1) The document discusses optimization of production processes through condition based management and integration of intelligent process instrumentation and analytic technologies. 2) Key topics include life cycle management, asset management, process efficiency, and reducing unplanned downtime through predictive maintenance. 3) Various process automation and instrumentation solutions are presented for applications in industries like oil and gas, chemicals, and biofuels production.

1. ISA Saudi Section 2013
Optimization of Production Processes and Life Cycle Management
by Integration of Intelligent Process Instrumentation and
Analytic Technologies
© Siemens AG 2010. Alle Rechte vorbehalten.
Analytic Technologies

2. Industrial Automation Delhi November 2012
New Trends in Process Automation
Life Cycle Management
Asset Management
Condition Based ManagementCondition Based Management
Process / Energy Efficiency
Plant and Production OptimizationPlant and Production Optimization
Reduction of unscheduled Down Time by Preventive / Predictive
Maintenance ConceptsMaintenance Concepts

3. Life Cycle Management – Single Source for Services
A t ti I t t ti El t i l d PAutomation, Instrumentation, Electrical and Power
Introduction/ Situation Requirements Service Concept Benefits SummaryConcept in detail
Become a substantial
t f th t '
Introduction/ Situation Requirements Service Concept Benefits SummaryConcept in detail
part of the customer's
operations team for
entire scope of delivery
PLC
Automation &
OTN
Multi Vendor Services
Operation of the maintenance concept
Planning
Value Added Services
Remote assistance & diagnostics
Condition based
Product Related Services
Keeping specialists – readiness for
24/7 hotline support and
Telemetry
Scheduling
Performance Improving services
focused on Key Performance
Indicators
Reliability guarantees on demand
Condition based
monitoring
Modernization & Migrations
Shut Dows Services
Consultation for Energy Saving, Project
24/7 hotline support and
On-site fault elimination
Software & Hardware updates
Maintenance & uptime Services
Includes third party equipment
y g
Management and Maintenance ProcessIncludes third party equipment

4. Life Cycle Management Concept
f f O
C biliti f j t d l t I l t ti d ti
The whole Lifecycle of Plant Operation
S t T t
Capabilities for project development, Implementation and operation
Assembly/
Erection
System Test
Putting into operation
Delivery/Shipment
engineering
Project-
management
Delivery/Shipment
Documentation
Lifecycle Management
HW, SW Engineering
- Product Related and Value Added Services
- Operation Related Services (Frame Agreement)
Modernization / Migration Services
Studies / Planning
- Modernization / Migration Services
- Total Cost of Ownership / Plant Availability

5. Production Efficiency
Process Optimization with intelligent Analytics androcess Optimization with intelligent Analytics and
Instrumentation Solutions with advanced DiagnosticInstrumentation Solutions with advanced Diagnostic
functionalities in order to improve Plant / Energy Efficiencyfunctionalities in order to improve Plant / Energy Efficiency

6. From Condition based Monitoring to
C diti M tCondition Management
Condition based Monitoring / Management is a major process in order toCondition based Monitoring / Management is a major process in order to
optimize production processes concerning facility operation, efficiency ,
production quality, quantity and to achieve production repeatability particular
d i th i d tiduring the running production process.
A major step is to identify the actual requirements, demands and future trends in
various industries in all international regions part of this process is thevarious industries in all international regions, part of this process is the
development and establishment of the competence concerning detailed
segmentation of industries by total solutions, partial solutions as well as single
components applications and supportcomponents, applications and support.
In order to improve the achievement of business results, a reactive and
preventive maintenance process of production facilities has to be turned into ap p p
predictive concept .

7. S l ti C it i / R i t SSelection Criterias / Requirement Specs
Physical Measurements
Technology-Selectiongy
Industry-Segments Solutions
Application Database
Product-Selection Solutions

8. From Upstream to Downstream
F R fi i S i l Ch i lFrom Refineries to Special Chemicals
LNG
Oil&Gas
Pipeline
LNG
Offshore
Drilling
TankfarmCompression
Gas Storage
G
Onshore
Oil&Gas
Fields Refinery
Compression
Chemical Industry
Gas
Treatment
Injection
HPI
Petrochemicals
Basic
Chemicals
(e.g. Fertilizers)
HPI Air
Separation
Fibers/Foils
Specialty Chemicals
Bio
Fine Chemicals
(e.g. pharmaceutical pre-
products)
(e.g. Nylon)
Specialty Chemicals
(e.g. Oil additives)
Chemicals
(e.g. Bio-Ethanol)
products)

10. Process Optimization as part of Asset ManagementProcess Optimization as part of Asset Management

11. Advanced Automation for Emergency Shut down
Systems and Solutionstions in order to avoidSystems and Solutionstions in order to avoid
Blow Outs and Oil & Gas Leaks

12. Leak Detection and LocationLeak Detection and Location

13. Advanced Automation for Emergency Shut down
Systems and Solutions in order to avoid CatastrophiesSystems and Solutions in order to avoid Catastrophies
in Tank Terminals
Ethanol tank farm on fire in Australia Barton Solvents tank farm fire in Kansas, 2007
Chemical tank farm accident

14. Competence in Level Technologies and Solutions
Advanced Overspill ProtectionAdvanced Overspill Protection

15. Condition Based Management - Process Efficiency
Asset and Condition Management
Condition Monitoring and Process Optimization
using Process Automation and Analytic Technologiesusing Process Automation and Analytic Technologies
with intelligent Diagnostics and Condition Based Monitoring
Functionalitiesin in order to improve Plant Efficiency / Energy Efficiency

16. Major Market Trends in Process AutomationMajor Market Trends in Process Automation
Goal:
Asset
Goal:
Reduction of unscheduled
down-time, protection of
equipment improvements on P
Management
equipment, improvements on
safety and reduction of
maintenance.
Process
Analytical
PAT
Security
Wireless
Communication
M2M
Communication
Industrial
Ethernet
Intelligent
Field RFID
Wireless Machine
Field
Devices
RFID
Sensors Vision

17. P / E Effi iProcess / Energy Efficiency
The topic of energy efficiency has come to dominate the field of industryThe topic of energy efficiency has come to dominate the field of industry.
This is set to continue into the future as a result of political requirements
and concern about the environment and climate.
The opportunity to gain cost and competitive advantages through the more
efficient use of energy will also ensure that the topic does not lose itsefficient use of energy will also ensure that the topic does not lose its
importance.
Although efforts have been made in the area of energy efficiency in the
past, there is still significant room for improvement in the various
industrial sectors.

18. E Effi i
Studies show that from the energy source to the consumer up to 80 % of
Energy Efficiency
Studies show that, from the energy source to the consumer, up to 80 % of
the energy currently used in the various production, transmission and
conversion stages can be lost.
Source ZVEI

19. E Effi iEnergy Efficiency
Source ZVEI

20. Totally Integrated Automation:
S l I t ti f Fi ld t MESSeamless Integration from Field to MES
Automation Hierarchy
Products and SystemsMES
PAMSManagement level
Control level
Host computer
Monitoring & control
systemsMSOS
PAMS
systems
Programmable logic
controllers
MSOS
Field level
Sensors, actuators,
drives, field
instrumentsCMCM CM CM CM CM CM CM
CM CM
Detectors,
switches

21. Definition of Plant Asset ManagementDefinition of Plant Asset Management
Pl A MPlant Asset Management
Therapy /
Maintenance
Proposals and
support
Operation
Communication
Communication of
the below
Information
Provision
Operation
Prediction /
Prognosis
Forecast
and
Archiving
Maintenance
Diagnosis
Prognosis
Evaluation ->
Cause ->
Di i fi di
Evaluation
Analysis
Processing
Engineering
Condition
M it i
Signal ->
Characteristic ->
Diagnosis finding Distribution
Business admin.
Monitoring Analysis

22. Integrated Plant Asset Management –
M it i & O tiMonitoring & Operating
OS Clients with accessOS Clients with access
to maintenance area
(pictures, messages, faceplates)
Maintenance Station has
additionally direct online
C1 Cn
...
OS OS MSOS
MS
Maintenance Station
integrated into the
additionally direct online
access to PDM and
hardware engineering
...
AS1 AS2 ASn Sn
AS – Automation System
C – Client
S1
...
...
AS1 AS2 ASn
integrated into the
Operator Station
MS – Maintenance Station
OS – Operator Station
S – Server
Maintenance pictures
All diagnostic capable SIMATIC PCS 7 components + „non-intelligent“ assets
+
Common and unified symbols for representing the status of all assets
+
Good
Announcement of request
f i t (l )
Request for maintenance
k / t ti t d
Simulation
Function
Request for maintenance
(medium)
for maintenance (low)
Maintenance alert
(hi h)
unknown/not activated
Request for maintenance
activated
Request for maintenance
icontrol/ local (high) in process

23. Automation Interface
I t lli t S S t i t ith th A t ti S tIntelligent Sensor Systems communicate with the Automation System
f
IntelligentIntelligent
SensorsSensors
Flexibility
Start up
Parameter Set
Function Request
Information
Digital Value
Data Validation
Control Loop functionsFunction Request
Functions Upgrade
Software Download
Control Loop functions
Diagnosis Information
Asset Management
Information
Field device Integration wired or wireless is crucial

24. Automation Interface
Intelligent Sensor Systems communicate with the Automation System
DistributionPROFIBUS DP
PROFIBUS PA
Ethernet
PROFIBUS PA
Foundation Fieldbus
4…20mA with HART

26. Improvement on Production Efficiency
Condition Based Management and Energy Efficiency
From 1st to 2nd Generation – Bioethanol Production
YeastEnzymes Methylation
Petrolium spirit
Dehydration
Delivery Storage
Milling
Liquefaction
Saccharification
Fermentation Distillation Storage
Water
Yeast
Co2 Distillation
Enzymes
Fraction
ation
Methylation
Superheated
steam
Bioethanol
Destiller‘s wash
Cooling tower/cooling plant
Syrup
Concentration
Separation
Drying
DDGS
DGS
Bioethanol
Syrup
Storage / Loading

27. Production Process Optimization with advanced
P A t ti I t t ti d A l tiProcess Automation, Instrumentation and Analytics
YeastEnzymes Methylation
Petrolium spirit
Dehydration
Delivery Storage
Milling
Liquefaction
Saccharification
Fermentation Distillation Storage
Water Co2 Distillation
Fractionat
ion
Superheated steam
Bioethanol
Destiller‘s wash
Cooling tower/cooling plant
Separation
Drying
DDGS
Destiller s wash
Bioethanol
Syrup
Concentration
DDGS
DGS
Storage / Loading

28. T t ll I t t d A t ti
Operator Workstations
Totally Integrated Automation
Engineering
Workstation
Maintenance
Workstation
Redundant
Controller
Storage and Load Out InterfacesRedundant Fiber Optic PROFIBUS DP
Area 1 Area 2 Area 3
Distributed I/O Distributed I/O Distributed I/O
PROFIBUS PA Devices PROFIBUS PA DevicesPROFIBUS PA Devices
SMART MCC SMART MCC SMART MCC
Typical Application of a Digital Bus Network in an Ethanol Production Facility

29. Process Optimization with advanced
Diagnostic FunctionalitiesDiagnostic Functionalities
Evaluation of Frequencies / Frequency Shift / Phase Shift /
differiential Frequencies/ Frequency Attenuation

30. Flow Technologies
Fl V l D it C t ti d M fl tFlow, Volume,Density, Concentration and Massflowmeters
Open Channel,
non-filled pipes
Solids Flow/
Impact Flow
Belt Scales
Mass Dynamics
Flowmeter
t l
Venturi
US Flow
Magn. ind.
Flowmeters
Closed pipes
Impact Flow Mass Dynamics
rectangle-,
triangle weir
Volume-
meters
Volume-
flowmeters
applicable
Mass-
flowmeters
Non
Pipe
Ultrasonic
Flowmeters
Coriolis
omega /
bent tube
Vortex
flowmeterCoriolis
parallel
Rotary piston
meter
Intrusive
Oval wheel
meter
restricted
applicable
non applicable
Single
Beam
Multi
Beam
Single
Beam
Multi
Beam
Spool
Piece
Intrusive
(Clamp on)
Variable Area-
flowmeters
Effective Pressure
Technology
parallel
tubes
A li ti
Twist flow-
meter
Turbometer,
Positiv-
displacement
Coriolis
single
straight tube
Comparison
Beam BeamBeam Beam
Transit
Time
Transit
Time
Doppler
Magn. Ind.
flowmeters
Pulsed AC ACPulsed DC
Applications meter,
Woltman-
meter Thermal
Wide
Beam
Narrow Beam
(Shear Mode)
Transit
Time
Doppler
TransitTime
Narrow Beam
(Shear Mode) Beam (Shear Mode)(Shear Mode)

31. Technology Comparison, e.g. Detection of Flow,
V l D it C t ti MVolume, Density, Concentration, Mass

32. Magnetic Flowmeter Condition Monitoring
Metal Particles in MediaMetal Particles in Media
Metal particles in media

33. Reduction on waste of Natural Sources
Environmental Cleaning Costs > 1 Mio €
Leak Detection / Leak Location as part of Condition Based Monitoring
Condition Monitoring on Gas and
Liquids Flow Lines in
order to reduce the waste on natural
Environmental Cleaning Costs > 1 Mio €
order to reduce the waste on natural
resources and optimize Energy Efficiency
on Pumps, Compressors, Filters and
Shut Down Time for claening purposes

34. Differential Pressure Condition Monitoring
Fouling of Impulse Lineg p
Impulse
Line

35. L l M t T h l iLevel Measurement Technologies
Electronic Overfill
Mechanical
Electronic
Point LevelContinous
Interface
contact Protection
Mechanical
Non contact
Servo
Displacer
Oscillating
Vibrating
Capacitance
Servo
TDR
Optical
Capacitance
Servo
Displacer
Capacitance
Ultrasonic
Interface
Ultrasonic
Sense Disc
Float
Magneto-
strictive
TDR
Conductive
Laser
Nucleonic
Static
weighing
Capacitance
Conductive
Nucleonic
Capacitance
TDR
Static
Weighingstrictive weighing
Hydrostatic
Optical
Laser
Radar
S b ibl
Hydrostatic
Weighing
Hydrostatic
Delta P P lChi
Radar
Ultrasonic
Radar
TDR
FMCW
CW
Reflectometer
Low / High
F
Absolute
Bubble
System
Submersible
P K b d
Delta P PulsChirp
TDRCW
FrequencyPressure Keyboard

36. L l M t T h l iLevel Measurement Technologies
Sitrans LG Sitrans LU Sitrans LR Sitrans LR Sitrans LR Sitrans LCSitrans LG
Guided Wave
Radar / TDR
Sitrans LU
Ultrasonic
Sitrans LR
2 wire
Pulse Radar
Sitrans LR
4 wire
Pulse Radar
Sitrans LR
4 wire
FMCW Radar
Sitrans LC
Capacitance
LEVEL
I t f
Technology ApplicationLEVEL
TECHNOLOGIES
Interface
Technology
Description
Application
Simulation

37. Simulation of Process Conditions / ApplicationsSimulation of Process Conditions / Applications
Pulse 6 GHz Radar
Sitrans LR 200/300
Pressure
Sitrans P
FMCW/Pulse 24 GHz Radar
Sitrans LR 400/460/250
Capacitance
Sitrans LC500
Ultrasonic
Sitrans LU
Guided Wave Radar
Sitrans LG200

38. Process Optimization in Petrochemical Production Processes

39. Customized Solution in Synthol Production Processes
Optimization of Separation Process with advanced
GAS WATER & OIL SEPARATOR
p p
Interface Detection
GAS, WATER, & OIL SEPARATOR
Process Details and
Requirements
DE-MISTER PADS
HEAT EXCHANGERS1. Measurement section
determines transmitter
oscillator frequency
Gas intake
GAS
oscillator frequency.
2. Driver circuit applies same
frequency to active shield.
3 Electrical potential between
DP TX for Oil Level
OILWATER /
INTERFACE
MEASUREMENT OIL
INTERFACE
OIL OUTLETOIL
3. Electrical potential between
shield and measurement
section is zero.
Result:
WATER
WATER OUTLET
Ignores dust, vapor, and
material deposits on the
active shield portion of the
electrodeelectrode.

40. Capacitance vs. TDR Interface MeasurementCapacitance vs. TDR Interface Measurement
Sitrans LC 500 Sitrans LG200Sitrans LC 500
Capacitance
Sitrans LG200
TDR
Max Span: 20 mA – 59 pF
100 % Water
Min Span: 4 mA – 6 pF
Referenz: 12 mA – 44 pF
50 % Water /
50 % Test Benzine
Min Span: 4 mA – 6 pF
100 % Test Benzine

41. Process Optimization in Chemical Production Processes
ZUARI

42. Safety Requirements (Burst Conditions)
Operation on Styrene / Styrol ProcessesOperation on Styrene / Styrol Processes
Design related to Burst Safety Requirements 300 deg C at 40 bars

43. Maintenance optimization with advanced Instrumentation
Technologies Safety Check during Operation of the ReactorTechnologies Safety Check during Operation of the Reactor
without Shut Down of Production
10dB
D t
Level Radar
Dust
Vapour
Steam
ConstructionConstruction
Obstacles
Tubings
Interference
Foam
Turbulent
Product surface
Votex
30dB
Agitator
Heating Coils
Reduction of unscheduled Down Time

44. Process Optimization in the Chemical Production Processes
C t i d S l ti i th F tili I d t S tCustomized Solutions in the Fertilizer Industry Segment
The fertilizer plant produces both
simple (classic) and composed
fertilizers. The process which is at
concern here goes about the basic
fertilizers and comprises several
reactors in line, where mainly acids
t li d ith iare neutralized with ammonia,
which is a known basic component
for fertilizers.

45. Monitoring of Deposit and Corrosion on Sensor Probe and
Reactor in order to increase Production Efficiency and reductioneacto o de to c ease oduct o c e cy a d educt o
on Maintenance Costs purging and coating of sensor probes
highly adhesive endhighly adhesive end
product
hardens out very fast
consistency of cementconsistency of cement
existing solution
inaccurate
Coated Sensor
Probes
In the reactors this process causes aIn the reactors, this process causes a
very erosive, abrasive and corrosive
liquid which ends up as a solid final
product This hardens out very fast and isproduct. This hardens out very fast and is
then granulated.
Reduction of unscheduled Down Time

46. Monitoring of Deposit on Sensor Probe and Reactor Condition
in order to increase Production Efficiency and reduction on
Application:
Process requirements: Encrustation inside the
in order to increase Production Efficiency and reduction on
Maintenance Costs by controlled cleaning in place
Process requirements:
Measuring safe and
maintenance free level- and
volume detection Use of a
integrated purge kit
Raw materials
antenna
integrated purge kit
Technologies:
Process Radar
Solution:
20mA
Flushing in/out
20dB
Solution:
Condition Management
By the comparison of the
internal antenna reflection
th i t t d fl hi
Encrustation
the integrated flushing
system is activated and
deactivated.
The additional status and
diagnosis information
4mA
diagnosis information
avoids production
interruption
Titan dioxide production
Very dirty and sticky
30dB
Production
Operation
Very dirty and sticky
dioxide process reactor
Reduction of unscheduled Down Time

47. Foam Layer Monitoring in order to avoid overspill of Foam,
increase of Production Efficiency and reduction onincrease of Production Efficiency and reduction on
Maintenance Costs
Application:pp
Resin production
Foam during vacuum phase
Process requirements:
Vacuum
Vacuum outlet
Condensation filter
Condition Monitoring
Level control and reduction of
foam layer
Avoidance of pipe and filter
20mA
Avoidance of pipe and filter
blockages
Technologies:
Process Radar Instrumentation
Resin
10cm
Foam
Solution:Condition Management
Foam layer control by evaluation
of attenuation of the microwave 4mA
Resin
products
radiation while penetrating through
the foam
Start and stop of vacuum phase
t ll d b fid h B ili ti l t d
Production
Operation
40dB
controlled by confidence echo Boiling process stimulated
by vacuum
Reduction of unscheduled Down Time

48. Pressure Technologies
Piezo resistive Capacitance Inductive
Resonance
B bbl t
DiaphragmRemote seal Dry / ceramic cells VibrationCeramic cell
Absolute
pressure
Submersible
Bubble system
air/nitrogen
Injection
Differential
pressure
Gauge
pressure
S b iblAb l t Bubble-LEVEL
Differential
SubmersibleAbsolute Bubble-
system
Air/ nitrogen
Injection
LEVEL
e e t a
pressure
Differential
with PLC
FLOW Orifice
Hydrostatic
incl. density
CLOSE
Screen
condition
FLOW Orifice
Gold-plated
diaphragm
Calibration
CLOSE detection
Venturi
p g
P300Steam Shock

49. Pressure Measurement
d l f lCondition Monitoring - Fouling of Remote Seal
Condition ManagementCondition Management
Remote Seal Purge Kit

50. Advanced Diagnostics on Positioner Technologies
Actuaters Electric Pneumatic Hydraulic
RotaryLinearValves
Perforated Plug Valves
Linear Plug Valves Ball Valves
Flame proof
PS3 Enclosures
Eccentric Plug Valves
Bray Butterfly Valve
Sliding Gate Valves Turn Plug Valves
Gate Valves
Stainless Steel
Plastic Damper Drive
Positioners Pneumatic
Electro
Pneumatic
Electro
Pneumatic
Digital
Intelligent
Single Acting
Intelligent
Double Acting
CLOSE
Double Acting
Configuration
SimulationExploded view
Diagnostics
3D PDF

51. Kompetenz in Lösungen mit Stellungsreglern
Asset Management / TCO / Condition ManagementAsset Management / TCO / Condition Management
Optimization on Configurations of Valves and Positioners

52. Competence in Valve Positioner Technologies
Asset Management / TCO / Condition Management
Shaft
Stopfbuchse
Spindel
g g
Valve and Positioner Configuration Optimization
Stopfbuchse
Ventilsitz
Valve

53. Condition Monitoring and Managementon Valves and
Flow Lines in order to optimize Plant Operation and SafetyFlow Lines in order to optimize Plant Operation and Safety
Partial Stroke Test, Leak Detection, Valve Wear and Deposit

54. Energie Savings with advanced Condition Based
Monitoring 500 000€/a Energy Savings on Motors Drives
Condition Monitoring on Valves and Pumps Wirtschaftlichkeitsvergleich
Monitoring 500.000€/a Energy Savings on Motors, Drives,
Pumps of 137.000€/a
Condition Monitoring on Valves and Pumps
Optimization of Energy Efficiency, Production
Efficiency and Operation Costs with intelligent
Prozess Sensors and Analytical Technologies
andsetzung)
g
einer Schlauch-Membran-Kolbenpumpe
mit und ohne Online-Ventildiagnosesystem
300.000 €
400.000 €
500.000 €
andsetzung)
300.000 €
400.000 €
500.000 €
Kosten(InvestitionundInsta
0 5 10 15 20 25 30
0 €
100.000 €
200.000 €
Jahre
Kosten(InvestitionundInsta
0 5 10 15 20 25 30
0 €
100.000 €
200.000 €
Jahre

55. Process Optimization with advanced Process Analytic Technologies
Solutions and Applications
Oxygen
UV Single or few components
Stack Emissions Monitoring
Continuous Gas Analyzers
yg
FID
Hydrogen
Combustion Control
Incinerator Measurement
StandardGas Chromotagraphy
y g
Infrared
Multi Component
H2O/Trace H2O
Standard
Miniature
Gas Chromotagraphy
Laser Spectrometry
Multi Component
Complex Gas Streams
Single or few components
Spectrometry
Laser Spectrometry
Mass Spectrometry
AOTF
Single or few components
Stack Emissions Monitoring
Combustion ControlAOTF
FTIR/FTNIR
Combustion Control
Incinerator Measurement
H2O/T H2O
E-box
SibenchExhaust Gas Analysers
H2O/Trace H2O

56. Recovery of Hydrocarbons with an Energy
E i l f 7 i Lit f C d OilEquivalence of 7 mio Liter of Crude Oil per year

57. The Cooperation as part of Customer Relationship
C t d i f diff t j t h b id tifi dCost drivers for different project phases can be identified
CAPEX OPEXPre CAPEX Modernisation/ Decommissioning
Advanced automation and instrumentation technology knowhow made
it possible to find flexible solutions for various harsch applications,p pp
based on the creativity of the customers and supplier.
Optimization on configurations and application knowledge opens
doors in industry segments for reliable and cost saving solutions.doors in industry segments for reliable and cost saving solutions.
The cooperation between industries and suppliers very close, the
support and testing are done within a framework of consequent
partnershippartnership.

58. Safety Requirements
Regional Requirementsg q
Approvals, Certificates, Declarations, Typ Testing

59. Chemical Companies
A id t & C t t hAccidents & Catastrophes
Algeria 2007: The explosion in the industrial town of Blida killed 5 people
and wounded 10 others

60. Chemical Companies
A id t & C t t hAccidents & Catastrophes
Texas, 2005

61. Condition based Monitoring / Management
Health & SafetyHealth & Safety
The goal and target is competent support starting with the planning process ofThe goal and target is competent support starting with the planning process of
production facilities until the commissioning and start up as well as support and
consultancy over the whole facility life cycle in order to reduce follow up costs as
part of Total Costs of Ownership and Down Time and avoid additional unexpected
modifications to optimize production volume and quality.
The key tasks for the increase of efficiency during the implementation of condition
management are:
Reduction of unexpected down timeReduction of unexpected down time
Production quality
Production quantity
Production effectivity and repeatabilityy p y
Protection equipment and components
Increase of safety
Reduction of non useful preventive maintenance
Up to 50% of preventive maintenance investments are not necessary, these
expenses can increase up to 20% of the total maintenance costs.
This conclusion is a clear statement and fact to change from preventive to predictive
i imaintenance strategies.