Condition Based Maintenance:

Use Real-Time Equipment Data to Reduce Downtime

Matrikon, Inc.
 2

Copyright © 2005 Matrikon, Inc. All rights reserved. The information contained
in this document is proprietary to Matrikon, Inc. No part of this document may
be reproduced, stored in a retrieval system, translated, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, without prior written permission from Matrikon, Inc.

Toll Free: 1.877.MATRIKON (1.877.628.7456)

In North America: 1.780.448.1010
In Australasia: +61.2.4960.1000
www.matrikon.com
 3

INTRODUCTION
Industry Pacesetters use real-time equipment data
to prioritize and optimize their maintenance
resources. The process is straightforward in
concept: simply use real-time data to determine the
equipment health, but only inform the Computerized
Maintenance Management System (CMMS) when
maintenance is actually necessary. From there, the
CMMS automatically produces the work-order and
uses the workflow that is already familiar to all
Maintenance personnel.
Pacesetters take two steps to achieve this goal.
First they acquire and store real-time process data from their Automation system (sometimes called
SCADA or DCS). This automated data acquisition enables the Pacesetters to consistently have access
to timely and accurate measurements. Second, the Pacesetters establish a Condition-Based
Maintenance (CBM) system that uses the stored data to determine equipment health. The CBM
system makes intelligent decisions regarding Work-Orders, thus enabling Maintenance to focus on
activities that have the most impact on their operation.

AUTOMATED DATA ACQUISITION PROVIDES TIMELY AND ACCURATE MEASUREMENTS

Pacesetters use their existing Automation systems to
collect real-time equipment data at regular intervals
using standards-based software. OPC is the de facto
communication standard for acquiring real-time data
and is based on industry tested Microsoft
technology. In fact, every Automation system that is
able to communicate with the outside world can be
retrofitted with OPC. Available since 1996, OPC has
spread to every industry.
Software applications use OPC to acquire real-time
data, and make the archived information available to
external systems. By automating the data collection,
Pacesetters eliminate the slow and error-prone
manual labor that is typically required. For example,
reading metered data from one computerized system
or measuring equipment health with stand alone
instruments, recording it, and then entering it into a
computerized maintenance system. Consequently,
Figure 1: In the first step, Pacesetters use
Pacesetters are able to access the latest data on
software applications to capture metered
demand. They are also comforted by the fact that the equipment values in real-time using the OPC
data was recorded exactly as it was in the original communication standard.
Automation system including all values and
timestamps. The precision and frequency of data acquisition enables organizations to use a true CBM
program.

CONDITIONS-BASED MAINTENANCE USES REAL-TIME DATA

Once they capture real-time data, Pacesetters implement a Condition-Based Maintenance (CBM)
program that enables them to optimize their Preventative Maintenance efforts. The problem with
traditional Preventative Maintenance is that all maintenance is scheduled on a periodic, regular basis

Toll Free: 1.877.MATRIKON (1.877.628.7456)

In North America: 1.780.448.1010
In Australasia: +61.2.4960.1000
www.matrikon.com
 4

regardless of equipment usage and operating condition. Thus, equipment that is rarely used will
receive the same amount of maintenance as frequently used equipment. As well, equipment that is
used under harsh operating conditions will be maintained as little as equipment that operates under
ideal conditions. Consequently, some equipment is maintained too often, thereby increasing
maintenance costs unnecessarily, and yet other equipment suffers undue wear-and-tear while waiting
for its scheduled maintenance. This results in expensive repair costs that could have been avoided,
and more importantly ignores required maintenance activities that should be performed immediately.
This helps with the prevention of unscheduled downtime because Maintenance can handle problems
proactively, before they grow into more serious issues.
Pacesetters understand the key measurable factors that influence their equipment performance, and
therefore, condition. Since these factors can be measured, software applications can automatically
monitor them and alert Maintenance only when the equipment condition necessitates action.

Getting started with CBM

The most obvious factor to measure is equipment Runtime (or Running) Hours. By acquiring the
real-time data, the CBM system can determine when the equipment is running and automatically
count the Runtime Hours. Once the count reaches the manufacturer-specified limits, the CBM system
can immediately alert the CMMS.
The CBM system can then be augmented by taking other factors such as vibration analysis,
temperature readings, fluctuating flow rates, and others into consideration. That is, if the operating
conditions are especially harsh, these factors will alert Maintenance long before the Runtime hours
are exceeded, which will prevent premature damage. Furthermore, equipment that operates under
optimal conditions may be able to operate long past its prescribed Runtime Hours thus saving undue
maintenance. While these factors provide an excellent basis for CBM, software applications can use
measurement from the process itself to determine equipment health.

Figure 2: In the second step, Pacesetters implement CBM systems that assess equipment health based
on timely and accurate information. This enables them to optimize maintenance efforts because the
CMMS only generates Work Orders when they are truly required.

Toll Free: 1.877.MATRIKON (1.877.628.7456)

In North America: 1.780.448.1010
In Australasia: +61.2.4960.1000
www.matrikon.com
 5
Process alarms can pinpoint malfunctioning instruments
The CBM system can incorporate alarms from the Automation system to help identify malfunctioning
instruments. At first, the alarms slowly stream out of the Automation system. So it takes keen
observation (and considerable time) for the operators to recognize the pattern of repeating alarms,
especially if they span multiple shifts.
By capturing these alarms, the CBM system can quickly determine that the number of alarms for a
specific instrument have exceeded a preset limit over a period of time. The CBM system can inform
the CMMS that the instrument should be inspected, which will automatically trigger a Work Order
Generation. This enables Maintenance to recalibrate or repair the instrument even before Operations
is fully aware of the problem, thus eliminating potential hazardous operating conditions and urgency
associated with unscheduled shutdowns.

Complex equipment benefits from monitoring of multiple factors

The CBM system can associate multiple metered equipment values to calculate an overall equipment
health factor. For instance, a feedwater pump might require the lube-oil pressure to be at a different
reading when it idles than when it is at full capacity. Consequently, placing high and low alarm
points on the lube-oil pressure may not be accurate at different operating conditions. Process
analysis software determines the relationship between the various metered equipment values and
their interactions. A normal relationship between the values indicates a good health factor. As well,
an abnormal relationship indicates a poor health factor, and is a warning that maintenance is
required.
Pacesetters use their CBM system to monitor the equipment health factors in real-time and inform
the CMMS when an abnormal relationship is detected (the feedwater pump operates at quarter
capacity, but the lube-oil pressure is still at full capacity levels). This issue is typically overlooked by
busy operators and frequently causes unscheduled downtime, production loss, or both.

Control loops can be maintained like traditional assets

The CBM approach to automation assets
treats control loops as though they are
physical assets, which enables
Maintenance to trigger Instrumentation
Work Orders based on the health of the
control loop. Industry studies show that
while 80% of control loops could use
some maintenance, only 20% are critical
enough to significantly impact the process
operation and demand immediate
maintenance. Unfortunately, most
organizations take a reactive approach
and the control loops are left to perform
inefficiently, or turned to manual
operation, which defeats the purpose of the Automation system altogether.
By implementing continuous health monitoring of critical control loops, Pacesetters significantly
reduce the work load of Instrumentation personnel. The CBM system notifies the CMMS to focus
Instrumentation’s efforts on the worst actors that have the most impact. This maximizes production
while simultaneously reducing the Maintenance workload and costs.

Toll Free: 1.877.MATRIKON (1.877.628.7456)

In North America: 1.780.448.1010
In Australasia: +61.2.4960.1000
www.matrikon.com
 6

CBM ENABLES MAINTENANCE TO PRIORITIZE ACTIVITIES

It takes Pacesetters two steps to optimize their maintenance efforts. First they automate their real-
time data acquisition and storage using standards-based software applications. Second, they
implement CBM systems that assess equipment health based on timely and accurate information.
This enables Pacesetters to prioritize their maintenance efforts by moving human and capital
resources away from well functioning equipment to areas that scream for early attention.
While at first it might seem that Pacesetters’ accomplishments are currently out of reach, most
corporations are indeed surprised to find out that these steps are easier to complete than initially
perceived. Using commercial-off-the-shelf software and standards-based applications, such tasks can
be completed economically and provide exceptional add-on value to the CMMS installations.

FOR MORE INFORMATION

For more information about real-time data via the OPC communication
standard, condition based maintenance or computerized maintenance
management systems, please e-mail your requests to
[email protected] or visit the following website links:
Condition Based Maintenance: www.Matrikon.com
Real-time OPC Communication Standards: www.MatrikonOPC.com
OPC Multimedia Tutorial: www.MatrikonOPC.com/tutorial
Figure 3: OPC Multimedia
Tutorial

Toll Free: 1.877.MATRIKON (1.877.628.7456)

In North America: 1.780.448.1010
In Australasia: +61.2.4960.1000
www.matrikon.com