Monitors keep watch over asset performance

A novel series of novel asset performance management solutions enable users to monitor, predict and effectively manage both the availability and utilisation of their industrial assets.

Invensys Process Systems have announced a series of novel asset performance management solutions that - for the first time - enable users to monitor, predict and effectively manage both the availability and utilisation of their industrial assets to help maximise overall asset value and improve business performance.

These applied solutions draw on technology and expertise from across Invensys Process Systems (Avantis, Foxboro, SimSci-Esscor, Triconex, Wonderware) and its technology partners.

"In the past, asset availability was the domain of maintenance departments and asset utilisation was the domain of operations".

"As a result, vendor solutions were typically aimed at one or the other, depending on the vendor's particular area of expertise", said Mike Caliel, President of Invensys Process Systems.

"However, maximum asset value is derived by balancing asset availability and utilisation in a manner that best meets current business objectives".

"This requires a holistic approach that, unfortunately for users, is beyond the 'comfort zone' of most automation vendors".

"With our broad portfolio of capabilities - ranging from process measurements and control [Foxboro]; through safety systems [Triconex]; simulation and optimisation [SimSci-Esscor]; plant intelligence [Wonderware]; plus real-time equipment condition monitoring and enterprise asset management [Avantis] - Invensys is arguably the only automation vendor that can deliver comprehensive asset performance manage ment solutions that address both availability and utilisation".

Initially, Invensys Process Systems is introducing a family of nine component- and system-level asset performance management solutions, or "monitors".

These build on new and existing capabilities and will soon be expanded to encompass performance management solutions for entire industry-specific asset sets.

The initial component-level solutions monitor and/or help manage the performance of field devices, process control loops, and plant equipment.

The first of these is an instrument monitor - in addition to providing comprehensive device configuration functionality for any vendor's field devices, this advanced solution is the first to enable field devices to be managed from the host system by installing the device vendor's device descriptors, their FDT-compliant device type manager plug-ins, or both.

These system-resident DTM plug-ins, which are being developed by almost all field device vendors, provide the device vendors' most advanced diagnostic tools.

The solution integrates into enterprise wide predictive maintenance management, activating predefined workflow action based on advanced analysis capability.

The valve monitor exploits the advanced design features and diagnostics of intelligent positioners to help deliver maximum availability and performance from control valves - the most critical, yet also the most maintenance-prone element in many control loops.

Powerful tools are provided for both predictive maintenance and valve management.

Self-surveillance and diagnosis follow the Namur Recommendation NE107.

Based on the loop management services introduced last year, the loop monitor uses advanced diagnostic methods (performed either locally or remotely) for determining control loop performance.

The qualitative metrics derived provide an indication of both control loop tuning and field device performance.

Examples include the detection of hysteresis and stiction and plugged impulse lines in control valves - both intelligent and conventional.

The pump monitor is a novel solution providing a variety of online diagnostic and analysis tools that include an advanced method for measuring friction, shock, and dynamic load transfer between moving parts.

High frequency acoustic sensing technology filters out background levels of vibration and audible noise and provides a graphic representation of pump health.

This works like a "computerised stethoscope" for critical pumps to determine corrective workflow activity that can virtually eliminate unplanned pump-related downtime and minimise pump-related production slowdowns.

The equipment monitor combines appropriate elements of traditional vibration monitoring capabilities, sonic signature profiling technology, empirical and first principles modelling, and advanced condition monitoring technologies with sophisticated analysis tools and workflow guidance to drive preventive and predictive maintenance, operations, and engineering activities for all critical plant equipment - both rotating and nonrotating.

With this advanced applied solution, unplanned equipment breakdowns can be largely replaced by scheduled maintenance events and users can move from preventive to predictive maintenance, resulting in fewer production interruptions, shorter outage times, reduced maintenance cost, lower capital expenditures and improved asset availability and utilisation.

The initial system-level solutions monitor and/or help manage plant alarms, process control network security, safety system integrity and control system performance.

The alarm management monitor is based on the alarm management services introduced last year.

The new alarm management monitor significantly enhances the performance and safety of process control operators and other human assets by providing an applied toolset for rationalising process, system and equipment alarms to dramatically reduce irrelevant nuisance alarms and virtually eliminate the possibility of alarm storms.

It includes intelligent alarming capabilities that direct operators to the root cause of an alarm, so they can respond quickly and effectively and thus prevent or minimise the impact of events.

Reflecting current security standards and guidelines such as ISASP99, NERC CIP002-CIP009 and 21CFR11, the security management monitor works within a strong security program to help users identify site-specific network security vulnerabilities, plus provides ongoing services (monitoring, detecting, alarming and documenting) to help protect the process control network against potentially catastrophic external intrusions or malicious internal tampering via corporate intranets or plant networks.

This solution is based on the network security services introduced last year.

The safety integrity monitor is a powerful maintenance decision-support tool based on the actual probability-of-failure-on-demand (PFD) for safety instrumented functions (SIF) throughout a plant.

Using a continuous online Safety Integrity Level (SIL) management methodology, it reconciles testing events against PFD statistics, and allows predictive "what-if" scenarios to be conducted to optimise testing cycles and help ensure that the plant's operating SIL remains within design specification.

Comprehensive audit trail documentation is delivered as part of safety system lifecycle management.

Thus, this monitor facilitates compliance with IEC61508/61511, while helping to maximise plant uptime and safety.

The automation platform monitor is an extension of Invensys' well-proven "FoxWatch" remote system support capabilities, the automation platform monitor utilises new remote diagnostic tools to help ensure that plant automation systems are operating at peak performance at all times.

Highly secure connection to the Invensys remote services centre can be made via router (modem or ISDN) or virtual private network (VPN) internet access.

A state-of-the-art security appliance, combined with advanced virus detection and removal software, help protect mission-critical process control systems from external intrusions.

The automation platform monitor is available for current versions of I/A Series systems, with plans in place to extend this powerful remote support capability to other Invensys and third-party automation platforms.

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