime • Absolute downtime • No visibility of actual • Minimal visibility of • Clear visibility on state of • High replacement cost wear & tear actual maintenance cost equipment Cost Reduction in downtime Operability 7 Predictive Maintenance Solutions by Indalyz AG
pTec Product Presentation 8 Predictive Maintenance Solutions by Indalyz AG
pTec is an innovative software solution predicting failures before they occur 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. 9 Predictive Maintenance Solutions by Indalyz AG
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 Sensors attached to object proprietary software to present forecasts of machinery integrity. Sensors attached to environment (e.g. weather stations, water flow, etc.) Manual data entry of historical and pTec present data 10 Predictive Maintenance Solutions by Indalyz AG
Data processing flow Data Input Data Processing Data Output Expert systems compare the Routines on local hardware future evolution with analyze the sensor signals technical basic data of the and send relevant condition components to determine information to central data break downs and arrange an bases. optimal maintenance schedule. Routines on central servers compute from current and Sensor systems collect condition historical condition data from technical equipment information and additional environment information the about the wear of individual future evolution of the components. technical state of all components. 11 Predictive Maintenance Solutions by Indalyz AG
DELIVERABLES Reduce OPEX & Increase ROA 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. 12 Predictive Maintenance Solutions by Indalyz AG
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. 13 Predictive Maintenance Solutions by Indalyz AG
pTec is highly sophisticated having multiple facets and solution processes to provide the most accurate forecast possible. Process Uses historical & current artificial intelligence data algorithms Able to process by Multiple parts or masses time horizons without compromise in forecasting Robust Forecasting of filtering & projection future probability formalization techniques of defaults Customized condition Recommendation on Monitoring optimal conditions of machine status 14 Predictive Maintenance Solutions by Indalyz AG
Selected Areas Of Application 15 Predictive Maintenance Solutions by Indalyz AG
Some of the pTec applications in the real world. STATIC DYNAMIC Already applied Under development ü Wind Railways o ü Pipelines & pump stations Hydro plants o Refineries o 16 Predictive Maintenance Solutions by Indalyz AG
Case Study 800 Wind Turbines 17 Predictive Maintenance Solutions by Indalyz AG
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 18 Predictive Maintenance Solutions by Indalyz AG
PROCESS Continuous data collection Sensor system & weather station Local application Data compression SQL-database Collective prognosis system & dynamic expert system Vector database 19 Predictive Maintenance Solutions by Indalyz AG
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 Damaging event Damaging event NOT prognosticated prognosticated Results over 6 month period Alarm signal 94.83 % 4.65 % No alarm signal 0.52 % • First-time pro-active maintenance planning • High accuracy of forecasting improves profitability • Calculation of residual term of partially damaged components 20 Predictive Maintenance Solutions by Indalyz AG
INTERPRETATION OF TEST RESULTS Day of prognosis: March 24, 2013 - Figure: historical parameter (gray) and forecast parameters (magenta) - Forecast horizon from one week to 12 months 21 Predictive Maintenance Solutions by Indalyz AG
QUALIFIED SAVINGS Time-based maintenance Condition-based maintenance One-time reduction of mean 0.362 ct/kWh $0.00234/kWh electricity production costs Payback 6 months 1 year Postponement of down time Reduction of unscheduled down time preventive condition- Reduction of scheduled down time based maintenance preventive time-based maintenance Reduction of maintenance costs Cost savings of pTec compared to preventive condition-based & time- timely error detection based maintenance - 100.000 200.000 300.000 400.000 500.000 (cost savings potential in EUR) 22 Predictive Maintenance Solutions by Indalyz AG
Case Study Refinery 23 Predictive Maintenance Solutions by Indalyz AG
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. 24 Predictive Maintenance Solutions by Indalyz AG
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 25 Predictive Maintenance Solutions by Indalyz AG
RESULTS & ALERT PARAMETERS 26 Predictive Maintenance Solutions by Indalyz AG
ADVANTAGES o Technicians can access all predicted component and assess information. o Ranking of critical assets. o Reasons for component failures are easily comprehensible. o Reduction in the backlog of maintenance work. o Reducing refinery downtime. o Asset availability greater than 98%. o Avoid unplanned environmental, health and safety (EHS) events. 27 Predictive Maintenance Solutions by Indalyz AG
Our Services 28 Predictive Maintenance Solutions by Indalyz AG
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