Plant asset management

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The terms used in the art asset management and plant asset management are a derivative of the economics and business management concept used the asset management . Assets can be tangible and intangible, e.g. B. Production facilities or brand names and patents .

Under Plant Asset Management (PAM) is defined as the management of assets in the form of fixed assets of a company, specifically for the production are used.

definition

The basic concepts of plant asset management apply equally to the process industry and the manufacturing industry. In this article, the subject of “Plant Asset Management” (PAM) is considered from the point of view of the process industry. Assets in the process industry are considered (see committees 1–4):

  • Assets at the plant level
  • Assets at the level of the unit
  • Assets at the level of the investment part

Asset management is defined by the following tasks and goals (see Committees 1–2):

  1. Generation and provision of information, in particular about the course and prognosis of asset health.
  2. Organization of the use and maintenance of the assets
  3. Manage assets across their entire lifecycle. Identification, asset history, business and technical data are of particular interest

With the aim of:

  • an increase in reliability and efficiency
  • a reduction in replacement requirements
  • an increase in value through expansion of use

The entire life cycle of an asset generally includes phase planning, engineering, procurement, commissioning, operation, replacement and disposal. In contrast to asset management, plant asset management (PAM) essentially only considers the operating time (use in a company / plant) of the assets.

Differentiation of PAM from asset management

From today's point of view and for business and image reasons, it is important for a company to optimize the means of production in terms of your use and income.

In contrast to asset management, plant-related asset management (PAM) only relates to a certain part of the assets, namely to the plants and their lower levels in production. A plant is not understood as such, but rather an entire plant complex is defined as an asset. Depending on the type and complexity of a system, a subdivision can be made on the level of the sub-system and that of the system part. In the case of a subsystem, an entire part of a system is considered that can be defined and differentiated independently. The last level is that of the so-called system part. Here, the individual components are considered, which according to the Association of German Engineers (VDI) are described as static equipment, rotating equipment, machines, field devices, hardware and software .

Another extremely important aspect that distinguishes PAM from AM is the area of ​​the life cycle considered. General asset management looks at the entire life cycle, which extends from purchase to replacement parts. Plant-level asset management only considers a specific, but probably the longest and most important part of the life cycle: operation and maintenance. The other part not taken into account is covered by the so-called user groups, who access information from the PAM, but are not an essential part of it. Users are understood to be people who are close to other functional areas , e.g. B. Maintenance management or litigation . For example, data from the PAM are important for them; yet they are not an essential part of it. The environment can be set up differently, as it depends on the operating mode, size and product.

Model of the PAM

The model emerged from practical experience. The Association of German Engineers (VDI) has brought these empirical values ​​together in order to clarify relationships and logical sequences in plant asset management.

The plant asset management model

The assets are monitored. Diagnoses are determined from this monitoring. Promises for the future are made from the diagnoses. From this, plans and possible measures against occurring problems are derived.

All of these function blocks are permanently archived. This information is evaluated before it is made available to the user. They are evaluated, analyzed, compared with comparison values ​​and distributed to the right users.

Possible recipients are business economists, engineering, maintenance and operations management.

Tasks of the PAM

It is basically broken down into three main aspects. Assessment of the condition of assets, processing, provision and archiving of information, core tasks of interaction with the user.

Assessment of the condition of assets

  1. Performance Monitoring monitors the performance of the individual assets.
  2. The asset messages serve as an alarm function in the event of inappropriate or strongly fluctuating values. Messages can be configured depending on the system and plant.
  3. Condition Monitoring (CM) has been included as a very general term and can be defined in various directions. In general, it is used to record the condition and its subsequent evaluation.
  4. Signal monitoring keeps an eye on the asset with regard to its signal pick-up and then carries out signal processing.
  5. Functional test: in which the functional reliability of an asset is checked. This can be done automatically or by the operator.
  6. The condition diagnosis
  7. Maintenance request
  8. Behavior prediction
  9. Determining the usage reserve means that the system announces how long an asset will be used. This is made dependent on various factors.
  10. the therapy proposal. It defines the creation of measure proposals for the required function of the asset.
  11. The performance optimization creates proposals or regulation for an optimization process taking into account the performance of an asset.

Processing, provision and archiving of the information

  1. Master data management lays down a basis for the master data of a special asset.
  2. The asset history is understood to mean the chronological and systematic storage of this data.
  3. The version management ranks with the asset history, is defined as a task but explicitly because of its importance. It is used to manage the version history over the entire life cycle of an asset.
  4. Document management considered. It provides the asset-related documents taking into account the specific information of the asset.

Core tasks of interaction with the user

  1. Manage operator intervention. This describes nothing more than the recording and analysis of the activities carried out by an operator.
  2. Parameterization and configuration of the modules and components, which were selected or adapted for the task of the asset.
  3. In the case of operational reliability, one speaks of a qualification of the asset in the technical sense, based on the evaluated data. This proving is also one of the main tasks of the plant asset management and provides the qualifications with regard to the area.
  4. Business parameters, where instead of the technical assessment, there is a business assessment of the assets.

Due to different PAM models and requirements in the application, a PAM system does not have to fulfill all of the tasks mentioned.

Benefits of plant asset management

The permanent monitoring of the assets and the recordings of the system conditions allow conclusions to be drawn about the expected service life and the degree of wear. These analyzes enable demand-based maintenance, which lowers costs and the risk of failure of the assets. In addition, identified problems can be used to develop optimization processes that pursue the goal of increasing performance. This leads to an increase in efficiency and an increase in production.

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Bodies

  1. Technical Committee 6.23 “Plant Asset Management” of the VDI / VDE Society for Measurement and Control
  2. Working group 4.13 "Asset Management" of NAMUR "Interest group for automation technology in the process industry"
  3. Open O&M - Multiple industry standards organization - standards for the exchange of Operations & Maintenance (O&M) http://www.openoandm.org
  4. MIMOSA - Standards for Operations and Maintenance in manufacturing, fleet, and facility environments. http://www.mimosa.org
  5. ISA-95: the international standard for the integration of enterprise and control systems http://www.isa-95.com
  6. ISA-88 : the international standard for flexibility in production http://www.isa-88.com

literature

  • Plant asset management - where do we stand? - A. Horch - GMA Congress 2007
  • Sustainably increasing efficiency - five core theses on asset management - M. Büßelmann - Process, issue 11-2006
  • Asset-Management provides predictability for Process Industry - M.Büßelmann - SPS / IPC / Drives 2004, conference proceedings, Franzis Verlag
  • NAMUR recommendation NE 129: Plant Asset Management, Edition 10-2009, Leverkusen: Namur
  • NAMUR recommendation NE 033: Requirements to be met by systems for recipe-based operations. Leverkusen: Namur
  • DIN 31051: 2003-06 Basics of maintenance; (Fundamentals of maintenance) Berlin: Beuth Verlag
  • ICS 35.240.50, 71.020 Association of German Engineers: Guideline Plant Asset Management (PAM) in the process industry; Edition 09/09
  • J. Reichel, G. Müller, J. Mandelartz (Eds.); Operational maintenance; Springer 2009