asset reliability through integrated asset management

Specialists.

Engineering Innovation.

Asset Reliability Thru’

Integrated Asset Management

Presented by

Murali ChandrahasanHead-Engineering IT Soutions&Services

Date 3rd May,2016

June 8, 2016 | 2 Confidential | L&T Technology Services

Aligning Operations, Assets & People - Enhance Asset Reliability

Industry Challenges on Asset Reliability

The global process industry loses $20 billion, or 5% of annual production, due to unscheduled downtime, with an average hourly cost of about $12,500” - ARC advisory group

Information Management

Single Source of Information

Management of Change (MoC)

Large Asset Data Management

Data Handover

Extensive System diversity

Operational

Improve Asset availability and Reliability

Reduce Asset Downtime

Optimise Inventory

Increased Complexity of Assets

Compliance

Meet regulatory requirements

Improve HSE Performance

Stringent Safety regulations and Warranty checks

Finance

Reduce CAPEX

(Capital Expenditure)

Optimize OPEX (Operating Expenditure)

Improve ROA and Access to capital


Business &

Technology

Drivers for

Asset Integrity

Management

Compliance & Regulations• Standards: ISO55000, ISO 18001, ISO 15926 , 14224, IEC 61508,

• Higher Health, Safety and Environmental awareness

• Compliance with the Statutory / legal Regulation

Asset Lifecycle Information Management• Aging Assets

• Asset information – Completeness, Correctness & Consistency (3Cs)• Automation of Knowledge Work

Operations & Maintenance• Asset Longevity and Reliability

• Visibility and Cost control

• Quality and Safety Compliance (PTW / LOTO integrated - ERP)

Technology Trends

• Software as a Service (SaaS) , Cloud, Mobility

• Industrial IoT

• IT/OT Integration

•Asset Data Analytics


Business Transformation with Asset Information Management

EDMS

EDW

CMMS

CIMS

RBI/RCM

ERP

Standalone Systems

Equipment Performance

Operational Performance

History

Non-Integrated

Asset Performance Management(EAM, FSM)

Asset Integrity

Management

Engineering Information

Management(Design Tools, EDMS, EDW)

Reliability & Maintenance Management(CMMS, ERP,

RBI/RCM)

CorrosionInspection

Management(CIMS, PACER)

Inspection Management

(VISIONS, IPRSM)

Operational Applications(PLC/RTU,

SCADA, Historian)

Integrated


Integrated Asset Information Management Model

Design Tools

EDMS

EDW

Document Control

Engineering Information

Management

Policy, Standards & Guidelines

Records Management

HR

HSE

Content Applications

Collaboration Workspace

EPC Information Management

Risk Assessment

Maintenance & Material Management

Reliability & Corrosion Inspection

Remote Monitoring and Tracking

Enterprise Asset Management

Asset Operation Applications

Handover & Integration


Improving Asset Integrity and ReliabilityClient Concern Value Delivered

IM Processes &

Governance

Information Quality

Standards

Ensuring asset information

correctness, completeness

and consistency (3Cs)

Availability of Integrated ,

updated and reliable Asset

Information

Benefit to Business

Single source of

information and faster

access of Asset data and

document

Easy & Quick search of

reliable information leads

to faster & effective

maintenance planning and

scheduling

Latest information

availability results in more

accurate decisions

Non availability of

strategy for

managing

Information

Delay in

information retrieval

Poor information

control,

reliability,

integrity,

completeness

Existing

information dump

accuracy &

governance


Unstructured Documents

Existing Information dump

PresentFuture

Missing Information/Tags

Quick Search for Engineers

Handy Commissioning Data

Efficient Handover

Integrated Approach: Project Phase


Document Non-Integrated

Duplicate

Documents

Hidden Documents

Missing Information/Tags

Retired/Superseded

Documents

Non As built

Documents

Identified & Separated

As Built Documents

Document Integrated

Unique Documents

Complete

Information/Tags

Extracted Documents

Maintainable Asset Information

Fixed Equipment Information

Asset RegisterDesign Information

Relief System Information

Ach

ieve

d 3

C –

Co

rrec

tnes

s,

Co

mp

lete

nes

s, C

on

sist

ency

Suggested Approach

Integrated Approach: Operate and Maintain Phase

Desired StateCurrent State


NextGen Asset Performance Management with Industrial IoT

Connected assets with integrated information flow support forecast analysis,

automated alerts and accelerated actions.

Application/

Rule Engine

IoT

Foundation/

Adapter

Ass

et

Senso

rs

Smart Asset Management

Predictive Maintenance

Smart Asset

Industry, Cloud, Device

Agnostic Platform


Augmented Reality in O&G

Valve status Information: Current Condition Last serviced Internal tools info Understand the internal structures

Image CaptureImage Compare

3D Model Rendering

Image

Detail Information


PPE Monitoring System

During loading of finished goods in warehouse the personnel will have to work at a height of 5-6m. Most often, these personnel fail to use the necessary PPE which might result in a possible accident

Problem Statement

Identification of the possible equipment to be monitored for the industry

Identification of the type of sensors to be integrated.

Integration of sensors with PPE and data collection

Notifications, alarms as needed if any deviation on safety

Solution

Detect Non – Usage of necessary PPE by personnel during loading/unloading of trucks and alert the concerned stakeholders

Proper monitoring of PPE ensures the safety & security of crew and makes workstation PPE compliant

Business Benefits


Future Operations with Resilient Asset Management

IT-OT Integration

Social Media Integration Field Service Team

Actionable Decisions/Situational Awareness

Exception-based

Business process model/process/asset

Informed Business Decisions

Twitter Integration

On-line Weather

Twitter Alarm/Events Notifications

Enabled Field Force Service Team

Capture planned, emergent work;

Plan, Execute across Team

Tune work processes

Mobile Alarm/Event Notifications

Real-time Business Process Orchestration

Asset Meta Model

Asset Data Synchronization across IT-OT apps

Real Time Enriched Analytic Dashboards

Resilient

Asset Info Management

IT-OT Integration

Process Orchestration

Asset

Management

Social Collaboration Intelligent Control Center

Operational Analytics IT-OT Integration


LTTS Integrated Asset Management (IAM) Services and Solutions

Material & Inventory optimization

• BOM preparation

• MRO inventory optimization

• Material Coding & Cataloguing

Asset Data Management

• Engineering Data Management

• Asset Data build

• Engineering Dara handover

Operation and Maintenance

• Enterprise Asset Management

• Field Service Management

• Asset Mobility Solutions

Predictive Asset Management

• IT-OT integration

• Predictive Asset Analytics

• Mobility with Augmented Reality

Asset Performance Management

• Reliability Centered Maintenance

• Asset Integrity Management

• Root Cause Analysis

Integrated

Asset

Management

Remote Asset Monitoring Services

• RFID, QRC & GIS asset tagging

• GIS based Asset Management

• KPI and Data Analytics

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