This document discusses intelligent asset performance and energy management solutions for pulp and paper industries. It outlines the business drivers for asset performance management including increased profitability, workforce enablement, safety management, and regulatory compliance. It then describes the need for asset data synchronization across various stakeholders and systems. The proposed solution architecture integrates asset performance management, predictive maintenance, energy management, and intelligent asset tagging. Real-time dashboards would provide visibility into key performance indicators for assets and energy usage to support decision making. The integrated solution is expected to provide benefits like optimized asset efficiency and energy usage, reduced operating expenses, and improved decision support.

1. 1Copyright © 2012 Tata Consultancy Services Limited
Intelligent Asset Performance&Energy Management
for
Pulp & Paper Industries
Prepared by : Murali Chandrahasan
Practice Head- Plant Solutions

2. 2
Brief Agenda for the presentation
 Business drivers for Asset Performance Management
 Asset Life Cycle Management for Process Industries
 Need of Asset Data Synchronization.
 Solution Architecture for Asset Performance Management
 Pulp&paper Industry Asset Data Model
 Intelligent Asset View for real time decision support
 Business Benefits of integrated Asset Performance and Energy Management

3. 3
Asset Performance Related Business Drivers
Asset Performance
Management
PROFITWORKFORCE
ENABLEMENT
SOCIAL
RESPONSIBILITYSAFETY
MANAGEMENT
Asset Uptime
Asset Longevity
Asset Utilization
Energy Reductions
Decision Support
Collaboration Tools
Workflow Tools
Accident Prevention
Safer Work Environments
Safety Practices
Emissions Control
Carbon Footprint
Regulatory Compliance

4. 4
Asset Information view and various stake holders
Plant Engineer
• Pressure
• Flow
• Speed
• Energy
Site Manager
• Volume pumped
• Product throughput
• Operation history
• Power consumed
Maintenance Manager
• Running hours
• Performance spec
• Spares on hand
• Maintenance date
Operations Engineer
• Related equipment
• Energy
• Vibration data
Asset Planner
• Purchase date
• Warranty
• Manufacturer
• Engineering specsFinance Manager
• Asset Cost
• Capex planning
• Opex budgets
Control System/HMI
Historian
Asset
Database
ERP Systems
Maintenance
Management
System
Asset information viewed in silos
across operational and enterprise
systems and people
Plan Design Procure Build Operate Maintain
Retire &
Recycle
Project Performance
Management (PPM)
Asset Performance
Management (APM)

5. 5
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Engineering Drawing P & ID Name Plate Legacy Database Purchase Order
EAM Users
Engineering
Systems
Vendors Catalogs/ Manuals
ERP Systems
EAM System
Asset Performance Management needs data synchronization

6. 6
Intelligent Asset Performance Management
Solution Architecture for Pulp and Paper Industry
Configurator
Business
Activity
Monitor
Asset /Energy
KPIs
PLC/DCS
EAM
Legends: Web PortaliASM Partner Systems
Predictive
Maintenance
Preventive
Maintenance
Energy
Management
Intelligent
Asset Tag
Asset Performance
Management
Paper Industry
Asset model
Energy
Meters
Plant
Engineering
APM Dashboards Energy Dashboards
ERP
SCADA and
Historian

7. 7
Pulp and Paper Industry Asset Model

8. 8
Intelligent Asset view enable real-time decision support
 Single Click view of all assets in Utility
 Provide user based Intelligent asset View
 Drill down based on asset type
 Provide the following information
– Operational Information
– Maintenance History
– Specific Energy Consumption
– OEE for all the assets
– Engineering Specification
– Manufacturing vs Actual Efficiency
– Cost associated to Efficiency Improvement
– Monitor alarms on Efficiency and Energy
– Plan Asset Repair vs Replace vs Refurbish
– Reduce OPEX and plan your CAPEX
Intelligent Asset Tag

9. 9
Asset Performance Management Dashboard

10. 10
Energy Management Dashboard

11. 11
Who benefits?
Executives
Decision making support
Information transparency
Plant Manager
Cost Analysis
Maximize asset availability
Maintenance
Supervisors
Repair vs. Replace
Energy
Managers
Energy analysis
Optimize Usage

12. 12
Business Benefits of Intelligent APM and EMS
…Your apps are seamlessly
integrated …
…You have visibilityin a
heterogeneous environment …
…You can have Real-time
asset performance and energy
and PAT dashboards…
…Manage your asset efficiency and
manage Energy
…Your asset information
are in sync with enterprise and
operational apps …
…You can monitor your assets
in real-time for exceptions…

13. 13
Thank You
Murali Chandrahasan
Practice Head – Plant Solutions
Murali.chandrahasan@tcs.com
+91 98402 99072