Engineering in Food & Beverage - EngineersOnline.nl de Vries - Endress+Hauser.pdf · System DCS, PLC/SCADA Data : Real time ... maintenance •Migration plan •MPE Value ... Engineering

03/14/2017

Products Solutions Services

Endress+Hauser Engineering in Food & Beverage

Slide 1 / 28 Ronald de Vries

03/14/2017

Engineering in Food & Beverage

Agenda

• Introduction, Endress+Hauser at a Glance

• Fit for Purpose instruments

• Follow the signal

• Asset Management

• Why and how ?

• Energy management

• Follow the signal

• Example UHT


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• Holding company in Reinach, Switzerland

• 19 production facilities in 11 countries

• Sales centers and representatives in more than 100 countries

• Regional sales support centers


Our structure


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Endress+Hauser at a glance 2014

Our “world”

We provide sensors, instruments, components

and systems for tasks in the field of

• Level measurement

• Flow measurement

• Pressure measurement

• Temperature measurement

• Analytics and sampling

• Data management

• Device communication and integration

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Instrumentation & (Level |Flow | Pressure | Temperature | Analysis)

Infrastructure

Asset information (AIM)

Device information (DIM)

Calibration CM

Energy monitoring/

management

Inventory (IMS)

Tank Terminal

Management (TTM)

Analyse

ERP

En

gin

eeri

ng

| S

ervic

es |C

on

sult

ancy

Maintenance management

BPI (Business Process Integration) | Middelware |ERP Integration |

Field of activity key focus


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Follow the Signal

CMMS : Computerized Maintenance Management

System

CMS : Calibration Management System

DCS : Distributed Control System

EMS : Energy Monitoring System

ERP : Enterprise Resource Planning

MES : Manufacturing Execution System

PAM : Plant Asset Management

PLC : Programmable Logic Controller

SCADA : Supervisory Control And Data

Acquisition

SiS : Safety Instrumented System

User : Process Manager System : MES, EMS (Energy) Data : Not real time (hour/day) Signal : 4-20mA, Fieldbus (digital)

Driver : Efficiency

Energy Management aM&T

User : Quality Assurance/Metrology System : CMS (Calibration) Data : Not real time (week/month) Signal : 4-20mA, Fieldbus (digital)

Driver : Quality

Quality Management

Diagn

ostics

Valu

e /

Asset

infor

matio

n

User : Engineering / Maintenance Systems : PAM, CMMS (Asset) Data : Not real time (hour) Signal : Status (digital)

Driver : Reliability, Availability

Asset and Life Cycle Mngt.

User : Logistics System : ERP (Material Management) Data : Not real time (hour/day) Signal : 4-20mA, Fieldbus (digital)

Driver : Delivery, Flexibility

Inventory Management TankVision

User : Safety System : SiS (Safety) Data : Real time (second) Signal : 4-20mA, Fieldbus (SiS, PROFIsafe)

Driver : Safety, Reliability

Safety Management

User : Operator System : DCS, PLC/SCADA Data : Real time (second) Signal : 4-20mA, Fieldbus (digital)

Driver : Process, Accuracy

Process Management


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Triangle approach

Platform

Installation Instruments

Demand



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Shorten time to production, Ensure & improve asset performance during operation

Maintenance management

Documentation management

Spare part management

Calibration management

Inspection and monitoring of assets

Performance Monitoring, Maintenance Analysis

Maintenance/Calibration Planning & Scheduling

Device Configuration Management

Asset Information Management


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Enable Continuous Improvement

Vision, Mission and Strategy

What is necessary to achieve to support the Vision, Mission and Business Strategy

Install Base Audit

• Criticality of Tags

• Current Level of maintenance

• Migration plan

• MPE Value

Existing Systems

SOP & WI

• Clear assignments

• Checklists

• Inspection

• Calibrations

• Business processes

Adequate Administration

• Right Level of detail, tagnumber level

• Timeliness

• Planning

• Within Specification Out of specification

• Certification

• Time consumption

• Breakdown

Analyses of Data

• Breakdown Overview

• Calibration Data

Focused Maintenance

• Effective result

• Efficient execution

VISION, MISSION &

STRAGTEGY

As Is Audit CONCEPT

DEVELOPMENT IMPLEMENTATIO

N EXECUTION IMPROVEMENT

Continuous

Improvements

Consistent Data

Standardization

of Activities

AS IS Audit High level

Objectives

Objective: Optimum

Availability


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Solutions packages and services mix

Your business process philosophy defines the mix

Outsourcing Maintenance Management

Insource Maintenance Management

Maintenance Management

Maintenance Management

Solution Packages

……………………………….

Your Business Process

Your Business Process philosophy

The mix is determined via Consulting

………………

……………… E+H offering mix is based on your strategy mix/operating point

Maintenance Management Services ……………………………….

Solution Packages for Maintenance Management

Service Agreements for Maintenance Management


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Slide 11

Information assurance

W@M Enterprise

CER

Serial# Flow

Pressure

Level

Temperature

Dynamic hyperlink / Web Services

Endress+Hauser Product center • Serial number • Order code • Manuals • Certificates • Purchase info Events: • Production info • Calibration info • Repair info Analysis

Endress+Hauser Sales center • Maintenance reports • Calibration reports • Service reports • Repair reports • Inspection reports within maintenance or calibration contracts


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Self-Monitoring and diagnosis of field devices

4. Failure (F = failure)

2. Check function (C = check)

3. Off-spec (S)

1. Maintenance required (M = maintenance)

OK Device is operating normally



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Example: Temperature diagnostic functions

• Sensor drift detection If the measured values of the two sensors deviate by a preset value, a warning signal is given to the PLC.

• Ambient temperature monitoring The temperature of the electronics is controlled constantly.

• Monitoring of the sensor limits The physical measuring range of the connected sensor was exceeded/under-cut.

• Open circuit or short-circuit Failure of the sensor cables is recognized on RTD's and TC's. Short-circuit detection on RTD's.

• Sensor backup In case of a sensor failure the trans-mitter automatically switches to the second sensor and sends a warning signal to the PLC.

• Cable-corrosion-detection Corrosion control on the sensor cables of an RTD 4-wire or TC sensor.

• Simulation active



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Reference Topology


DWG NO REV

0

SCALE 1:1 SHEET 1 OF 1

0

REV. DESCRIPTION DATE BY

PAM | LCM 22-7-2013 KBL

CUSTOMER

FSCM NOSIZE

A4

PROJECT

Cargill Krakatau

PAM | LCM

Plant Asset Management | Life Cycle Management

ET-200iSP/M:RIO PROFIBUS DP/HARTHART-PASSTHROUGH

Profibus DP

Profinet

FlowLevel Pressure Temperature

Control Workstation | HMI

Maintenance Workstation |

Device configuration & Asset Information

Fieldcare central Device configuration &

Device Performance Monitoring (Namur 107 compliant)

W@M Enterprise (Asset information)

DP

PA

Profibus PA

Intelligent Ethernet/PROFIBUS gateway

Ethernet TCP/IP

W@M Portal (CER)

Internet replication

*Note: Before Device Performance

Monitoring (DPM | Namur 107) can be

implemented it’s important to check if the

PLC hardware is compatible.

* see note below


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Business Process Integration

Calibration Management

CompuCal

Mobile

Service results from:

- Customer (CMMS)

- E+H (CompuCal)

Manual

Field Calibration

Beamex

MC5 Automated

Field Calibration

Integration

Middleware

Calibration executed

& Managed

Any

System

Integration

Middleware

Middleware

SAP-PM

CompuCal

W@M Portal/Enterprise

Instrument specific

Central Asset information

Asset update

for audit trail

KPI update

In dashboard

Update

Work order

data

Calibration

Work order


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How is the plant condition and how is it supported when it needs attention?


OSI

Pi

Service results from:

- Customer (CMMS)

Data Historian

Beamex

MC5

Automated

Field Calibration

Inspection executed

& Managed

Device Performance

Monitoring

OPC UA Middleware

SAP-PM

E+H SMP

via Netviewer

W@M Portal/Enterprise

Instrument specific

Central Asset information

Send notification

to Service supplier

Store data

in historian Update status

in Asset Logbook

Workflow


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Project Approach projects: Overview and process


Folie 17

• On site analysis of the installed base.

• Final report and presentation.

• User Requirement specifications

• Functional Design Specifications

•Detailed and modular offer based on the PAM concept.

• Project plan.

• Components delivery and installation.

• Installation of software.

•Inclusion of existing instrument data.

• Commissioning.

• Project management.

• Training.

• Service.

• Analysis and interpretation of the collected data and identification of areas for potential savings

• CMMS

• W@M

(life cycle management)

• Suggestions how to do maintenance on demand to improve efficiency.

• Device performance Monitoring

• KPI

• Develop and implement continuous improvements and thereby increase efficiency

• Scope and budget definition

Inventarisation Concept Implementation Project Evaluation Data Analysis Optimization Continuous

improvement

1 day 1 day 1-2 weeks 1-2 months years

OPEX Savings CAPEX Savings


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Energy Management


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Follow the Signal

CMMS : Computerized Maintenance Management

System

CMS : Calibration Management System

DCS : Distributed Control System

EMS : Energy Monitoring System

ERP : Enterprise Resource Planning

MES : Manufacturing Execution System

PAM : Plant Asset Management

PLC : Programmable Logic Controller

SCADA : Supervisory Control And Data

Acquisition

SiS : Safety Instrumented System

User : Process Manager System : MES, EMS (Energy) Data : Not real time (hour/day) Signal : 4-20mA, Fieldbus (digital)

Driver : Efficiency

Energy Management aM&T

User : Quality Assurance/Metrology System : CMS (Calibration) Data : Not real time (week/month) Signal : 4-20mA, Fieldbus (digital)

Driver : Quality

Quality Management

Diagn

ostics

Valu

e /

Asset

infor

matio

n

User : Engineering / Maintenance Systems : PAM, CMMS (Asset) Data : Not real time (hour) Signal : Status (digital)

Driver : Reliability, Availability

Asset and Life Cycle Mngt.

User : Logistics System : ERP (Material Management) Data : Not real time (hour/day) Signal : 4-20mA, Fieldbus (digital)

Driver : Delivery, Flexibility

Inventory Management TankVision

User : Safety System : SiS (Safety) Data : Real time (second) Signal : 4-20mA, Fieldbus (SiS, PROFIsafe)

Driver : Safety, Reliability

Safety Management

User : Operator System : DCS, PLC/SCADA Data : Real time (second) Signal : 4-20mA, Fieldbus (digital)

Driver : Process, Accuracy

Process Management


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Triangle approach

Platform

Installation Instruments

Demand



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Motivation for Energy Management

• Reducing energy costs (Save money, KPI)

• Legal and political possibilities (e.g. tax exemptions ,

subsidies eq SDE+, EIA & MIA)

• Improve company image / Marketing / Public relations

• Sustainability management – Strategy for Energy and

Environment

• Management system certification (EMAS, DIN EN 16001,

ISO 50001, DIN ISO 14001)

• Competitive advantages (Cost price)

• Produce and sell „Green“ products and services

• Improvement/ optimization of production processes

Sustainabilit

y

• responsible

• independent

• awareness of values

• eco-friendly

Reasons why energy Management is a current topic in companies


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Energy Trends


Energy Solutions

Sustainability

50% of end-consumers require

sustainable products

Product Carbon

Footprint Will be very

important for

each and every

product

DIN ISO 50001 International standard

for energy

management

Cost Savings To gain advantages

against competitors

and be more efficient

Green Image Create sustainable company

image by advertising of

companies green activities

Big Data

Data Integration

Large amounts of data that

will be analyzed and used

for forecasting and

identifying improvements 01

00

101

Rising Energy

Prices Flexible integration of energy

relevant data into other systems


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Potential Savings

Research has shown that realistic savings

of 5%-15% are achievable


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Topology of an full scale EMS


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UHT-Temperature curves of product and sensor


T [°C]

Dropping below

minimum

temperature micro-

biological risks!

Exceedance of

maximum

temperature

loss of quality,

waste of energy!

Product temperature

Temperature signal

competitor insert with

standard technology

Product temperature

Temperature signal

Improvement of

control accuracy!

higher safety

lower costs

Slow control loop: Fast control loop:

t [s]

Standard

control

limits

QuickSens

control

limits


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UHT - Temperature curves of product and sensor


T [°C] Shorter response time of insert leads to:

• Faster control loop, narrower control band

• Higher measurement and control accuracy

• Higher food safety, optimum quality, energy/cost savings

Product temperature

Temperature signal

competitor insert with

standard technology

Product temperature

Temperature signal

Slow control loop: Fast control loop:

t [s]

Lower

average

temperature

Average product

temperature

standard sensor

Average product

temperature

standard sensor


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UHT - Example calculation for possible cost savings

• 1 UHT treatment module

• Runtime: 5,000 hours per year

• Higher control accuracy by usage of fast response time technology

• Example: decrease of average product temperature by 2 °C through narrower

control bandwidth and faster temperature detection.

2 °C lower average temperature means 30 kg less steam per hour!

Average costs for 1 kg steam = 0.08 €


30 kg/h x 5,000 h/year x 0.08 €/kg steam =

= 12.000,- €/year

Benefits:

Cost savings of 12.000,- €/year and

at the same time higher food safety!


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Any questions?


Documents

Engineering in Food & Beverage - EngineersOnline.nl de Vries - Endress+Hauser.pdf · System DCS, PLC/SCADA Data : Real time ... maintenance •Migration plan •MPE Value ... Engineering