The global process industries lose an estimated $20 billion annually due to unscheduled downtime and poor quality.

Its no surprise that, in a joint survey by Plant Services and ARC Advisory Group, respondents indicated improve uptime as the primary driver for deploying predictive maintenance (PdM) solutions (Figure 1). PdM is the practice of applying condition-based monitoring techniques to collect and analyze asset data to gain an understanding of asset performance and perform appropriate maintenance as indicated by the asset. e survey polled end users regarding current status of PdM programs, as well as future plans for improvement. is PdM survey provides insights on practices and maintenance management. Users should compare their operations with the survey results to gain a better understanding of best practices and obtain ideas for proven improvements. For production to meet targets, equipment must be available and in acceptable working order. Ine ective maintenance accounts for $60 billion annually, according to ARC research. is PdM survey re ected that manufacturers are well aware of this, too, as reduce operational cost was the runner-up, followed closely by reduce maintenance cost. A sound PdM strategy can improve workforce and nancial performance. With a combined view of asset availability and other operational constraints, workers can make information-driven decisions.
PDM TECHNOLOGY USAGE

PdM is frequently referred to as condition-based maintenance, but, regardless of what its called, these types of solutions quantitatively evaluate equipment condition relative to an established baseline or standard. e value of PdM lies in its diagnostic capabilities, which greatly aid in the maintenance decision-making process. Spending for PdM systems continues to outpace that of the automation industry in general, as manufacturers seek to leverage a deeper knowledge of equipment condition as a means of increasing asset utilization and productivity and reducing maintenance costs, according to ARC research. e increased amount and complexity of automation equipment currently installed in plants requires a higher-order approach to maintenance provided by PdM systems. As the discipline of asset performance management (APM) matures, process industries are exhibiting a greater understanding of its principles. As users become more familiar and pro cient in condition-based monitoring techniques, they will demand more from the equipment, and suppliers must keep pace.
BUSINESS DRIVERS FOR PDM

Reduce risk Reduce energy consumption Regulatory compliance Environmental, health and safety concerns Increased visibility to reliability problems Knowledge capture of aging workforce Improve uptime Reduce operational cost Reduce maintenance cost
20% 26% 25% 30%

47% 43% 33% 38%

35% 26% 29% 25% 44% 35% 87% 33%

16%

3% 5%

12% 6% 14% 13% 12%

42%

58% 56%

31% 34%

8% 3% 7% 3%

High

Medium

Low

Not a factor

Figure 1. Almost 90% of survey respondents deploy PdM solutions to improve uptime.

PREDICTIVE MAINTENANCE / CONDITION-BASED MONITORING

e survey results indicate that oil analysis, infrared, and vibration are implemented widely now (Figure 2). Predictive monitoring solutions continue to expand in capability, as indicated by the interest in corrosion monitoring. e e ects of corrosion cost the process industries roughly $300 billion annually in lost production, failure of key equipment, and nes for environmental and safety violations. Corrosion monitoring (CM) can signi cantly lengthen the life of mechanical equipment and piping, as well as prevent abnormal situations from occurring. In addition to traditional PdM technologies, reliability, predictive so ware modeling, and CM in EAM/ CMMS were included as choices for survey respondents. Responses for reliability and CM in EAM/CMMS were very similar. However, it appears that utilization of predictive modeling as a PdM technology is not yet mainstream.
INTEGRATION ENHANCES VALUE OF PDM

Stand-alone solutions can provide excellent value for newcomers but may not be su cient for sustainable improvement due in part to the islands of information stand-alone solutions create. e industry has progressed far beyond proprietary one-o connectors to certi ed interfaces to facilitate information exchange. In organizations where increasing physical asset reliability as a means to improve asset availability is

deemed the primary goal, connecting PdM applications that directly or indirectly administrate, measure, analyze, resolve, and improve asset performance in a comprehensive fashion will drive appropriate workforce actions. e good news is that, for the most part, survey respondents are integrating PdM solutions with other enterprise systems, particularly with historians and EAM/CMMS (Figure 3). e current generation of plant equipment is far more intelligent than previous generations. ese more intelligent assets require a more strategic, integrated management approach. Leveraging the rich information in these solutions can improve the e ectiveness of each. Ideally, all solutions should be connected in real time. Integrating solutions based on function o ers a practical approach. For example, the most advanced PdM and EAM systems have embedded readymade networks for the collection of disparate data. Combining reliability information with PdM solutions can improve the predictive capability of the PdM solution by identifying assets for critical assessment and thereby minimize the possibility of asset failure. Survey respondents are integrating PdM with historians most frequently. However, what is not clear from the survey is if the historian is being utilized as a data archive, as has

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been the case traditionally, or as an improvement tool. With increased data throughput and higher data resolutions, historians have evolved to become a tool for managing plant assets, thanks to new visibility and trending tools. Todays historians also support techniques, such as complex event processing, which can analyze multiple streams of plant data in real time to identify and diagnose emerging problems before they disrupt production. Remote access to historian data via the Web enables central management of assets, whether within a single plant or across multiple plants. PdM solutions are widely integrated with EAM/CMMS, according to the survey. EAM systems have also evolved to include greater functionality to accommodate the broad spectrum of features needed to e ectively integrate and manage the di erent types of asset classes found throughout the enterprise. New EAM systems con gured to support the maintenance business processes of an enterprise can integrate, consolidate and help prioritize data for a single version of the truth throughout the enterprise. Features such as realtime data collection, diagnostics, and analysis tools enable individual users to prioritize and track information in the context of their functions. Equally important is integrating applications using standardized formats that permit the enterprise to undertake

corporation-wide initiatives. Additional value is derived from the sharing of best practices among individual plants for continuous improvement throughout the organization. From a management perspective, the addition of risk and simulation functionality provides management with deeper insight into the nancial implications of PdM before making a decision to adjust resources.
RECOMMENDATIONS

E cient management of assets is critical to improving plant performance. As a component of a comprehensive asset performance management strategy, PdM solutions o er huge bene ts. However, the value realized by the enterprise is
METHODOLOGY

Of the 234 respondents, 85% were directly involved in maintenance activities with titles of maintenance or reliability manager, engineer, or technician. Approximately 10% were either plant or operations managers. The other respondents were a mixture of application engineers, IT, or corporate executives. Plant size ranged from a single facility to multinationals with multiple sites.

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PREDICTIVE MAINTENANCE / CONDITION-BASED MONITORING

PDM TECHNOLOGY DEPLOYMENT

35% 69% 67% 33% 23% 5% 46% 65% 16% 6% 36% 23% 10% 25% 6% 14% 6% 14% 6% 8% 16% 59% 33% 20% 13% 27% 8% 4% 10% 45% 9% 26% 14% 19%

Reliability (RCM, FMEA, RBI etc.) Oil analysis Infrared Corrosion Acoustic Ultrasonic Vibration Predictive software modeling Condition monitoring in EAM/CMMS
Have now In 2012 budget

55% 29%

Within 3 years

No plans to integrate

Not applicable

Figure 2. More than two-thirds of survey respondents use oil analysis, infrared, and vibration testing as part of their PdM practices. PDM INTEGRATION WITH ENTERPRISE SYSTEMS

ERP system EH&S EAM/CMMS system Historian information Reliability solutions

Have now In 2012 budget

15% 13%

6% 5% 39% 46%

19% 14% 11% 7% 20%

32% 40% 17% 13% 29% 19% 21%

28% 27% 14% 13% 22%

24%

6%

Within 3 years

No plans to integrate

Not applicable

Figure 3. Almost half of survey respondents indicate they use an historian for collected data.

dependent upon selecting solutions that ll gaps in existing practices. Companies that adopt a strategic approach to plant assets and their management will drive the enterprise to optimal performance. Here are a few key steps. support core objectives and goals of the enterprise. ule, including implementation resources, regulatory requirements, the type and version of applications and systems, proprietary data sources, and types of processes that will be impacted. functionality that provides the ability to perform dynamic or real-time calculations and to compare current and historical data. tifying the bene ts realized will help build the case for
28
JULY 2012 WWW.PLANTSERVICES.COM

in nancial terms that can be directly correlated to recommended actions or that clearly show the cost of

workers have a way of being successful, provided the goal is achievable and can be accurately measured. but the ability to easily integrate multiple applica-

insight to optimize asset availability and utilization while balancing operational constraints to improve financial results.
Paula Hollywood is senior analyst at ARC Advisory Group. Email her at phollywood@arcweb.com.

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