I work with a lot of engineers and other mechanically minded people, but I don’t know many that work on their own cars. Maybe an oil change here or there, but the sophistication of today’s engines and internal networks makes DIY work so impractical that it really must be left to specialists. The same idea applies to much of the technology used in process manufacturing today. Think of the differences between a mechanical pressure gauge compared to our Rosemount 3051S Pressure Transmitter, and you get the idea.
Where does that leave our customers? Are there still armies of instrument techs and specialized maintenance people left in chemical plants and refineries in the real world? While there may be some, the likely answer is no, or at least far too few. Our solution for this conundrum is the topic of my article in Processing magazine, Employing Predictive Maintenance as a Service to Improve Operations. This is the first installment of a three-part series, so more will follow looking at specific areas in greater depth.
The situation leaves a company considering what areas are critical enough to keep in-house, and what should, or must be farmed out.
A facility will likely buy services for commoditized tasks such as electric motor repair, or it will have highly sophisticated equipment, such as an analyzer, serviced externally. Internal maintenance efforts are usually reserved for specialized process equipment where both critical skills and timing are paramount. For most companies, the list of maintenance tasks kept in house has declined.
Where does your company fit into this picture? If the control room loses view of a critical process variable, is it due to the instrument transmitter, the device-level network, the automation host system, or something else altogether? How quickly can you solve the problem? Do you have the necessary people in the plant ready to respond? Was that instrument sending out a diagnostic warning that something was wrong before it went dark?
The personnel to perform basic maintenance functions are universally available, and the skills necessary are largely the same at any process plant or facility. However, in today’s plants, there is required maintenance at a higher level to keep sophisticated instrumentation, device-level networks and automation host systems operating flawlessly to maintain optimized processes. This convergence of operational technology (OT) and informational technology (IT) also presents unique challenges in process plants.
OK, that presents a major problem because such highly skilled people are hard to find and retain in most plants. Your local motor shop and even many traditional maintenance contractors can’t handle it either. What’s the solution?
Maintenance-for-hire will fix things that are broken. Some sophisticated providers may even use predictive techniques in strategic situations, but a true lifecycle services provider will help their client’s teams work safer, smarter and faster by enabling them to make better decisions. Plant personnel gain efficiency, productivity and clear insight thanks to the services and solutions provided by partner firms.
So, what does that look like?
Emerson Measurement Lifecycle Service’s approach for instrumentation assets provide end users with an outcome-focused, service-based solution. Relationships are built by transforming the way maintenance, calibration and repair tasks are handled — with a goal of delivering sustainability, reliability and uptime. These services help process manufacturers safely optimize facility performance, monitor overall equipment effectiveness (OEE) for those assets and develop strategies to fulfill their business goals.
The article goes into more detail, so give it a full reading. It explains how these services work, and what our client companies have come to expect.
Utilizing efficiency tools such as automation, continuous monitoring, optimization, and performance services provide for timely, data-driven decision making when it comes to maintenance and repair, while ensuring safety and reliability remain intact. Our services keep facilities operating safely, consistently, and economically, improving asset reliability and return on investment.
Visit the Emerson Measurement Instrumentation Lifecycle Services page at Emerson.com.
