Machines and maintenance are becoming more and more intelligent. Internet of Things, predictive analytics and Big Data are new tools that will have to be part of the toolbox of the maintenance teams of the future.
In times of industry 4.0 we want to award the Asset Performance 4.0 Award for a digital transformation that focuses on maintenance, reliability and availability of the assets. In principle, all types of digital improvement processes are eligible, i.e. both technical and organizational improvements.
The 2020 finalists
- Engie European Maintenance Support: Improve asset performance of our thermal fleet by the use of best-in-class analytics technology by Marc Eyckmans (Knowledge – Innovation & Digital Manager) & Carl Van Honacker (Subject Matter Expert Boiler & Balance of Plant)
To support the business performance of its thermal powerplants ENGIE decided to invest in Robin Analytics in order to enhance it and transform it as the Group digital platform dedicated to thermal assets.
TCV (Temperature Control Valves) and FWP (Feed Water Pumps) are within BUGEN, 2 BOP related equipment’s that impact significantly the asset performance. Failed TCV forced ENGIE twice to an unplanned stop last 5 years, resulting in a negative S-P impact. During planned shutdowns of FPW’s, ENGIE were faced to unforeseen repair costs linked to equipment malfunction consequence damage. Anticipating equipment degradation will also impact maintenance cost in a positive way.
Based on supervised analytics ENGIE trends the equipment malfunction and forecasts the degradation into human readable recommendations. So, maintenance can be easily planned before the equipment end of life. Based on Robin analytics, the COI will increase by 0.3% in 2021 by avoiding unplanned equipment failure.
- Yara Tertre: Maintenance & Industrial major risks into a 4.0 context by Aurelien Flamme (Production Manager – Ammonia dpt)
The objective of Yara’s digitalization strategy was to develop new sources of performance data and deploy methodologies and technology to measure and quantify plants performance in all transparency. Furthermore they wanted to develop digital tools to harvest more predictive information from existing data collected.
They are specifically proud of the key drivers in different 4.0 pilot tests, such as energy efficient monitoring and the control of the ammonia plant (550 MW). They were also able to change the curve interface possibility in the purpose of ‘Process Safety’ and ‘Reliability’ of the site. Most importantly, there were extra human interaction benefits: colleagues from different departments (process, operators & maintenance) were ensured of up to date development and improved their personal skills.
- Siemens Logistics: Critical asset monitoring applying ML, FFT based on edge and cloud computing by Frank König (Senior PM) & Vishal Kr. Gupta (Data Scientist)
Siemens faced unexpected down time and unnecessary maintenance. In an annual cycle, the timing belts or heavy rubber chains were replaced by the lowest bidding service organization. The work was executed poorly and caused drive shaft misalignment, higher vibration that has led to looseness.
Siemens started working together with 3 major airports on modern technology, which encompassed data collection and pre processing using modern wireless vibration sensors (with external power connection) recording 24/7, edge and cloud computing and the use of Siemens MindSphere Ecosystem as data repository, and modern dashboarding allying scatter plot diagrams that enable ‘non-technician’ to identify failure without being obliged of analyzing complex technical data.
As a result, labor intensive and high risk surveys (working at height and in confined space) were reduced to a minimum. Unexpected downtime on monitored assets were reduced significant and for the last year ‘eliminated’.
Register now and discover the cases
You can register via www.assetperformance.eu.
Participation is free of charge for BEMAS members and for those who are already subscribed to the Asset Performance 4.0 platform. Non-members pay € 95.
You can also choose to purchase the entire Asset Performance 4.0 package. For € 495 (members) / € 595 (non-members) you get access to +100 presentations and weekly webinars, which you can watch whenever you want.