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Reduce Unscheduled Downtime with
Predictive Maintenance
Mike Reed, Manager of Engineering and Analytics, Schneider Electric
Digital Transformation
Industry 4.0 and IIoT transforming industrial companies
Immersive asset simulation &
virtual reality (VR) training
Contextual content on device of
choice and overall asset health
ranking
Condition-based, predictive, machine
learning and augmented reality (AR) for
improved decision making
Enforce best practices for data
collection & operator rounds
Enable analysis and
decision making
Design and commission
assets at the lowest cost
Produce safely and
profitably and meet
regulatory compliance
Ensure availability and
reliability of assets and
safety of workforce
Reduce Total Cost of
Ownership
Agnostic, to leverage existing
investments. Flexible deployment - on
premise, cloud, hybrid
Industry Imperatives Enabling Capabilities
Performance Losses &
Downtime
Reduce O&M Costs
Optimize Maintenance
Strategy
Overall Asset
Performance



Safety & Asset
Reliability


Resulting BenefitsTechnology Trends
IIoT & CONNECTIVITY
CLOUD & MOBILITY
BIG DATA & ANALYTICS
AR & VR
We are THE Leader in Industrial IoT
Digital Transformation to Maximize Return on Assets
2 Million
Licenses
Installed
100,000+
Sites Worldwide
20+
Billion
Operating
Parameters
10+
Trillion
Industrial
Transactions/Day
12+ Petabytes
of Data Stored/Year
4000 Ecosystem
Partners
Beyond traditional control and connectivity: Open and flexible operating modes, on premise, cloud and hybrid.
Strategic
(increased asset utilization,
improved performance and
better maintenance planning)
Operational
(reduce downtime, asset
utilization, improved quality,
production performance)
Engineering
(decision support, less-time
analyzing and more time
acting, mobile solutions)
Financial
(reduced operational and
maintenance costs)
Safety
(reduced risk, early warning of
impending catastrophic
equipment failures)
IT
(data quality, utilization,
improved models, real-time
and predictive insights)
Benefits of Predictive Maintenance
Achieve the Next Level of Maintenance Maturity
Apply the right strategy
Risk-based
Condition
Preventive
Predictive
Prescriptive
• Software based modeling of equipment using advanced
pattern recognition and machine learning
• IIoT Data Integration
• Predictive Asset Analytics Engine (Optics)
• Scalable Data Management Infrastructure
• Web Services API
• Alert Management
• Alert Notification
• Case Library
• Web Based Analysis and Visualization
Predictive Asset Analytics Software
Sample Customer Savings Achieved
Reduce Unscheduled Downtime
Prevent Equipment Failures
Optimize An Assets Maintenance Strategy
Reduce Maintenance Costs
Increase Asset Utilization
Extend Equipment Life
Identify Underperforming Assets
Improve Safety
Monitoring without advanced analytics
Plot-0
4/6/2008 4:39:21.791 PM 4/9/2008 4:39:21.791 PM3.00 days
60
62
64
66
68
70
72
74
76
58
78
96
108
86
102
107
113
94
102
46
64
0
14
110
170
52
70
25
75
Monitoring Approach
Traditional Monitoring
• Constant alert/alarm limits are
typical
• Damage accumulates prior to
reaching limit
• Actual minus estimated (residual)
signal detects anomaly as-soon-as-
possible
APR Monitoring
Model Templates
Make new templates or projects
based on templates
Web Alarm Management and Diagnosis
Fault Diagnostics
Problem Cause Identification
Case Library
Predictive analytics is a key
part of a comprehensive
Enterprise Asset
Performance Management
(APM) solution. These
solutions connect vast
amounts of data, providing
context and analysis to
prescribe the appropriate
actions.
• Improve asset
performance
• Increase reliability and
reduce unscheduled
downtime
• Increase asset utilization
and extend equipment
life
• Reduce operations and
maintenance costs
Maximize Economic Return on Assets
Closed Loop Asset Performance Management
Maximize
Economic Return
on Assets
Organizations can maximize return on
their assets by adopting Enterprise
APM
Enterprise APM empowers
organizations to:
• Improve asset performance
• Increase reliability and reduce
unscheduled downtime
• Increase asset utilization and
extend equipment life
• Reduce operations and
maintenance costs
AEP uses predictive
analytics to detect turbine
damage & avoid forced
outage
Client:
American Electric Power
Location:
Columbus, Ohio
Closing the Loop:
Predictive analytics helped AEP use a
scheduled opportunity outage to repair a
damaged turbine engine. Prior to the
scheduled outage, the plant notified the
M&D center indicating a vibration sensor
anomaly and a change in one bearing.
AEP was able to use a planned outage
to investigate the turbine, and found a
chunk out of a stage 3 blade on the
compressor.
Results:
The solution enabled AEP to:
‣ Detect equipment failures before
they occur
‣ Prevent unscheduled system
downtime
‣ Harness real-time information that
brings plant operators and
engineering experts together to
collaborate
Predicting an
8-week
Unplanned outage
Using
Real-time Data
To detect unforeseen events
Saving
+17.5 Million
On reactive maintenance repairs
and unplanned downtime
$
Duke Energy Leverages
IIoT and Predictive Analytics
to Reduce Failure
Page 17Confidential Property of Schneider Electric |
Client:
Duke Energy
Location:
Charlotte, NC
Closing the Loop:
Duke Energy is a regulated and non
regulated utility with over 60+ plants in 6
states, including coal, simple cycle
combustion turbines, combined cycle and
integrated gasification combined cycle
plants. Duke Energy centrally monitors
power generation assets with predictive
analytics technology
Results:
Predictive analytics enabled Duke Energy
to:
‣ Empowering people with early warning
notification of equipment problems
‣ Optimizing assets with low-cost sensors
and connectivity for high-fidelity data
access enabling predictive maintenance
‣ Improving operations by providing
contextualized insights for smarter
decision making and efficiency
Serving
7.2 Million
Customers
Generating capacity of
58,200 MW
Saving
+7.5 Million
Due to early warning of a crack
in a turbine rotor
$
Total Savings: $31 million and growing
Air Liquide uses predictive
analytics to detect
compressor problems &
avoid forced outages
Client:
Air Liquide
Location:
Global
Closing the Loop:
Predictive maintenance helped Air
Liquide use a scheduled opportunity
outage to repair a damaged turbine
engine. Prior to the scheduled outage, the
plant notified the M&D center indicating a
vibration sensor anomaly Air Liquide was
able to use a planned outage to
investigate the compressor and found a
cracked impeller.
Results:
Predictive maintenance helps Air
Liquide:
‣ Detect equipment failures before they
occur
‣ Prevent unscheduled system
downtime
‣ Harness real-time information that
brings plant operators and
engineering experts together to
collaborate
Predicting a
Compressor
Failure
Using
Real-time Data
To detect unforeseen events
Saving
+500K
Preventing reactive maintenance
and unplanned downtime
$
Questions?
Michael.t.Reed@schneider-electric.com
+1-312-894-7908 office
+1-312-213-5488 mobile
http://software.schneider-electric.com/solutions/enterprise-asset-performance-management/

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1415 reed

  • 1. Reduce Unscheduled Downtime with Predictive Maintenance Mike Reed, Manager of Engineering and Analytics, Schneider Electric
  • 2. Digital Transformation Industry 4.0 and IIoT transforming industrial companies Immersive asset simulation & virtual reality (VR) training Contextual content on device of choice and overall asset health ranking Condition-based, predictive, machine learning and augmented reality (AR) for improved decision making Enforce best practices for data collection & operator rounds Enable analysis and decision making Design and commission assets at the lowest cost Produce safely and profitably and meet regulatory compliance Ensure availability and reliability of assets and safety of workforce Reduce Total Cost of Ownership Agnostic, to leverage existing investments. Flexible deployment - on premise, cloud, hybrid Industry Imperatives Enabling Capabilities Performance Losses & Downtime Reduce O&M Costs Optimize Maintenance Strategy Overall Asset Performance    Safety & Asset Reliability   Resulting BenefitsTechnology Trends IIoT & CONNECTIVITY CLOUD & MOBILITY BIG DATA & ANALYTICS AR & VR
  • 3. We are THE Leader in Industrial IoT Digital Transformation to Maximize Return on Assets 2 Million Licenses Installed 100,000+ Sites Worldwide 20+ Billion Operating Parameters 10+ Trillion Industrial Transactions/Day 12+ Petabytes of Data Stored/Year 4000 Ecosystem Partners Beyond traditional control and connectivity: Open and flexible operating modes, on premise, cloud and hybrid.
  • 4. Strategic (increased asset utilization, improved performance and better maintenance planning) Operational (reduce downtime, asset utilization, improved quality, production performance) Engineering (decision support, less-time analyzing and more time acting, mobile solutions) Financial (reduced operational and maintenance costs) Safety (reduced risk, early warning of impending catastrophic equipment failures) IT (data quality, utilization, improved models, real-time and predictive insights) Benefits of Predictive Maintenance
  • 5. Achieve the Next Level of Maintenance Maturity Apply the right strategy Risk-based Condition Preventive Predictive Prescriptive
  • 6. • Software based modeling of equipment using advanced pattern recognition and machine learning • IIoT Data Integration • Predictive Asset Analytics Engine (Optics) • Scalable Data Management Infrastructure • Web Services API • Alert Management • Alert Notification • Case Library • Web Based Analysis and Visualization Predictive Asset Analytics Software
  • 7. Sample Customer Savings Achieved Reduce Unscheduled Downtime Prevent Equipment Failures Optimize An Assets Maintenance Strategy Reduce Maintenance Costs Increase Asset Utilization Extend Equipment Life Identify Underperforming Assets Improve Safety
  • 8. Monitoring without advanced analytics Plot-0 4/6/2008 4:39:21.791 PM 4/9/2008 4:39:21.791 PM3.00 days 60 62 64 66 68 70 72 74 76 58 78 96 108 86 102 107 113 94 102 46 64 0 14 110 170 52 70 25 75
  • 9. Monitoring Approach Traditional Monitoring • Constant alert/alarm limits are typical • Damage accumulates prior to reaching limit • Actual minus estimated (residual) signal detects anomaly as-soon-as- possible APR Monitoring
  • 10. Model Templates Make new templates or projects based on templates
  • 11. Web Alarm Management and Diagnosis
  • 14. Predictive analytics is a key part of a comprehensive Enterprise Asset Performance Management (APM) solution. These solutions connect vast amounts of data, providing context and analysis to prescribe the appropriate actions. • Improve asset performance • Increase reliability and reduce unscheduled downtime • Increase asset utilization and extend equipment life • Reduce operations and maintenance costs Maximize Economic Return on Assets Closed Loop Asset Performance Management
  • 15. Maximize Economic Return on Assets Organizations can maximize return on their assets by adopting Enterprise APM Enterprise APM empowers organizations to: • Improve asset performance • Increase reliability and reduce unscheduled downtime • Increase asset utilization and extend equipment life • Reduce operations and maintenance costs
  • 16. AEP uses predictive analytics to detect turbine damage & avoid forced outage Client: American Electric Power Location: Columbus, Ohio Closing the Loop: Predictive analytics helped AEP use a scheduled opportunity outage to repair a damaged turbine engine. Prior to the scheduled outage, the plant notified the M&D center indicating a vibration sensor anomaly and a change in one bearing. AEP was able to use a planned outage to investigate the turbine, and found a chunk out of a stage 3 blade on the compressor. Results: The solution enabled AEP to: ‣ Detect equipment failures before they occur ‣ Prevent unscheduled system downtime ‣ Harness real-time information that brings plant operators and engineering experts together to collaborate Predicting an 8-week Unplanned outage Using Real-time Data To detect unforeseen events Saving +17.5 Million On reactive maintenance repairs and unplanned downtime $
  • 17. Duke Energy Leverages IIoT and Predictive Analytics to Reduce Failure Page 17Confidential Property of Schneider Electric | Client: Duke Energy Location: Charlotte, NC Closing the Loop: Duke Energy is a regulated and non regulated utility with over 60+ plants in 6 states, including coal, simple cycle combustion turbines, combined cycle and integrated gasification combined cycle plants. Duke Energy centrally monitors power generation assets with predictive analytics technology Results: Predictive analytics enabled Duke Energy to: ‣ Empowering people with early warning notification of equipment problems ‣ Optimizing assets with low-cost sensors and connectivity for high-fidelity data access enabling predictive maintenance ‣ Improving operations by providing contextualized insights for smarter decision making and efficiency Serving 7.2 Million Customers Generating capacity of 58,200 MW Saving +7.5 Million Due to early warning of a crack in a turbine rotor $ Total Savings: $31 million and growing
  • 18. Air Liquide uses predictive analytics to detect compressor problems & avoid forced outages Client: Air Liquide Location: Global Closing the Loop: Predictive maintenance helped Air Liquide use a scheduled opportunity outage to repair a damaged turbine engine. Prior to the scheduled outage, the plant notified the M&D center indicating a vibration sensor anomaly Air Liquide was able to use a planned outage to investigate the compressor and found a cracked impeller. Results: Predictive maintenance helps Air Liquide: ‣ Detect equipment failures before they occur ‣ Prevent unscheduled system downtime ‣ Harness real-time information that brings plant operators and engineering experts together to collaborate Predicting a Compressor Failure Using Real-time Data To detect unforeseen events Saving +500K Preventing reactive maintenance and unplanned downtime $