|
Asset
Management in Pulp/Paper
Application
Asset
management tools for the automation industry have been available
for many years. These tools
are focused on streamlining maintenance tasks, troubleshooting
field devices, making ongoing maintenance more efficient and
documenting maintenance activities.
Saving time and avoiding expensive equipment failures are
key benefits to asset management programs.
A
large pulp mill’s reliability team launched a project to
evaluate critical maintenance tasks and improve system
reliability. During
this evaluation, it was determined that a large number of valves,
critical to system operation, were being removed during the annual
shutdown period for evaluation, repair and replacement.
Because the valves were critical to the operation of the
mill, it was considered necessary to physically check their
condition annually, even though the cost was high and frequently
revealed nothing was wrong.
The
team implemented a pilot program using Asset Management Software
to evaluate data from these valves. This allowed continuous
monitoring of their operation and reported their condition without
removing them.
The
mill uses Rockwell Automation ControlLogix PLCs for process operation.
The controllers are networked via Ethernet to a network
server that catalogs process data.
Spectrum Controls' Analog I/O Modules with HART Protocol
interface to the valves. Installation
cost was limited as no additional wiring to the valves was needed.
HART communication protocol allowed the user to retrieve
cycle and position data real-time.
The benefit to this system is significant.
Technicians are now able to perform fast troubleshooting,
minimizing the number of unscheduled shutdowns.
HART communication also allows faster and improved
diagnostics. Control
routines built around the HART data advise operators of alert
conditions and atypical system operation.
The
end result is an integrated system that not only improved
diagnostic capabilities but also improved control and monitoring
capabilities.
|
