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SPECIAL REPORT

Beyond Condition Monitoring:


Prevent failures through
condition management
Go beyond condition monitoring p.2
Sponsored by
CMMS provides real-time transparency p.8

The changing role of the CMMS vendor p.10


Go beyond condition monitoring
Despite condition monitoring, unplanned outages continue to be an issue, significantly
impacting financial performance through lost production and extra repair costs.
By Neil Cooper, Invensys Operations Management

I
n todays environment, chemicals makers face ongoing sense of the data. Exacerbating the problem, the aging
pressure to operate safely and reliably at the lowest pos- workforce means that plants are losing more and more
sible cost. Most companies have adopted condition moni- people with critical operational experience, knowledge
toring technologies as a key approach to improve the avail- and interpretive skills.
ability and reliability of process equipment and to proactively 3. Many companies still have operational silos. Plant per-
avoid downtime. sonnel arent collaborating to detect, manage and ana-
While these condition monitoring solutions are providing lyze emerging issues. The net result is continued out-
solid value for most plants, unplanned outages continue to ages, even when the underlying condition or trend had
be an issue, significantly impacting financial performance been correctly detected.
through lost production and extra repair costs.
So, in this article, well explore the underlying challeng- Condition management defined
es and introduce the concept of condition management Addressing this set of challenges requires an enhanced,
an enhanced approach that helps companies reap the full more holistic approach condition management. Under this
benefit from their condition monitoring investments. Well approach, the vast array of condition data is the entry point to
also discuss how to get started in condition management, a five-step process where the data are:
looking at both business and technical considerations.
1. aggregated and rationalized;
Building upon a baseline 2. combined to create context and support proper analysis;
For years plants have tracked the health of key equipment. 3. clearly presented and communicated;
Sites generally have focused on a relatively limited deploy- 4. systematically managed to ensure the timely, accurate,
ment of specific monitoring technologies aimed at protect- consistent and effective resolution of the underlying is-
ing critical assets primarily large rotating equipment. sues; and
This has become simpler with the widespread availability 5. used as input to an ongoing continuous improvement
of highly capable fieldbus-enabled monitoring tools, e.g., process.
for vibration, temperature, pressure, corrosion and fluid
analysis.
Now, the advent of intelligent field devices and sensors as
well as low-cost wireless units that can be deployed into ar-
eas where hard wiring would have been cost-prohibitive is
extending these base capabilities and the data they provide.
Unfortunately, plants arent enjoying the full potential of
the data for three reasons:

1. T
 he focus of condition monitoring deployments is too
narrow. Sites need to instrument a wider range of as-
sets, so management can look beyond specific equip-
ment to entire process areas or complex asset sets such
as heat exchangers, dryers and other plant units.
2. The volume of data available now is huge and will con-
tinue to grow exponentially. This creates a significant
knowledge management challenge around making

2
The first three elements are aimed at turning the data company operates a 300-MW captive power plant. The
into information, changing the condition information from site had deployed condition monitoring tools on assets
noise in the eyes of operations personnel into useful deci- there vibration, rpm, and amperage on the pumps in
sion support intelligence for all personnel. the cooling towers, the manufacturers monitoring tools
The aggregation and rationalization also need to ad- on the turbine, and assorted flow and temperature me-
dress the varying types of data, the time element (real- ters throughout the cooling system.
time, near-time and offline) as well as the various access When the primary pump in the cooling tower failed, the
and communication methods utilized by vendors. control system initiated a cutover to a back-up pump and
Once the data are turned into properly contextualized and then cleared the alarm. An operator entered the occurrence
actionable information, its critical to manage the use of the in the log, where the required follow-up was to have main-
information. It comes back to the fundamental difference tenance staff repair the primary pump.
between condition monitoring and condition management. Shortly after this initial incident, the operator started re-
Condition management information helps unlock the use- ceiving alarms that the temperatures in the cooling system
fulness of the condition data by: were drifting out of range, coupled with pressure warnings.
Assuming that this was a storm created by the cutover to
driving the appropriate workflow/processes to resolve the back-up pump, the operator acknowledged and cleared
the issue(s), bringing together the key personnel across the alarm set.
operational disciplines (engineering, maintenance, con- Close on the heels of this second set of indications, the
trol, safety, etc.). turbine monitoring system flagged a significant tempera-
providing input to an ongoing knowledge management ture variance and recommended an immediate shutdown.
process where new situations and their appropriate Again, on the assumption that this was a blip caused by the
resolution are systematically captured and documented. cutover, the operator cleared the alarm.
After two minutes, which was the defined re-alarm
Further, condition management supports Six Sigma or time, the turbine monitoring system reported dangerously
Lean Sigma initiatives by supplying input for an ongoing high temperatures and again recommended a shutdown.
process where the knowledge base is regularly reviewed This time, the operator (per the written procedures) contact-
and refined. ed the plant manager, who gave approval to proceed with
the shutdown.
A telling example This caused a production outage that impacted de-
A leading specialty chemicals maker discovered the livery of a critical intermediate to one of the companys
value of the approach but only after a serious incident. key customers. Further, the sequence of events and the
The process uses a significant amount of power, so the elapsed time from initial warnings to shutdown resulted

3
Figure 1. Success depends upon properly using wide variety of inputs from all plant levels.

in extreme temperatures within the turbine. This led to sig- The foundation for success
nificant damage, necessitating the replacement of its main As the example underlines, effective condition manage-
bearings. ment must address all of the elements together. Specifi-
The root cause turned out to be that back-up pump had cally this means:
not come online as expected. In doing the situation analy-
sis, the company discovered a number of specific issues: collecting the right data (condition, process area and
system);
1. The back-up pump wasnt instrumented in the same gathering the complete set of data necessary to provide
manner as the primary one, so there wasnt any critical the context needed to accurately assess an issue and its
warning to the operator. impact;
2. Condition information for the primary pump and the automating the response, including actions and escala-
back-up pump werent linked. tions; and
3. The pump, temperature/pressure and turbine data enforcing the post-event analysis and continuous im-
werent connected. Each was handled discretely by provement process.
the operator in separate areas of the human/machine
interface (HMI); the combined elapsed time in dealing Moving to condition management is ultimately a knowl-
with the discrete events exceeded the safe shutdown edge management challenge. In many companies, such a
point for the turbine. move requires a change in both technical and business pro-
4. No automated communication alerted mainte- cess practices. This challenge is manageable but firms need
nance, engineering or plant management to the to be committed to the change in approach and need the dis-
developing issue. cipline to effectively implement and sustain it.
5. The operator didnt have any way of seeing the The process has to include the use of supporting tools
maintenance status of the primary assets including and technologies that allow the capture of the institutional
the pumps this would have shown that the back- knowledge currently existing in plant personnel across all
up pump had a pending inspection because of previ- the disciplines.
ously reported issues. Condition management fundamentally is a closed-loop
Looking at this real-life example in its entirety, no particu- model with four main elements collect, analyze, act and
lar action or practice alone could be blamed. Instead, the optimize. This model provides the framework for translat-
situation arose because of the lack of context and ineffec- ing the business needs into a solution architecture for a
tive use (i.e., management) of available information. plant. Figure 1 shows the relationships among these ele-

4
Figure 2. In CALM, the
operate/maintain stage
offers the largest por-
tion of return-on-asset
improvement.
Source: ARC

ments, starting at the process measurement level through At a broader level check whether a formal lifecycle man-
decision support and feeding back to the process. agement program is in place. A recent survey conducted
by the ARC Advisory Group found that companies that
Getting started had adopted such a program had a significantly better
As with any change process, its critical to understand the return on assets than those that hadnt. The research also
starting point. This demands taking a hard look at several indicated that the largest portion of the gains come from
areas and asking some tough questions: properly managing the operate and maintain stages of
Culture. Does the company understand that there are the lifecycle. Its precisely here where condition manage-
issues and that theres inherent and significant value in ment is a key enabler of improvements. The ARC lifecycle
resolving them? As a simple test, can people articulate the model, (Figure 2) shows the relationship between plant
impact or cost of an unplanned outage? Is the company asset management (PAM) and an asset lifecycle manage-
really willing and ready to change? Effective condition ment scheme. Corporate knowledge. Does the company
management will include changes to business processes have a knowledge management process or tools? Whats
and roles, so these points are fundamental. the current state of the work force? Is a retirement bubble
Business processes. Are the firms processes document- coming up that necessitates immediate action? Does the
ed? Have they recently been validated or benchmarked company really know where the necessary knowledge
against others in the industry and best practices? In many resides?
cases, simple process enhancements or better communi- Skill base. Does the firm have the essential expertise
cation can deliver significant performance improvements. in areas such as reliability-centered or condition-based
Dont apply technology without this process baseline. maintenance, optimization, advanced process control
Note in particular that a formal approach based on root- (APC), and condition monitoring and analysis?
cause analysis and including continuous improvement ef- Technology base. To fully achieve the promise of con-
forts is a fundamental requirement. dition management, a wide range of technologies both

5
Figure 3. Plant- and corporate-level technologies need to come together effectively.

in the plant and at the corporate level need to come to- ment by performing the advanced analytics that warn
gether (Figure 3). of a developing issue long before it becomes a pro-
So, engineers, planners and managers need to work to- cess or system alarm or alarm storm.
gether and ask themselves a series of technology questions
that focus on five key areas. 2. The current level of condition monitoring. What instru-
mentation is in place? Which assets are addressed?
 he state of the core automation systems. Is the
1. T What data can these current tools provide? How are
distributed control system current? Is the plant us- the data currently used? What tools are being used?
ing a digital fieldbus with intelligent devices, tra- What processes are in place to deal with the issues
ditional 420-mA analog or both? This will impact identified? Is there any automation of these processes?
what data are available and how to access them. Find out if the information already being gathered
Its important to understand that the plant doesnt is handled in systematic or automated fashion and
need to be state of the art. Many new analytic tools moves across departmental boundaries. One of the
can infer conditions from the simple data points that major values of condition management is making in-
are being collected as part of the control strategy. formation useful beyond the realm of the collection
point or device putting it in a broader context.
Its also crucial not to confuse alarm management
with condition management. Alarm management 3. The current level of APC and process optimization.
plays a critical role in dealing with the huge number Is the company using such solutions? These models
of discrete input/output points that are part of the con- can play a key role in identifying and understanding
trol strategy, working in real time at a discrete level. the dependencies and context for the condition data.
Condition management complements alarm manage-

6
Figure 4. Such a
graphical display
often serves as the
vehicle for deliver-
ing information.

4. Integration infrastructure. Does the firm have a stan- With the foundation effort complete, a company can
dardized way for integrating applications at the plant better see the possibilities for value and improvement,
level, applications at the business level and among determine risk/reward and identify which parts of condi-
plant and business applications? This will be critical tion management can be implemented first. The success
for gathering the condition information at the plant of initial low-risk/high-reward projects, in turn, can fund
level and then driving the workflow necessary to an ongoing program.
resolve issues. For example, if a critical condition is Many chemical makers can gather the information for a
recognized, automated workflow tools should page condition management baseline from within. This valuable
or email the key personnel, automatically trigger the effort can enable them to more clearly understand their re-
necessary work requests or work orders to the main- sources, processes, limitations and options.
tenance team and update the necessary HMIs and However, the subsequent steps can be complex and
management dashboards. likely will involve the assistance of a technology part-
ner familiar with the tools and solutions required for a
5. Business intelligence. Is there an integrated measure- condition management architecture, not just condition
ment system as well as a vehicle to deliver the informa- monitoring.
tion across the company? The vehicle most commonly Condition management is an over-arching solution that
employed is some form of portal or dashboard solution makes use of the mountains of data generated by individ-
such as the one shown in Figure 4. ual condition monitoring systems. It combines, rational-
izes, presents and communicates decision support infor-
The next steps mation effectively. It truly can help management identify
The analysis that establishes the foundation or starting the actions and practices needed to get full benefit from
point is the most important step in the path to condition monitoring investments and, in turn, optimize the return
management. It is a comprehensive effort that brings in- from plant asset investments.
formation and, importantly, people, together. It also pro-
vides the groundwork for setting priorities and expecta- Neil Cooper is vice president of asset performance management
tions and for understanding the implications on processes solutions for Invensys Operations Management, Burlington, Ont.
and roles. E-mail him at neil.cooper@invensys.com.

7
CMMS provides real-time transparency
How your CMMS gives maintenance a clear view of the current situation.
By David Berger, P.Eng., Contributing Editor, Plant Services

M
any contemporary CMMS software packages pro- Condition-based maintenance (CbM) functionality, ei-
vide two key functions. First, the CMMS is a plan- ther built into the CMMS or through integration with spe-
ning tool, from long-term capacity and capital cialized software, achieves greater transparency in mainte-
planning, to medium-term budgeting and work planning, to nance operations and provides insight into four key areas.
short-term work order planning and scheduling. Second, the By monitoring the state of a process, CbM can alert you
CMMS analyzes and reports on collected data and compares to when corrective action is required. For example, if a
it to plan, which gives users much-needed transparency into valve doesnt open wide enough to allow the correct flow
maintenance operations on a real-time basis. Lets explore of raw material, production quality or volume might suf-
some of the features modern CMMS packages use to maxi- fer. Visibility into the process will, therefore, ensure that
mize this transparency. you can react quickly to the situation. In some cases, an
Business intelligence provides a user-friendly interface automated control loop can bypass the need for human
that gives insight into what is working and what isnt work- intervention, although a record of the incident might be
ing relative to plan. With its dashboards, graphs, alerts, warranted.
reports, ticker tapes and other output formats, business Another dimension to consider for gaining transparency
intelligence makes it quick and easy for users to interpret is monitoring the measures that are relevant to the prod-
the collected data and, in turn, make better decisions. uct, such as critical external dimensions. If a problem with
However, like any software product, business intelligence a given asset causes product defects, determine which
is no panacea. In fact, business intelligence requires sig- metrics, such as a gradual loss of power, correlate with the
nificant human intelligence to configure properly and en- defects. By configuring CBM to monitor the variables, you
sure its at all useful. can better anticipate and correct problems before product
For example, dashboards use speedometers, stoplights defects appear.
and gauges to alert the user when managements atten- The third transparency-producing capability is monitor-
tion is required. Youll know when PM compliance is too ing the environment through which products and process-
low, a project is over budget, spare parts havent been de- es pass. This can sometimes provide important insight
livered on time, and so on. This is great stuff, to be sure, into asset health. For example, if the ambient temperature
but significant thought is required to determine which exceeds an acceptable upper control limit, there might be
measures are priorities, how best to display them, what a problem with another asset.
algorithm best defines each measure, how often the mea- The fourth and most obvious dimension in terms of pro-
sure should be refreshed, appropriate upper and lower viding visibility into maintenance operations is monitoring
control limits, and many other configuration decisions. the assets themselves, using measures such as downtime
Its well worth the effort needed to obtain this improved and performance. In some cases, this requires finding a
visibility into maintenance operations. But be wary. It re- metric that correlates well with higher-level measures,
quires a good understanding of whats important to you such as vibration, current drawn or the number of pieces
and how to measure it. that pass a proximity sensor every hour.

8
Partners and customers want transparency in the main- whereabouts and productivity of technicians in the field.
tenance department. For example, when a maintenance The technology applies automatic date and time stamp-
customer initiates a work request, maintenance has an ob- ing when technicians scan the assets and enter work order
ligation to manage customer expectations. This includes information.
acknowledgement that the work request was received, Even more contentious are managers who track the
notification that the work has been scheduled and will be movement of technicians using GPS devices in their vehi-
completed on a specific date, and status updates if plans cles or mobile devices, or simply monitor the coordinates
must change. This level of transparency ensures business of assets scanned or reported as visited.
partners and customers will be satisfied that formal or im- Transparency drives decision-making by exposing areas
plied service levels are met. that are a priority for improvement. Many things drive the
A few CMMS vendors offer advanced features that help business. Examples include identifying opportunities for
provide transparency for customers and business part- greater asset reliability, reducing energy consumption,
ners. Those software packages include service level agree- greater product consistency, and a host of other possi-
ments, contract management, help desk and a full-service bilities. In general, visibility into maintenance operations
management module optionally accessible by the cus- helps find ways to reduce the total cost of ownership for
tomer. Each of these features helps set expectations and every asset and increase the quality and quantity of output
track actual results for maintenance and its customers. from operations.
Mobile transparency is for technicians on the move. Regardless of your business, transparency provides
The increase in popularity of portable, connected devices technicians, their supervisors, maintenance planners, and
extends transparency toward technicians, wherever they other stakeholders in operations and maintenance with
might be. Mobile devices and related software allow them a means to make more insightful decisions. The key is
to download all sorts of useful data that gives visibility to pick a few high-priority measures that truly drive your
into the location, status, equipment histories, as well as business, and configure your CMMS to collect, analyze
providing various analysis tools that help to diagnose and report on any variances from expected results. Ulti-
problems. mately, the onus is on you, not the CMMS, to take timely
Technicians can upload data such as root cause and rem- and appropriate action that reaps the rewards of greater
edy codes, time taken to complete the work order, spare transparency.
parts used, and inspection measurements taken relevant
to completing the work order. This provides transparency E-mail Contributing Editor David Berger, P.Eng., partner,
that allows planners and management to know whether Western Management Consultants, at david@wmc.on.ca.
work was completed to plan or, perhaps, that the job plan
was unrealistic and requires modification.
Some CMMS integration points, including GIS, bar code
and RFID capability, can increase the visibility potential of
mobile solutions. GIS capability allows users to access
maps on mobile devices, determines which assets are
within a user-defined polygon drawn on the map, redlines
assets that have been installed or mapped incorrectly, and
many other features. This gives transparency, for exam-
ple, as to what assets lie underground before work at a
given location commences.
A bar code or RFID reader integrated into a mobile de-
vice allows technicians to scan equipment on a route and
quickly and accurately identify them, which, in turn, trig-
gers the downloading of work order history and other rel-
evant information. Although somewhat controversial with
technicians, some managers can gain visibility into the

9
The changing role of the CMMS vendor
You should expect more than a shrink-wrapped box of software from your supplier.
By David Berger, P.Eng., Contributing Editor, Plant Services

C
MMS vendors have seen a lot of change during the maintenance routines, estimated or standard hours to com-
past 30 years, including many start-ups and wind- plete tasks and coded field options (e.g., problem and cause
downs, a plethora of mergers and acquisitions, sev- codes). Data can be specific to an asset type or classification,
eral generations of new technology, a roller coaster of eco- such as data for electrical devices. As well, it can be industry-
nomic activity, and ever-changing demand from a growing specific, for example, data relevant to pulp and paper mills.
customer base. But one of the most significant trends from Process mapping: CMMS vendors can further demon-
your perspective as the customer is that CMMS vendors strate their knowledge of best practices by facilitating pro-
are no longer simply purveyors of software. As CMMS cess improvement during the software implementation.
software becomes more sophisticated and mission-criti- This typically involves drafting process maps reflecting the
cal, the dependence on your vendor increases. Its there- current state, and comparing them to future-state processes
fore important not only to choose a CMMS package that that incorporate the appropriate CMMS functionality. The
is right for you, but a CMMS vendor with whom you can gap between current and future states must be addressed
partner over the long term. carefully in terms of configuration of software, training on
In moving from a supplier of software licenses to a full processes, project management and, most importantly,
strategic partner, the CMMS vendor has amassed a num- change management to ensure CMMS users buy into the
ber of products and services that can help you manage your new processes.
growing investment in assets. Configuration: The flexibility of modern CMMS software
is demonstrated by the ease with which it can be tailored to
Best practices your needs, such as configuring menus, data entry screens,
One noteworthy change in the relationship between you reports, alerts, approvals, equipment hierarchy and work-
and your CMMS vendor is the increasing reliance on vendor flows. In years past, this often required customization, a term
knowledge of asset-management best practices. This stems synonymous with a large, upfront investment in time and
from the common assumption that because a given vendor money, and a costly upgrade path. Todays software is easy
has sold CMMS software to hundreds or even thousands of
companies, it must have acquired considerable knowledge
that it can transfer to its customers. The more savvy vendors
have picked up on this supposition, and are offering many of
the following products/services:
Industry-specific software: As competition increases,
CMMS vendors are looking for more marketable competi-
tive advantages such as deep knowledge of a given industry.
This includes software features that ensure compliance with
industry-specific legislation, as well as more intimate under-
standing of industry practices. Some vendors have hired ex-
perts with extensive experience in a given industry to help
develop relevant product and service offerings.
Standard data: A handful of CMMS vendors have stan-
dard data to sell or provide free of charge when custom-
ers purchase their software. Standard data can include job
plans, standard operating procedures (SOPs), preventive

10
ity of a successful implementation for both you and your
CMMS vendor if:

Special Report: Objectives are well documented and communicated to


everyone, including the performance targets that define
The Full Impact of ERP success
Russell Smith, senior vice president of Edge- Payment is in the form of a bonus, not built into the ven-
water Fullscope, discusses how ERP can man- dors base fee
age logistics, distribution, inventory, shipping, Users also will receive an equally meaningful bonus for
invoicing, accounting, and HR functions with meeting the same objectives
Plant Services Chief Editor Mike Bacidore. Listen now Targets are achievable

to configure to a wide range of business process options, Software as a service


regardless of company size, industry, competitive strength, An option that has received a lot of attention in the past few
level of sophistication or organizational readiness. Configu- years, software as a service (SaaS), is a rebirth of a concept
ration takes little time and the cost is minimal compared to popular in the days of early mainframe computers more than
customization. Because the source code isnt altered, there is 30 years ago. Although CMMS vendors dont yet define SaaS
little or no effect on the upgrade path. consistently, there are some common threads. At a mini-
Training: Once best practices are embedded in proce- mum, vendors that offer SaaS charge a monthly subscription
dures through process mapping and baked into the soft- rate that covers at least software licenses and maintenance
ware via configuration, users must be trained in the new fees, for example, $30 per module per user per month. At the
processes and supporting systems. The CMMS vendor other end of the spectrum, some SaaS providers bundle ab-
plays a critical role, especially if industry experts are avail- solutely everything into the subscription price, including soft-
able who can better gain the trust and confidence of ner- ware, hosting infrastructure on your site or that of the vendor,
vous users and skeptics. Training should be just-in-time maintenance, unlimited support, all the training you want,
and comprehensive to facilitate retention, employing mul- and whatever implementation services are required.The pric-
tiple tools and techniques such as classroom, on-the-job, ing might be, say, $200 per 100-hour block of use, regardless
video-based and online training. of the number of named users or modules accessed.
Consulting: If you have gaps in the capabilities or avail- Users have jumped on the SaaS bandwagon because of
ability of specialized resources in your company, the CMMS the reduced burden on cash flow, the appeal of paying only
vendor can fill them in with its consultants. For example, a for what is used, and the flexibility to scale up or down quick-
vendor might have specialists who are familiar with best ly in terms of functionality or the number of users. Although
practices in implementing process, system and organiza- some companies argue about the economics of SaaS com-
tional change, as well as technical areas like call centers, pared to traditional pricing, theres no way to tell without
reliability-centered maintenance, linear assets or calibration. crunching the numbers.
Although CMMS vendors might not be 100% third-party
objective, they usually can be relied upon to conduct sur- Formal long-term partnership
veys on organizational readiness before implementation and The most intimate relationship possible between you and
stakeholder satisfaction following implementation. Vendors your CMMS vendor is some sort of formal, long-term con-
also can assist with benchmarking other organizations. tract such as a joint venture or outsource arrangement. Al-
Web site: Another tool thats fast becoming a preferred though many CMMS vendors offer hosting services for their
source for best practices is the CMMS vendors Web site. Us- CMMS, there are very few that have ventured as far as tak-
ers can search for and download information such as white ing responsibility for maintaining any of your assets. Most
papers, technical bulletins and conference proceedings that are happy to work with a third-party contract maintenance
cover a host of relevant topics. In addition, some vendor Web company and supply the CMMS, but are reluctant to supply
sites provide opportunities for users to share tips and traps, and manage the maintenance technicians or their managers.
solve problems in chat rooms, and conduct surveys. Perhaps this will eventually change if CMMS vendors con-
tinue on their current path of transformation, from CMMS
Fee for results software supplier to asset-management services provider.
One option (that admittedly hasnt yet gained much mo-
mentum) is to pay the vendor an amount based on long- E-mail Contributing Editor David Berger, P.Eng., partner,
term results. This can dramatically increase the probabil- Western Management Consultants, at david@wmc.on.ca.

11
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from quenchIng A thIrst to
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