Best Practices for the OSIsoft UC and Slide Template...design mistake (hidden defect) 17 . ... [Volume 4, EU Guidelines for Good Manufacturing Practice for Medicinal Products for Human

© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015

Corporate Overview


Facility & Maintenance Center Austria

FAMAC Responsibilities:

As asset owner

~ 12,000 assets (8400 facilities and rooms, 4000 utilities and critical media systems) in Vienna and Orth over the life cycle

As maintenance organization

~ 450 production equipment in Austria

(7 production plants in Vienna, Orth)

These tasks are managed by three operation groups (Vienna, Orth and Krems [project phase]), a Planning & Scheduling group and a Reliability engineering organization with more than 300 technicians.

5


Primary Business Case 1

Project started to support ISO 50001 implementation of an energy management system

Annual energy cost of ~15M€

We selected the PI System from OSIsoft

Why

• To keep long term historical data

• Alarm on abnormal energy / media usage to reduce waste of valuable resources

• Utilize Energy Models to identify our big consumers - raising its efficiency gives the fastest ROI

6


Primary Business Case 2

2013 Status • Common and easy to use reporting software for all users • ~ 700 meters online (500 Vienna, 200 Orth) • ~ 4000 Tags • Centralized data storage • Growing expectation appr. 50 energy meters per year ( ~ 500 tags ) • Relationships created between consumed energy and produced units

Improved Data Access, Reporting and Analysis • For root cause analysis from historical data is essential • Data stored in the PI System as the common technology platform

– accelerates root cause analysis and reporting – reduces training expenses to produce more system experts to utilize data

• Easy global access for corporate engineers to run Energy audits on factory data

7


Business Case Change

8

Why:

• There is much more potential than just Energy Monitoring

• Energy is important but as an Engineering Organization adding value to our maintenance function made a more compelling business case

Enhanced the project scope to implement an Engineering Management System

What does this mean?

The life cycle of all assets will be managed with the PI System



9

• Identify Need Phase

Need for utility support (asset) will be requested only if PI System data show a bottle neck in the supply and no load balancing or equipment optimization is possible

Avoiding a lot of investment!


Avoided Investment Using Load Balancing • Identify Need - cooling tower

“Load management” with reliable PI System data Initial situation:

Some hydraulically connected cooling towers with a total capacity of 1,8MW supply one production facility, additional chiller capacity was requested!

Solution: PI System data showed that an additional chiller in the same plant offered ~1MW of free chiller capacity (free based on a different load profile). So only a connection to the additional chiller system was needed to solve the load issue.

10


Smart Investment using Load Balancing • Identify Need – Photovoltaic investment

“Load management” with reliable PI Data Initial situation:

Electrical load of the plant is close to 90% of the grid cable capacity. An 8M€ investment and a project phase of >3y was estimated.

Solutions: PI System data was used to analyze the daily load curve (driver: chiller power for humidification, dehumidification) leading to an alternative investment in an 1,2M€ photovoltaic plant which covered the daily peak loads much more efficiently.

11

0

1,000,000

2,000,000

3,000,000

0

100,000

200,000

Monthly consumption with photovoltaic in kWh

PV Netz

6.000

4.000

2.000

0 Net

0.00

1,000.00

2,000.00

3,000.00

4,000.00

5,000.00

Reduced Peakload with photovoltaics in kWh

PV

Netz Net



12

• Plan Phase new equipment is planned based on available reliability data of similar equipment

• Reliability data include:

Load, Corrective/ preventive maintenance, energy consumption and efficiency KPIs, CAPEX and OPEX costs


Avoiding Investment Using Load balancing • Plan - Chilled water system

”Load management“ with reliable PI Data

• Initial situation: A Plant has 2 hydraulically disconnected cooling systems with a total generating capacity of 5,6MW. Insufficient cooling capacity was estimated (counters were missing) in case of failure of system (= lack of redundancy). means an investment in an additional chiller (Investment: ~ 1.400k€)

• Solutions: Energy readings (electrical and chilled water) via the PI System showed that even during peak loads sufficient cooling capacity is provided also with one chiller operating if the two hydraulically systems would be connected. A invest of <100t€ for one additional chilled water counter and a control valve allows chiller capacity balancing between the two hydraulic systems.

13



14

• Design Phase In the design (user requirement specification) of new equipment all historical data of similar equipment / technology is included in the following:

• User related specification

• Owner related specification

Historical data includes all PI System relevant equipment parameters


Design - Specification

• Service Level Agreements (SLAs): The agreed internal customer performance targets are made visible via appropriate counter structure. Annual Review of goal achievement is based on PI System data and Work Order data.

• Current reporting of SLA performance: Word document including visualization from OSIsoft client tools

• Current Challenge: Linking Work Orders and PI System Events

15



16

• Procure/Build Phase Supervising suppliers to assure build conforms with specifications using

• Factory Acceptance Tests and Site Acceptance Tests as needed

• Definition of maintenance, life cycle and spare parts costs in detail.

• Set up of Master data and parameterization in systems

• Monitoring is started!

• Commission Phase Most important phase to assure that all specifications are fulfilled

• Qualification / validation is performed according to GMP

• we also run online monitoring of the new asset using the PI System to verify efficiency, load and performance


Procure / Build & Commission

• Cooling tower “Performance test“ using reliable PI System data Initial situation:

4 hydraulically connected cooling towers with a total capacity of 1,8MW (design data 32°C / 12 g/kg) supply one production facility

Solution: Based on monitoring and evaluating the data an underperformance of approximately 0,4MW was found

There is an ongoing discussion with the supplier about the design mistake (hidden defect)

17



18

• Operate, Maintain & Monitor Performance Phase PI System is used as a monitoring system with no resources needed as long as no alarm occurs

• Early signal detection generates an alarm as a notification for the technician

• Performance KPIs are generated online and reported directly in Excel based SLA reports


Operate, Maintain & Monitor Performance • Early signal detection is currently used e.g.:

for air handling units (pharmaceutical production)

The filter differential pressure (DP) and the related air handling system is continuously monitored.

When the DP exceeds a predetermined limit or the air handling systems shows abnormal data, the PI System

issues a notification by e-mail to the technician.

The filter maintenance is now condition based without increasing production risk. In addition, the circulated quantity of air (proof of air exchange) is recorded and PI System issues notifications for low deviations.

This monitoring function for quality relevant or critical equipment parameter is a prerequisite for optimizing the maintenance concept (e.g. shut down reduction).

19


Operate, Maintain & Monitor Performance • Robust continuous data analysis

via online data and performance KPIs can

replace the traditional process validation/ qualification of process equipment and critical utilities according to the “Continuous process verification.” [Volume 4, EU Guidelines for Good Manufacturing Practice for Medicinal Products for Human and Veterinary Use, Annex 15: Qualification and Validation]

Important resource optimization possibility

20


Operate, Maintain & Monitor Performance

• For one campus media billing is automated • All relevant media readers (electricity, water,

steam, waste water, …) are connected to the PI System

• Via PI DataLink an automated Excel report is generated and sent to the accounting department of the other company sharing the campus

• Sewage reimbursement • Public sewage reimbursement (Austrian Authority) is

also documented via Readers in the PI System and requested via automated Excel report out of the PI System data

21


Operate, Maintain & Monitor Performance

Live data from the weather station are going directly into

the PI System for:

• Daily evaluations

• System operation

• Support of route cause analysis

22



23

• Modify or Update Phase Performed based on PI System reports (for unplanned events - bad actors, waste production)

Root cause analysis is based on online PI System data


Modify or Update

• Work Order Mgmt. (Bad Actor) Reliability Engineering (RE) and the operation groups runs a weekly corrective maintenance review sustainable actions for the bad actors are defined

• RE-analysis (Bad Actor + waste producer) RE is collecting and preparing data from all available systems (technical alarm system, JDE, quality systems, purchasing system, PI System…), analyze that data for optimization potential and initiate improvement projects

24



26

• Decommission (Replacement) Phase

this Phase is also based on the calculated business case of whether

• the old asset should still be maintained

or

• a new asset with better efficiency (in human, spare parts, break down, energy, …) will justify the investment

© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015 27

All these IT tools independently manage master data, life data, asset structures and visualization:

• ERP system

• Building control system (Desigo)

• Process control system (S7, Beckhoff)

• Monitoring/ technical alarm system (hard-wired)

• Purchasing system

• OSIsoft PI System

• Room data base

Therefore

A lot of resources are needed to keep systems up to date Data quality and data synchronization is not assured / depending on human Request: better linking of systems

Challenges - Master Data Management


Challenges – Asset Master Data

28

• Equipment Hierarchy (ERP [JDE] vs. the PI System)

The structure of the equipment hierarchy and the master data must be set up individually in the systems. An interface would be helpful to assure data quality and reduce resources


RESULTS AND BENEFITS BUSINESS CHALLENGES SOLUTION

Summary

29

Connection and integration of different systems, with reliable

PI System data, and a clear goal delivers a great benefit for the Asset management business

A. ISO 50001

B. Lifecycle Management of assets was based on estimations

C. Investments were not data based

D. Transparence of asset performance to show the “Value of the Maintenance”

A. From energy reader to early signal detection

B. Engineering Management System is implemented via ERP/ PI System

C. Available asset with available control system are connected to PI System, together with other systems the asset life cycle is managed

• Investment could be avoided/ reduced in >M€

• SLA / billing for customer is base on online data

• Reliability Engineering is now fed with online data

• Resources of engineers are focused on the right areas of improvements


Contact Information

30

Christian Bugl [email protected]

Director Facility&Maintenance Center Austria

Baxalta

30

mailto:[email protected]

© Copyright 2015 OSIsoft, LLC EMEA USERS CONFERENCE 2015 31

Questions

Please wait for the microphone before asking your questions

Please don’t forget to…

Complete the Online Survey for this session

http://eventmobi.com/emeauc15/

State your name & company


Thank You

OSIsoft PI System is that tool for an holistic approach in Asset Management

Documents

Best Practices for the OSIsoft UC and Slide Template...design mistake (hidden defect) 17 . ... [Volume 4, EU Guidelines for Good Manufacturing Practice for Medicinal Products for Human