We began exploring the key elements (5P’s) of Control System reliability and performance by looking at the considerations and recommendations around Protection with Cybersecurity. Here, we continue our examination of the 5P’s with:
Preventive Maintenance sets the foundation for the availability and peak performance of industrial control systems. Establishing processes and a regular cadence for experts to inspect, test, and maintain system components plays a crucial role in identifying and addressing potential issues before they degrade further into critical failures. Additionally, visits by experienced engineers help an organization lean on its unique expertise in identifying bottlenecks, optimizing performance, or simply recommending necessary adjustments and upgrades.
Preventive maintenance can be Utilization-based, Time-based, Predictive, or Diagnostic:
These strategies can help identify and address potential issues before they escalate to failures and downtime, ultimately maximizing and extending the lifespan of your control system assets. But no matter which one or combination of practices you employ, the following components are necessary to enhance the effectiveness of your maintenance strategy:
Holistic maintenance leaves nothing to chance
Aside from ensuring that critical tasks are not overlooked, having a standardized approach to preventive maintenance establishes consistency across periods and across multiple sites. This involves creating a comprehensive checklist for maintenance inspections and activities. The Preventive Maintenance Program Emerson developed for DeltaV distributed control system users includes an extensive roster of categories that service specialists review and check, including:
There are many other aspects of a control system that are checked as part of a comprehensive preventive maintenance program; these may include: batch system health, database performance, OPC integrity, operator interface, or even ad hoc procedures which may be required by industry regulations or requested by the site maintenance team.
The benefits of having a vendor-guided or delivered preventive maintenance program include close alignment with the control system development, ensuring that the checklists also evolve as new technologies are developed and integrated into the DCS.
People, Process and Tools combine for effective maintenance
The use of automated tools and collaboration technologies can greatly enhance a site’s preventive maintenance program. These not only ensure that no steps or elements are missed, but speed-up and streamline maintenance activities.
Some common maintenance tools and systems include:
In Emerson, results of preventive maintenance routines, including the standard report, are sent to an online collaboration portal accessible to both the customer and the local service team. This best practice ensures that both groups can visualize the results of the health checks conducted on the system and sees an updated action plan. Specific tasks are identified under this plan and assigned to either customer or vendor personnel which facilitates tracking to completion.
Reduce risk with certified engineers
A well-established certification process for service specialists ensures that vendor personnel coming to your site possess the necessary skillset and knowledge to handle your DCS and perform maintenance tasks effectively. This involves:
Together, these elements of standardized processes, diagnostic and collaboration tools, and certification programs constitute effective and holistic preventive maintenance. Without them, control system reliability and performance objectives will be difficult to achieve and sustain.
While some solutions linked above are mainly for Emerson DeltaV control system users, the concepts and principles should generally apply to any other Industrial Control System. If you want to learn more:
DeltaV Preventive Maintenance ensures the dependability and longevity of your system
The post 5Ps of Control System Reliability and Performance–Part 2: Preventive Maintenance appeared first on the Emerson Automation Experts blog.
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