intelatrac 2017 sp1 · water outfall inspection tank in service inspection neshap above ground...

The Schneider Electric industrial software business and AVEVA have merged to trade as AVEVA Group plc, a UK listed company.

The Schneider Electric and Life Is On trademarks are owned by Schneider Electric and are being licensed to AVEVA by Schneider Electric.

IntelaTrac 2017 SP1Presented by Jack Craighton, AVEVA

Industry-leading mobile workforce and decision support system

The “IntelaTrac” Solution

Confidential Property of AVEVA Group plc. |

Evolve Practices To Improve Performance

Solutions for maximum return on industrial assets

Operations

Lifecycle

Asset

Lifecycle

Industrial Software Platform

Mobile Rounds


Alarms andEvents

Startup/Shutdown Procedures

Compliance

Field Worker Training Process

Data

Production Variability

Field Worker

Rounds

Logbook

Lock Out / Tag Out

Maintenance WOE


Integrated Workflow with IntelaTrac

Continuous

Improvement /

Best Practice

Evolution

Work Process

OptimizationContextualized

understanding

& Situational

Awareness

Capture, Historize, and

View stranded asset

data

• Eliminate wasted work

• Improve info usefulness

• Intelligent work processes

• Rapid Decision Making

WISDOMKNOWLEDGEINFORMATIONDATA

Capabilities


IntelaTrac Capabilities

•Operator Rounds

•Maintenance Activities

•Equipment Inspections

•HSSE Rounds

•LOTO

•Learning – mobile on-the-job learning

•Projects & Turnarounds – status tracking & procedure enforcement

•Quality Assurance – Manual collected quality data sampling

Wider the range of uses, larger the potential return


IntelaTrac Product Suite

Procedure Builder– advanced procedure configuration

Auditor Plus– work process and procedure review

Mobile / Workstation IntelaTrac– procedure execution

SSRS Reports – configurable reports, emailing

Schedule Manager– advanced scheduling & workload balancing


Procedure Builder Drag & Drop Configuration

• Procedure Items -basic

building blocks

• Integrations to External

Systems

• Peripheral Integration

• Conditions define follow-up

Actions

• Single and Multiple Actions

• Decisions for Advanced

Workflow


IntegrationsIntegrations allows for data to be pushed/pulled to 3rd party

systems. Additionally, new integrations can be added to

IntelaTrac to accomplish custom functions or communicate

to 3rd party software that is not currently supported. Some

examples of Integrations are:

Custom

•Auto Schedule

•Tietonator EC

•GE Energy’s System 1

•IntelaTrac Tag

•Production Data

•Calibration

•LIMS

Supported Historians

•OSI PI

•Honeywell PHD

•AspenTech IP21

•Wonderware Historian

•Wonderware Galaxy

Supported EAM/CMMS

•SAP

•Maximo

•Avantis


IntelaTrac SDK

•Configuration

•Scheduling/Execution

•Storage

Database

Server

Synchronization

Server

Examples of Third Party Systems

SDK

Mobile Solution

Web Server

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http://junotsystems.com/

http://www.j5int.com/

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Schedule Manager

Calendar view of scheduled proceduresLook Ahead (Current or Future Scheduled)

Look Behind (Completed, Overdue or Missed)

Drag & Drop Scheduling


Mobile – Log On Screen

Field User is presented with the IntelaTrac Log On Screen

• User Selects ID from Drop Down List.

• List of Users is populated through a synchronized

service to Active Directory or Manually created.

• User will then select a Base and a Role or Roles

• User can only select Bases and Roles that they have

permissions to Access.

• User will then Enter Password.

• Password either comes from Active Directory or is

maintained within the IntelaTrac Admin module.

• User then presses Log On Button.


Mobile – Rounds & Procedures

Field User is presented with a

list of Tasks

• Using Defined Pick Lists

• Device / Virtual Keyboard


Mobile – Free Text Notes & Logbook

• Free Text notes may be

added at any time

• Or…triggered by an Action

• Enter free text or select a

default note

• Default Notes can be

edited

• Note is also available as a

Log Entry

History

• Now available

at the Task

View.

• Includes Notes

• History Details

• Historical

Trends

• Pan & Zoom

Mobile History


Analyze – Realtime in the Field

Ability to set multiple hard limits, evaluate rates of

change, and predict the potential of a future

alarm.


Enhanced Situational Awareness

Dynamic limits can be configured.

Variables can come from Operator

input or from 3rd party external

systems.



Message Text can be calculated or can be

delivered from an external system at run time.

Conditional Task(s) activated on the fly as

needed.



View Existing Work Request(s) or if

needed, Create a New WOR

Dynamically

Launch

another

IntelaTrac

Procedure.


Mobile Attachments

– Attach Documents

– Images

– Marked-up Images

– Videos

– One or Many….


Procedure Sign-off


Peripheral devices allow user to take advantage of more advanced inspection techniques to accurately identify defective components of an asset.

– Vibration probes enable Users with minimal training to capture vibration data that can be alarmed on using ISO 10816 standards for vibration monitoring.

– IR Temperature probes enable Users to capture various Temperature readings that can produce hard limits or be used in Calculations that are actionable.

• Compressor Valve Surveys

• Seal Flush Surveys

• Exchanger Fouling Surveys

– Ultrasonic enable users to identify issues related to Steam Traps, Check Valves, Bearings, etc.

– Pyrometers enable Users to inspect tube temperatures for “Hot Spots”.

Peripherals


IntelaTrac is compatible with a wide range of mobile devices

http://www.junipersys.com/


Review, Trend & Report

Use Cases


ODR Challenges – Why it is needed…

In the effort to enable plant operators to drive reliability at the front line, it

is necessary to assure that operator surveillance activity consists of tasks

that are focused on detecting or preventing failure mechanisms which

lead to potential “Critical” failure effects. These “Critical” failure effects

consist of intolerable economic, safety, and/or environmental

consequences.

http://www.pbfenergy.com/


Maintenance Challenges – Why it is needed…

Mobilizing Maintenance with IntelaTrac helps ensure the plant’s assets

are maintained to the finest specification so that variations which cause

defects and ultimately failures are eliminated as maintenance work is

executed. IntelaTrac systematically ensures maintenance tasks are

executed in the most efficient and effective manner.


●Carseal Checklists

●Water Outfall Inspection

●Tank In Service Inspection

●NESHAP Above Ground Piping Inspection

●Recovered Oil Tank Inspection

●Oily Water Sewer / QQQ Drain Inspections

●Stack Opacity Checks

●Weekly Visual LDAR (VOC)

●Method #9 Visual Emission Evaluation

●Chemical Truck Loading Inspections

Environmental Challenges – Typical Inspections


https://www.fhr.com/default.aspx


Fire & Safety Challenges – Typical Inspections

●Building Audit

●Fire Extinguishers & Blankets

●Lock-out / Tag-out

●Fresh Air Control Systems

●Hydrants, Monitors, PIVs, Hose Reels, Foam Totes

●Self Contained Breathing Apparatus (SCBA)

●Eyewash Stations & Safety Showers

●Ring Buoys, Life Boats, Life Preservers

●Fireman Locker Gear Inventory

●Fire & Gas Detectors

●OSHA Self Inspection Checks

Condition Monitoring Challenges – Typical Inspections

●Vibration Rounds (Reduce Maintenance Cost & Improve Safety)

●Seal Flush Surveys (66% reduction in seal replacement cost)

●Valve Temp Surveys (65% reduction in maintenance cost)

●Furnace & Boiler Tube Inspections (Reduced unplanned outages &

Safety incidents)

●Exchanger Fouling Inspection (Improved efficiency)

●Steam Trap Surveys ( <1year ROI)

●Lubrication Rounds (~$1MM annual savings)


https://www.fhr.com/default.aspx

Deriving Value


Chevron Deployed a

Standardized Mobile

Decision Support System

Client:

Chevron Corporation

Location:

Houston, Texas

Closing the Loop:

After a successful pilot, Chevron

Corporation selected Wonderware

IntelaTrac mobile operator round and

decision support system to collect non-

instrumented data and standardize work

processes. The mobile workforce

enablement tool enables Chevron to

achieve significant savings and reduce

costs year on year.

Results:

We’re Closing the Loop to help Chevron:

• Standardize work processes and

data collection to improve

productivity

• Proactively analyze and react to

potential problems to increase

efficiency and better plan

maintenance

• Increase equipment availability and

reliability

• Enable field workforce to improve

decision making

Early detection led to

$70K Saved Preventing a motor failure

Identified blocked plug on

floating roof tank

$120K Averted

Estimated

$3-5Millionannual maintenance savings

$


Valero Energy Driving

Reliability Process

Improvements

Client:

Valero Energy

Location:

San Antonio, Texas

Initial Project:

• Focused on driving reliability

process improvements

• Operational savings over $2M / site

• Expanded to accelerate additional

process improvements (HSE

compliance/Energy Optimization)

Today:

• Wonderware IntelaTrac is deployed

at 12 refineries

• Mission Critical for regulatory

compliance (OSHA PSM and EPA

Title V)

• Significant increases in field

workforce productivity

• IntelaTrac has yielded 99.5%

completion of scheduled rounds

Documented at several sites

3X improvement

Yielded

99.5%Completion of rounds


ExxonMobil Declares

IntelaTrac an

Enterprise-Wide Best

Practice

Client:

ExxonMobil

Location:

Baytown, Texas

Best Practice:

Using IntelaTrac Applications:

• Safety inspections

• Maintenance PM items

• Process inspection

• Work order request

• Process safety management

• Drum/tower level checks

• Environmental checks

• Equipment pressure drops

Results:

• Asian Refinery reports an 88%

reduction in pump failures in the

first year for a savings of $500,000

on this asset category

• California Refinery reports 66%

reduction in costs of seal

replacement

• U.K. refinery, saved over $175,000

in the first year on maintenance

costs alone

Refinery reports

$500K savingsReduction in pump failures

Reduction in costs of seal

replacement

66%

Estimated

$175Kannual maintenance savings

$

$


Integrated Operator Workflow ROI

Industries have seen the following improvements in their workforce when performing Integrated Operator

Workflow:

• Asset uptime/availability 10-30%

• Reduced Maintenance Costs & Mechanical Effectiveness 5-30%

• Increased Workforce Productivity 20-30%+

• Regulatory Compliance visibility >30%

• Increase in visibility to non-instrumented data 20-30%+

• Typical payback in 6-12 months

Source: Wonderware Customer Reference Statistics


Mobile Work Order Execution ROI

Industries have seen the following improvements in their workforce when performing Mobile Work Order

Execution:

• Safety incidents reduced to near zero

• Work capacity increased by 10 to 20%

• Labor productivity increased by up to 50%

• Rework reduced by 15 to 20% (Rework is 8-10 times more costly than the initial failure)

Mobile Work Order Execution has helped customers realize these asset-related benefits:

• Downtime and production delays reduced by 20 to 30%

• Preventable failures reduced by up to 90%

• Maintenance backlog reduced by up to 60%

• Inventory carrying costs reduced by 5 to 10%

Source: SAP Customer Reference Statistics