通过引入数字技术，设备维护成本可以大幅降低。
编译 | 惊蛰
据悉，Emerson通过其特有的数字技术优化设备检修周期，为客户节省了250亿美元。该款新产品基于Plantweb数字生态系统，利用无线传感技术、位置感知技术、预测诊断与数据分析等，并融合了Emerson的设备检修专业能力以及可靠的七步检修法。
Emerson表示，这种新方法将能够保证工期进度，提高作业效率，同时减少意外事故与排查作业。从而，人力与材料成本降幅高达10%，作业工期比计划缩短了6%。Emerson全球副总裁Johan Claassen说：“大约25％的检修项目都超预算，50％以上的项目都超计划工期。造成上述结果的罪魁祸首是在设备检修期间出现的意外情况。目前，我们可为客户的所有资产提供周期保障，以避免在执行检修作业的紧要关头发生意外。”
市场研究表明，60%的检修成本来自固定的工艺流程设备，如蒸馏塔、热交换器、管道与结构支撑。Emerson正扩展其能力，为这些关键设备提供预测诊断、数据分析与检修周期规划专业知识。该公司的战略是全面投资自动化与数据分析，将其深厚的专业知识、可靠的作业经验以及全寿命周期系列服务相结合，从而优化设备的检修计划与作业。
对于单次检修作业，上述优势可节省310万美元的人力与材料成本，并可至少缩短两天的工期。根据Emerson的说法，全年预计有8000次检修作业，因此全球业内的所有客户每年总共有机会节约高达250亿美元的成本。
新架构的其他要素包括:1、项目早期可与Emerson的可操作性咨询专家和检修专家进行合作，开展排查作业研讨会；2、利用移动数字应用程序，对已安装的基础设备进行数字化改造，并通过报告与建议形式，提供可视化检查；3、应用检修专业知识，根据现有资源与产量要求，优化预算与计划；4、利用Emerson的位置感知功能，这是Plantweb数字生态系统内的一个新型人员定位系统，通过避免劳动力过于集中与低效来管理作业安全，而且还可以在检修期间减少现场承包商与临时工的人数。
新型移动服务与指挥中心作为中心点，所有设备的检修数据都通过Emerson的专家进行监控与分析。它还可用来管理库存与备用零件。对于计划外的需求，它直接提供了厂家链接，利用Emerson的QuickShip程序可加速零件的配送。
Claassen表示：“基于坚实的数据技术基础，我们可提供一致、有效、决策驱动的方案。我们可以彻底改变全球流程工业的检修方式。客户能够降低成本，缩短工期，确保工人安全，实现业内领先的作业效率，同时还可避免数十亿美元的利润损失。”
数字转型有效与否，取决于应用成果，Plantweb可助一臂之力。Plantweb是一种可扩展的技术、软件与服务组合，通过为员工提供新见解与可操作的信息，可显著提高产量、可靠性、安全性以及能源管理能力。从小型、有针对性的应用程序到企业规模的解决方案，Plantweb可带来真正的性能提升，并加快您迈向高效率的进程。信息就是力量，但前提是你得知道如何运用它。Plantweb将数据转化为可操作的信息，驱动决策，从而获得显著的作业改进。
Plantweb功能
- 数据： Pervasive SensingTM利用现有测量技术与新型传感器增强了作业的可视性，从而能够获得更多重要数据。
- 连通性：无论在现场还是不在现场，都可确保现有系统中的数据无缝衔接，安全地连接至作业应用程序或专家。
- 服务：通过第三方服务为客户补充劳动力，基于新型监控解决方案、分析功能与商业模型来帮助客户提高产量。
- 分析：合理使用可扩展的分析来处理客户数据，在适当时间，生成可操作的信息，传递给相关人员，从而改进决策的制定。
主要技术模块
- Plantweb Optics：按照优先级，在正确时间为正确的人提供相关资产的健康信息。
- 连接服务：可安全地获得数据分析与行业专业知识，以改善资产的健康状况。
- Mile连接：可将数据安全传输到适当的应用程序，服务或移动用户。
- Pervasive Sensing策略：利用新型传感器技术，可轻松、经济高效地收集相关数据，从而提高作业的可视性。
- Plantweb Insight：策略性的解释数据，以优化特殊类型资产或设备的相关决策。
- Plantweb 顾问：将大量数据转换为可操作的信息，以优化现场整体决策。
- Fisher数字阀门控制器：可轻松获取作业流程与作业控制的相关信息。
- AMS设备管理器：利用通用的视窗来了解现场智能设备的健康状况，以避免不必要的维护费用。
This new offering is enabled by the Plantweb? digital ecosystem and includes use of wireless sensing, location awareness, predictive diagnostics and data analytics combined with Emerson’s turnaround expertise and proven seven-step turnaround process.
This new approach will provide scope assurance, schedule assurance and improved labour effectiveness while minimising emergent and discovery work. The result is reduced labour and materials costs of up to 10% and shortened schedules of up to 6%.
“About 25% of turnaround projects run over-budget, and more than 50% fail to meet targeted schedules – mainly due to discovery and emergent work during turnaround execution,” said Johan Claassen, vice president, Global Lifecycle Services, Emerson Automation Solutions. “We can now provide customers scope assurance across all their asset classes to avoid last-minute surprises during turnaround execution.”
Market research indicates that 60% of the turnaround cost comes from fixed process assets such as distillation columns, heat exchangers, piping, and structural supports. Emerson is expanding its capability to provide predictive diagnostics, data analytics, and scope planning expertise to these critical assets. Emerson’s comprehensive strategy is to leverage the investment in automation and analytics used to operate the plant to transform the planning and execution of turnarounds by combining this with deep industry expertise, proven work practices and a broad portfolio of lifecycle services offerings.
On an average turnaround, these benefits could save US$3.1 million in labour and materials and shorten the schedule by at least two days. According to Emerson, these savings multiplied across an estimated 8000 turnarounds performed annually could save customers as much as US$25 billion per year in opportunity costs across all process industries worldwide.
Other elements of the new framework include:
- Scheduling early engagement with Emerson’s Operational Certainty Consulting and turnaround experts to perform a discovery workshop.
- Emerson performs walkdowns using a digital mobile app to digitise the installed base and provide a visual inspection of the asset with report and recommendations.
- Applying turnaround expertise to optimise budgets and scheduling based on existing resources and production requirements.
- Leveraging Emerson’s Location Awareness, a new personnel location system within the Plantweb digital ecosystem, to manage safety by reducing labour congestion and inefficiencies of not only employees, but also contractors and temporary workers onsite during turnarounds.
The new Mobile Service and Command Centre acts as a central point where all turnaround asset data is monitored and analysed through Emerson’s experts. It also serves as an inventory warehouse stocked with parts. For unplanned needs, it provides a direct factory link to expedite parts for shipping through the Emerson QuickShip programme.
“By providing a consistent, effective, decision-driven solution grounded on a solid digital technology foundation, we can revolutionise turnarounds for the global process industries,” said Claassen, “This empowers customers to reduce cost and schedule, ensure worker safety, and create a path to peer-leading performance, recouping billions of dollars in lost profits in the process.”
Delivering results through enhanced insight
Effective digital transformation is about results, and Plantweb can help you get them. A scalable portfolio of technologies, software and services, Plantweb enables measurable performance improvement in the areas of production, reliability, safety and energy management by empowering personnel with new insights and actionable information. From small, targeted applications to enterprise-wide solutions, Plantweb?drives true performance gains and accelerates your journey to Top Quartile performance.
Enabling Meaningful Actions
Information is power – but only if you know what to do with it. Plantweb turns data into actionable information to drive decisions that lead to measurable operation improvement.?
What’s Inside Plantweb
Data：Harvest the?data that matters with Pervasive SensingTM?strategies that leverage existing measurement technologies and newly developed sensors for enhanced visibility.
Connectivity：Ensure data in your existing systems is seamlessly and securely connected to operational applications or to the appropriate expert – whether on premise or offsite.
Services：Supplement your workforce with third-party services that help deliver improved outcomes through new monitoring solutions, analytics capabilities and commercial models.
Analytics：Make sense of your data using scalable analytics to generate actionable information that can be delivered to the right person at the right time for improved decision making.
Enabling Technologies
Plantweb? Optics：
Prioritize and deliver relevant asset health information to the right people at the right time.
Connected Services：
Securely access analytics and industry expertise for improved asset health.
Secure First Mile? Connectivity：
Facilitate the secure transfer of plant data to appropriate applications, services or mobile users.
Pervasive Sensing? Strategies：
Easily and cost-effectively harvest relevant data through innovative sensor technologies that improve operational visibility.
Plantweb? Insight：
Strategically interpret data for improved decision making related to specific asset classes or devices.
Plantweb? Advisor
Transform vast amounts of data into actionable information for improved site-wide decision making.
Fisher Digital Valve Controllers
Gain easy access to information critical to process operation, as well as process control
AMS Device Manager
Avoid unnecessary maintenance costs with a universal window into the health of intelligent field devices.