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Value of Asset Management Strategies

Value of Asset Management Strategies. “I need to insure that my facility is operating the way I built it to run!”. improve maintenance staff effectiveness. reduce risk to service outages. disaster recovery. improved site security. keeping employees safe. reducing commissioning time & cost.

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Value of Asset Management Strategies

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  1. Value of Asset Management Strategies “I need to insure that my facility is operating the way I built it to run!”

  2. improve maintenance staff effectiveness reduce risk to service outages disaster recovery improved site security keeping employees safe reducing commissioning time & cost Common Water Supply & Water Treatment System Objectives monitor & protect systems complying with regulations

  3. Water Supply & Water Treatment System Benefits • Reduction in long term operating & maintenance costs and lowering the risks to the community served by… • Improve maintenance staff effectiveness • Root cause analysis & locked door device analysis automatically • Monitor & protect systems • Monitor devices on networks for abnormal operation including degradation or failure • Automatic integrated condition monitoring including notification • Automatic tracking of versions with security on all production intellectual property • Messaging (email) appropriate personnel • Facilitate more migration from reactive & preventive maintenance to predictive & reactive maintenance models • Increase site security for device access • Creating audit trails for asset configuration changes, detect unwanted changes • Back up asset intellectual property to a secure system for disaster recovery • Store every version of asset configurations in a secure system for archival and retrieval • Automatic verification of some device configurations against controlled masters • Extend service life of equipment through verification, condition monitoring & security

  4. Assets’ Influence on Objectives Each asset no matter how large or small is linked to the next asset. Even the smallest change can affect operations!

  5. RSMACC Systems • RSMACC Systems consist of an architecture that includes at least one core function. • That RSMACC System can be added to, creating a much more comprehensive solution. • The 4 core functions are: • Change Management, CM • Network Health, NH • Enterprise Online, EOL • Automated Asset Manager, AAM • You can purchase CM alone and add AAM at anytime • Or you can purchase a NH System and add EOL, etc…

  6. Typical Device Configuration Scenario • User starts RSLogix program • User locates the RSLogix controller program • User connects to the controller • Downloads or makes online changes, saves program on local disk drive, floppy or somewhere else • What version of the program is in your controller and where did the program come from & where did it go after the change?

  7. Access Control Authentication Archive Audit Verification/Recovery Reporting Change Management The Value is greatest when applied proactively rather than after the fact! The stream of managing change starts with “Prevention” and flows through “Reconciliation”. Prevention Control Accountability Detection Reconciliation

  8. Change Management • User starts RSLogix program • RSMACC security system ask your domain controller to authenticate the user • Regardless of results, RSMACC records workstation and user launching RSLogix • RSMACC security applies the defined security permissions

  9. Any type of file can be stored in this Archive system! Change Management • User retrieves application program from RSMACC archive using RSLogix 5 or 500 file open or the RSMACC client using the RSMACC security system to verify permissions • RSMACC records who retrieved the application program & where it went

  10. Change Management • File management system • Holds any kind of document • Manage user folder rights • Supports • Pinning/ mastering • Sharing • Branching

  11. Change Management • User connects to the controller • RSMACC records device connection • User makes online modifications to control program • RSMACC records each user change as it occurs

  12. Change Management

  13. Change Management • Secure operator changes from RSView SE or PanelView Plus during production • Set-point change (Tag write) • Command • Alarm acknowledgement • Recipe download • Signature required before operation occurs • Generates compliance enabling 21 CFR Part 11 audit trail

  14. Change Management • Documenting Configuration Changes • Supports self-documenting Change Management procedure • Ability to prove scope of change is limited to approved change • Contains information necessary to enable FDA 21 CFR Part 11 compliance • Date/Time of audit event • Source (Application) • Location (Workstation) • Username (Domain ID, and Full Name from Domain Id) • Automatically generated description of change with old and new value

  15. Change Management • User returns the application program to the RSMACC archive system • RSMACC archive compares the files and increments the version if it is different regardless of the type of program

  16. Change Management • RSMACC verifies automatically at the prescribed periodicity that the controller program matches the master program and version in archive • A message can notify that the function ran correctly or not, and differences were found or not. • A report of the differences found is saved.

  17. 509 -BOD 24vdc Brief Overview, Managing Device Configuration Security for: Archived files RSMACC functions RSLogix 5 v4.00.00 or greater RSLogix 500 v4.00.00 … RSLogix 5000 v11.00 … RSMACC Client v1.00.00 … RSMACC Change Management v1.00.00… RSLinx v2.20.01 … More products are coming as… FactoryTalk Security is integrated! RSLogix™ 5 or 500 Standard v6.10… RSLogix 5 or 500 Professional v5.50… RSLogix 5000 (English) v10.03... Verification for: All devices shown below… files on computers… and some robots Archive for: Virtually any form or type of file Audit: RSLogix editors listed RSViewSE & ME, RSBatch… (some integration) More products are coming as… FactoryTalk Audit is integrated! CM PLC3 DH+ CompactLogix ENet CNet DH+ PLC2 DH+ FlexLogix ENet CNet DH+ PLC5 DH+ ENet CNet DF1 ControlLogix DriveLogix ENet CNet DH+ PanelView Standard Enet, CNet, DNet, RIO, DH+, DH485, DF1 (Enhanced on RIO only) SLC* ENet DH+ DH485 DF1 MicroLogix DH485 DF1 PanleView Plus ENet, CNet, DH+, DH485

  18. RSMACC Systems • RSMACC Systems consist of an architecture that includes at least one core function. • That RSMACC System can be added to, creating a much more comprehensive solution. • The 4 core functions are: • Change Management, CM • Network Health, NH • Enterprise Online, EOL • Automated Asset Manager, AAM • You can purchase CM alone and add AAM at anytime • Or you can purchase a NH System and add EOL, etc…

  19. Typical Device Status Events • Event • Radio message or alarm ~75%

  20. Diagnostic Scheduler Services Automatic Device Health Status • Periodically the Diagnostic Scheduler Service, running on a local computer, scans the health of DeviceNet, ControlNet, and Ethernet/IP network devices and reports on their status to the RSMACC system. • Smart devices, when prompted, will identify their health status by responding with a coded number • Comparing that number to the type of device using the network configuration file allows us to automatically generate information about the failure

  21. Diagnostic Scheduler Services Automatic Device Health Status • That number corresponds to a real problem for the device at that node. • These are automatically logged to the centralized RSMACC Diagnostics and Health log database

  22. Diagnostic Scheduler Services Automatic Device Health Status • RSMACC log message includes a link to root cause and solution information from distributed RSMACC Clients • RSMACC requires no additional code or configuration to recognize a device code and communicate the device status to the system and subsequently the appropriate personnel

  23. Diagnostic Scheduler Services Automatic Device Health Status

  24. RSMACC Systems • RSMACC Systems consist of an architecture that includes at least one core function. • That RSMACC System can be added to, creating a much more comprehensive solution. • The 4 core functions are: • Change Management, CM • Network Health, NH • Enterprise Online, EOL • Automated Asset Manager, AAM • You can purchase CM alone and add AAM at anytime • Or you can purchase a NH System and add EOL, etc…

  25. Traditional Condition Monitoring • Machinery in the plant might malfunction so we must do our preventive maintenance periodically regardless of real indicators like cycles, revolutions, temperature, vibration, level or viscosity. • This requires a person to take local readings and then analyze those readings typically back at their desk. • In several industries this may even require travel • In all, it is extremely time consuming

  26. Automatic/Integrated Condition Monitoring • Our integrated and automatic protection systems are designed to provide continuous monitoring and protection to machinery • RSMACC system provides a live connection to sensor data from the XM modules • Vibration Analysis • Process Parameters • Temperature, Pressure, and Flow • Turbine Supervisory Instrumentation (TSI) • Thrust, Differential and Case Expansion, Valve position, and Eccentricity • No more traveling to the location or climbing on machines to take readings!

  27. Automatic/Integrated Condition Monitoring • RSMACC Client combines digital images of your plant equipment with monitored data for simple asset monitoring and alarm annunciation • EnWatch data can be combined with the XM data on the live monitor

  28. Automatic/Integrated Condition Monitoring • Online remote configuration capability

  29. Automatic/Integrated Condition Monitoring • Live Time data display from any XM channel • Trend, Spectrum, Waveform, Waterfall, Polar, Orbit, Shaft-Centerline

  30. Automatic/Integrated Condition Monitoring • Historical data can be added to real-time using our Emonitor systems • Emonitor Enshare • Data Storage, Alarming, Frequency Analysis, & Connectivity • Emonitor Odyssey Deluxe • Data Storage, Alarming, & Frequency Analysis • Emonitor Odyssey • Data Storage & Alarming

  31. RSMACC Systems • RSMACC Systems consist of an architecture that includes at least one core function. • That RSMACC System can be added to, creating a much more comprehensive solution. • The 4 core functions are: • Change Management, CM • Network Health, NH • Enterprise Online, EOL • Automated Asset Manager, AAM • You can purchase CM alone and add AAM at anytime • Or you can purchase a NH System and add EOL, etc…

  32. Automatic Messaging (Automatic) Work Order Generation • RSMACC binds process information from intelligent assets and RSMACC internal systems & messaging to MAXIMO to facilitate WORK ORDER generation and tracking • Predictive Interaction • Process data like… • N:7:0 > desired level • A work order for checking/calibrating the thermocouples should be issued • Operator interface sends signal requesting maintenance on machinery based on a reading or operator input • Reactive Interaction • An intelligent sensor or device is malfunctioning • Photo eye signal is degrading, work order issued to clean • RSMACC detects that an assets configuration does not match the master on file • Work order created to asses the situation a • RSMACC detects a security violation • Message sent to IT or Security to investigate issue • Process data • B120/12 not 0 • A work order for fixing a leaking valve should be issued • RSView SE Interface for Work Order generation/messaging • Track status of work orders & data • Plan for work based on status & changes • Adjust schedules and priorities of planned work MAXIMO

  33. Automatic Messaging (Automatic) Work Order Generation • A lot of plants are struggling with the increased work load including increased complexity of systems. • Consequently plants have moved to more of a run-to-failure, RTF, mode for some maintenance • This is as expensive in some cases as hiring more people and doing preventive maintenance • A balanced approach is more appropriate based on individual requirements • This type of system is deigned to help in the balance between RTF and total PMS • Moving some appropriate systems to Reactive models • Compensates for not having time to do PMS • Facilitates better time management • Facilitates a more appropriate cost model for maintenance MAXIMO

  34. RSMACC Systems • RSMACC Systems architecture includes some basic functions like • Reporting • Both manual ad-hoc and automatic • Security • Service Monitoring • Archive

  35. Manual & Automatic Reporting • RSMACC can be configured to generate automatic reports for changes to machines and their respective assets. • For instance, a maintenance manager might want a report for changes that occurred over the weekend or during the past evening.

  36. Manual & Automatic Reporting • Other Uses For Reporting • Generate a morning report for Maintenance/ Engineering Manager review showing ALL changes to PLC programs during 2nd and 3rd shift • Forces • Empty branches • Changes to rungs, ignoring value modifications • All employees that made modifications • Generate a weekly report for the Plant Manager showing all programmable assets that have been modified by name • Generate a report monitoring critical applications (e.g., pasteurization process) that have not been changed

  37. System Planning & Architecture Common Architecture with Plug-In Functions • RSMACC Server & RSMACC Client common to all applications • Plug-In Functions • RSMACC Network Health • Monitor, report, and diagnose device and network health • RSMACC Automated Asset Manager • Automate preventive, predictive, and reactive maintenance • RSMACC Enterprise Online Condition Monitor • Integrated automation condition monitoring • RSMACC Change Management • Authenticate, audit, archive, and verify device configuration

  38. RSMACC Server(s) Windows 2003 Server Windows 2000 Server w/SP4 Pentium 4, 2GHz or more 1GB RAM 1.5GB free on system volume 20GB shared volume, RAID-5 capable Only if hosting Microsoft SQL 2000 Server RSMACC Client Windows 2000 w/SP4 or XP Pro SP1 DO NOT USE XP SP2 Pentium III, 500MHz 256MB RAM 1GB free on system volume System Planning & Architecture Recommended Platform Requirements:

  39. RSMACC Server RSMACC Client System Planning & Architecture Ethernet TCP/IP / Microsoft Windows Domain • RSMACC Server • Service Monitor • Security Server • Administration Utilities • Verification • PLC5 • SLC500 • ControlLogix • PanelView • Reporting • RSLogix 5 • RSLogix 500 • RSLogix 5000 RSMACC Client Security client Archive client RSLogix 5 RSLogix 500 RSLogix 5000 Windows 2000 Server PDC SQL Server 2000 Profile dB Event & Audit dB Archive dB Tables Stored procedures

  40. RSMACC Server RSMACC Client System Planning & Architecture Ethernet TCP/IP / Microsoft Windows Domain • RSMACC Server • Service Monitor • Security Server • Administration Utilities • Verification • PLC5 • SLC500 • ControlLogix • PanelView • Reporting • RSLogix 5 • RSLogix 500 • RSLogix 5000 RSMACC Client Security client Archive client RSLogix 5 RSLogix 500 RSLogix 5000 SQL Server 2000 Profile dB Event & Audit dB Archive dB Tables Stored procedures Windows 2000 Server PDC

  41. Assets’ Influence on Objectives Each asset no matter how large or small is linked to the next asset. Even the smallest change can affect operations!

  42. improve maintenance staff effectiveness reduce risk to production disaster recovery improved site security keeping employees safe reducing commissioning time & cost Common System Objectives monitor & protect systems complying with regulations

  43. Water Supply & Water Treatment System Benefits • Reduction in long term operating & maintenance costs and lowering the risks to the community served by… • Improve maintenance staff effectiveness • Root cause analysis & locked door device analysis automatically • Monitor & protect systems • Monitor devices on networks for abnormal operation including degradation or failure • Automatic integrated condition monitoring including notification • Automatic tracking of versions with security on all production intellectual property • Messaging (email) appropriate personnel • Facilitate more migration from reactive & preventive maintenance to predictive & reactive maintenance models • Increase site security for device access • Creating audit trails for asset configuration changes, detect unwanted changes • Back up asset intellectual property to a secure system for disaster recovery • Store every version of asset configurations in a secure system for archival and retrieval • Automatic verification of some device configurations against controlled masters • Extend service life of equipment through verification, condition monitoring & security

  44. What’s next… • Action…

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