Value of Asset Management Strategies
“I need to insure that my facility is operating the way I built it to run!”
Common Water Supply & Water Treatment System Objectives
improve maintenance staff effectiveness
reduce risk to service outages
disaster recovery
monitor & protect systems
improved site security
keeping employees safe
complying with regulations
reducing commissioning time & cost
Water Supply & Water Treatment System Benefits
• Reduction in long term operating & maintenance costs and lowering
the risks to the community served by…
– Improve maintenance staff effectiveness
• Root cause analysis & locked door device analysis automatically
• Monitor & protect systems
– Monitor devices on networks for abnormal operation including degradation or failure
– Automatic integrated condition monitoring including notification
• Automatic tracking of versions with security on all production intellectual
property
• Messaging (email) appropriate personnel
• Facilitate more migration from reactive & preventive maintenance to predictive
& reactive maintenance models
– Increase site security for device access
• Creating audit trails for asset configuration changes, detect unwanted changes
• Back up asset intellectual property to a secure system for disaster recovery
• Store every version of asset configurations in a secure system for archival and
retrieval
• Automatic verification of some device configurations against controlled masters
– Extend service life of equipment through verification, condition monitoring
& security
Assets’ Influence on Objectives
Each asset no matter how large
or small is linked to the next asset.
Even the smallest
change can affect operations!
RSMACC Systems
• RSMACC Systems consist of an architecture
that includes at least one core function.
• That RSMACC System can be added to,
creating a much more comprehensive
solution.
• The 4 core functions are:
–
–
–
–
Change Management, CM
Network Health, NH
Enterprise Online, EOL
Automated Asset Manager, AAM
• You can purchase CM alone and add AAM at
anytime
• Or you can purchase a NH System and add
EOL, etc…
Typical Device Configuration Scenario
• User starts RSLogix program
– User locates the RSLogix controller program
– User connects to the controller
– Downloads or makes online changes, saves
program on local disk drive, floppy or
somewhere else
– What version of the program is in your
controller and where did the program come
from & where did it go after the change?
Change Management
The Value is greatest when applied proactively
rather than after the fact!
The stream of managing change starts with
“Prevention” and flows through
“Reconciliation”.
Access Control
Prevention
Authentication
Control
Archive
Accountability
Audit
Detection
Verification/Recovery
Reconciliation
Reporting
Change Management
• User starts RSLogix program
– RSMACC security system ask your domain
controller to authenticate the user
– Regardless of results, RSMACC records
workstation and user launching RSLogix
– RSMACC security applies the defined security
permissions
Change Management
– User retrieves application program from
RSMACC archive using RSLogix 5 or 500 file
open or the RSMACC client using the RSMACC
security system to verify permissions
– RSMACC records who retrieved the application
program & where it went
Any type of file can be stored in this Archive system!
Change Management
– File management system
• Holds any kind of document
– Manage user folder rights
– Supports
• Pinning/ mastering
• Sharing
• Branching
Change Management
– User connects to the controller
• RSMACC records device connection
– User makes online modifications to control
program
• RSMACC records each user change as it occurs
Change Management
Change Management
• Secure operator changes from
RSView SE or PanelView Plus during
production
– Set-point change (Tag write)
– Command
• Alarm acknowledgement
– Recipe download
• Signature required before operation
occurs
• Generates compliance enabling 21
CFR Part 11 audit trail
Change Management
• Documenting Configuration
Changes
– Supports self-documenting
Change Management procedure
• Ability to prove scope of change
is limited to approved change
• Contains information necessary
to enable FDA 21 CFR Part 11
compliance
–
–
–
–
Date/Time of audit event
Source (Application)
Location (Workstation)
Username (Domain ID, and Full
Name from Domain Id)
– Automatically generated
description of change with old
and new value
Change Management
– User returns the application program to the
RSMACC archive system
• RSMACC archive compares the files and
increments the version if it is different
regardless of the type of program
Change Management
– RSMACC verifies automatically at the
prescribed periodicity that the controller
program matches the master program and
version in archive
• A message can notify that the function ran
correctly or not, and differences were found or
not.
• A report of the differences found is saved.
Brief Overview, Managing Device Configuration
Security for:
Archived files
RSMACC functions
RSLogix 5 v4.00.00 or greater
RSLogix 500 v4.00.00 …
RSLogix 5000 v11.00 …
RSMACC Client v1.00.00 …
RSMACC Change Management v1.00.00…
RSLinx v2.20.01 …
More products are coming as…
FactoryTalk Security is integrated!
RSLogix™ 5 or 500 Standard v6.10…
RSLogix 5 or 500 Professional v5.50…
RSLogix 5000 (English) v10.03...
PLC3
DH+
PLC5
DH+
ENet
CNet
DF1
Audit:
RSLogix editors listed
RSViewSE & ME, RSBatch…
(some integration)
More products are coming as…
FactoryTalk Audit is integrated!
FlexLogix
ENet
CNet
DH+
ControlLogix
DriveLogix
ENet
CNet
DH+
PanelView Standard
Enet, CNet, DNet, RIO, DH+, DH485, DF1
(Enhanced on RIO only)
PanleView Plus
ENet, CNet, DH+, DH485
Archive for:
Virtually any form or type of file
CM
CompactLogix
ENet
CNet
DH+
PLC2
DH+
Verification for:
All devices shown below…
files on computers…
and some robots
509 -BOD
24vdc
SLC*
ENet
DH+
DH485
DF1
MicroLogix
DH485
DF1
RSMACC Systems
• RSMACC Systems consist of an architecture
that includes at least one core function.
• That RSMACC System can be added to,
creating a much more comprehensive
solution.
• The 4 core functions are:
–
–
–
–
Change Management, CM
Network Health, NH
Enterprise Online, EOL
Automated Asset Manager, AAM
• You can purchase CM alone and add AAM at
anytime
• Or you can purchase a NH System and add
EOL, etc…
Typical Device Status Events
• Event
– Radio message or alarm
~75
%
Automatic Device Health Status
• Periodically the Diagnostic Scheduler Service,
running on a local computer, scans the health
of DeviceNet, ControlNet, and Ethernet/IP
network devices and reports on their status to
the RSMACC system.
– Smart devices, when prompted, will identify
their health status by responding with a coded
number
– Comparing that number to the type of device
using the network configuration file allows us
to automatically generate information about
the failure
Diagnostic
Scheduler
Services
Automatic Device Health Status
– That number corresponds to a real problem for
the device at that node.
– These are automatically logged to the
centralized RSMACC Diagnostics
and Health log database
Diagnostic
Scheduler
Services
Automatic Device Health Status
– RSMACC log message includes a link to root
cause and solution information from
distributed RSMACC Clients
– RSMACC requires no additional code or
configuration to recognize a device code and
communicate the device status to the system
and subsequently the appropriate personnel
Diagnostic
Scheduler
Services
Automatic Device Health Status
Diagnostic
Scheduler
Services
RSMACC Systems
• RSMACC Systems consist of an architecture
that includes at least one core function.
• That RSMACC System can be added to,
creating a much more comprehensive
solution.
• The 4 core functions are:
–
–
–
–
Change Management, CM
Network Health, NH
Enterprise Online, EOL
Automated Asset Manager, AAM
• You can purchase CM alone and add AAM at
anytime
• Or you can purchase a NH System and add
EOL, etc…
Traditional Condition Monitoring
• Machinery in the plant might malfunction so
we must do our preventive maintenance
periodically regardless of real indicators like
cycles, revolutions, temperature, vibration,
level or viscosity.
– This requires a person to take local readings
and then analyze those readings typically back
at their desk.
• In several industries this may even require travel
• In all, it is extremely time consuming
Automatic/Integrated Condition Monitoring
• Our integrated and automatic protection
systems are designed to provide continuous
monitoring and protection to machinery
– RSMACC system provides a live connection to
sensor data from the XM modules
• Vibration Analysis
• Process Parameters
– Temperature, Pressure, and Flow
• Turbine Supervisory Instrumentation (TSI)
– Thrust, Differential and Case Expansion, Valve
position, and Eccentricity
• No more traveling to the location or climbing
on machines to take readings!
Automatic/Integrated Condition Monitoring
– RSMACC Client combines digital images of your
plant equipment with monitored data for
simple asset monitoring and alarm
annunciation
– EnWatch data can be combined with the XM
data on the live monitor
Automatic/Integrated Condition Monitoring
– Online remote configuration capability
Automatic/Integrated Condition Monitoring
– Live Time data display from any XM channel
• Trend, Spectrum, Waveform, Waterfall, Polar,
Orbit, Shaft-Centerline
Automatic/Integrated Condition Monitoring
– Historical data can be added to real-time using
our Emonitor systems
• Emonitor Enshare
– Data Storage, Alarming, Frequency Analysis, &
Connectivity
• Emonitor Odyssey Deluxe
– Data Storage, Alarming, & Frequency Analysis
• Emonitor Odyssey
– Data Storage & Alarming
RSMACC Systems
• RSMACC Systems consist of an architecture
that includes at least one core function.
• That RSMACC System can be added to,
creating a much more comprehensive
solution.
• The 4 core functions are:
–
–
–
–
Change Management, CM
Network Health, NH
Enterprise Online, EOL
Automated Asset Manager, AAM
• You can purchase CM alone and add AAM at
anytime
• Or you can purchase a NH System and add
EOL, etc…
Automatic Messaging
•
(Automatic) Work
Order Generation
RSMACC binds process information from intelligent assets
and RSMACC internal systems & messaging to MAXIMO to
facilitate WORK ORDER generation and tracking
–
Predictive Interaction
• Process data like…
–
–
–
N:7:0 > desired level
» A work order for checking/calibrating the thermocouples
should be issued
Operator interface sends signal requesting maintenance on
machinery based on a reading or operator input
Reactive Interaction
• An intelligent sensor or device is malfunctioning
–
Photo eye signal is degrading, work order issued to clean
• RSMACC detects that an assets configuration does not match
the master on file
–
Work order created to asses the situation a
• RSMACC detects a security violation
–
Message sent to IT or Security to investigate issue
• Process data
–
B120/12 not 0
» A work order for fixing a leaking valve should be issued
• RSView SE Interface for Work Order generation/messaging
–
Track status of work orders & data
•
•
Plan for work based on status & changes
Adjust schedules and priorities of planned work
MAXIMO
Automatic Messaging
• A lot of plants are struggling with the
increased work load including increased
complexity of systems.
– Consequently plants have moved to more of a
run-to-failure, RTF, mode for some
maintenance
• This is as expensive in some cases as hiring
more people and doing preventive maintenance
• A balanced approach is more appropriate based
on individual requirements
– This type of system is deigned to help in the
balance between RTF and total PMS
• Moving some appropriate systems to Reactive
models
– Compensates for not having time to do PMS
– Facilitates better time management
– Facilitates a more appropriate cost model for
maintenance
(Automatic) Work
Order Generation
MAXIMO
RSMACC Systems
• RSMACC Systems architecture includes some
basic functions like
– Reporting
• Both manual ad-hoc and automatic
– Security
– Service Monitoring
– Archive
Manual & Automatic Reporting
• RSMACC can be configured to generate
automatic reports for changes to machines
and their respective assets.
– For instance, a maintenance manager might
want a report for changes that occurred over
the weekend or during the past evening.
Manual & Automatic Reporting
• Other Uses For Reporting
– Generate a morning report for Maintenance/
Engineering Manager review showing ALL
changes to PLC programs during 2nd and 3rd
shift
•
•
•
•
Forces
Empty branches
Changes to rungs, ignoring value modifications
All employees that made modifications
– Generate a weekly report for the Plant
Manager showing all programmable assets
that have been modified by name
– Generate a report monitoring critical
applications (e.g., pasteurization process) that
have not been changed
System Planning & Architecture
Common Architecture with Plug-In Functions
–
–
RSMACC Server & RSMACC Client common to all applications
Plug-In Functions
• RSMACC Network Health
–
Monitor, report, and diagnose device and network health
• RSMACC Automated Asset Manager
–
Automate preventive, predictive, and reactive maintenance
• RSMACC Enterprise Online Condition Monitor
–
Integrated automation condition monitoring
• RSMACC Change Management
–
Authenticate, audit, archive, and verify device configuration
System Planning & Architecture
Recommended Platform Requirements:
•
•
•
•
•
•
RSMACC Server(s)
Windows 2003 Server
Windows 2000 Server
w/SP4
Pentium 4, 2GHz or
more
1GB RAM
1.5GB free on system
volume
20GB shared volume,
RAID-5 capable
–
Only if hosting
Microsoft SQL 2000
Server
RSMACC Client
• Windows 2000 w/SP4
or XP Pro SP1
–
DO NOT USE XP SP2
• Pentium III, 500MHz
• 256MB RAM
• 1GB free on system
volume
System Planning & Architecture
Ethernet TCP/IP / Microsoft Windows Domain
`
Windows 2000
Server PDC
RSMACC Server
Service Monitor
Security Server
Administration Utilities
Verification
PLC5
SLC500
ControlLogix
PanelView
Reporting
RSLogix 5
RSLogix 500
RSLogix 5000
SQL Server 2000
Profile dB
Event & Audit dB
Archive dB
Tables
Stored procedures
RSMACC Client
Security client
Archive client
RSLogix 5
RSLogix 500
RSLogix 5000
System Planning & Architecture
Ethernet TCP/IP / Microsoft Windows Domain
`
Windows 2000
Server PDC
SQL Server 2000
Profile dB
Event & Audit dB
Archive dB
Tables
Stored procedures
RSMACC Server
Service Monitor
Security Server
Administration Utilities
Verification
PLC5
SLC500
ControlLogix
PanelView
Reporting
RSLogix 5
RSLogix 500
RSLogix 5000
RSMACC Client
Security client
Archive client
RSLogix 5
RSLogix 500
RSLogix 5000
Assets’ Influence on Objectives
Each asset no matter how large
or small is linked to the next asset.
Even the smallest
change can affect operations!
Common System Objectives
improve maintenance staff effectiveness
reduce risk to production
disaster recovery
monitor & protect systems
improved site security
keeping employees safe
complying with regulations
reducing commissioning time & cost
Water Supply & Water Treatment System Benefits
• Reduction in long term operating & maintenance costs and lowering
the risks to the community served by…
– Improve maintenance staff effectiveness
• Root cause analysis & locked door device analysis automatically
• Monitor & protect systems
– Monitor devices on networks for abnormal operation including degradation or failure
– Automatic integrated condition monitoring including notification
• Automatic tracking of versions with security on all production intellectual
property
• Messaging (email) appropriate personnel
• Facilitate more migration from reactive & preventive maintenance to predictive
& reactive maintenance models
– Increase site security for device access
• Creating audit trails for asset configuration changes, detect unwanted changes
• Back up asset intellectual property to a secure system for disaster recovery
• Store every version of asset configurations in a secure system for archival and
retrieval
• Automatic verification of some device configurations against controlled masters
– Extend service life of equipment through verification, condition monitoring
& security
What’s next…
• Action…