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© Copyright 2016 OSIsoft, LLC 1
Data-Based Maintenance:
The Killer App of IIoTMichael Kanellos
Industry Champion, OSIsoft
© Copyright 2016 OSIsoft, LLC 2
Unplanned Downtime and Poor
Maintenance Cost Process Industries:
• 5% of their annual production
• $20 Billion in losses
• And 80% could have been
avoided
© Copyright 2016 OSIsoft, LLC
“A plant’s profitability is directly
proportional to the uptime of its
processes.”--Josh Lyon, Flowserve
3
© Copyright 2016 OSIsoft, LLC 4
So What Can You Do?
© Copyright 2016 OSIsoft, LLC
We Believe People With Data Can Transform Their World
© Copyright 2016 OSIsoft, LLC
The PI System: Operational Data into Actionable Insight
6
© Copyright 2016 OSIsoft, LLC
The PI System At Work For Renewables
310,000 sources, 250 data
formats, 140+ locations
8
Across Multiple Industries
Saudi Aramco eBay California ISO
© Copyright 2016 OSIsoft, LLC
Data-Based Maintenance
The Old Way:
monitor and fix
The PI System Way:
monitor and predict
9
© Copyright 2016 OSIsoft, LLC 10
The Data-Based Maintenance
Hall of Fame
© Copyright 2016 OSIsoft, LLC 11
Staying Out of
the Cold
Syncrude estimates
that data-based
maintenance saves
$16.75 per hour per
truck, or $20 million
per year. The
PI System also
helped reduce the
risk of certain types
of injuries by 85%.
© Copyright 2016 OSIsoft, LLC 12
Detecting
Turbine
Trouble
Maintenance can
cost 15x more at
offshore wind farms.
By reducing boat
trips with remote
monitoring, Dong
Energy believes it
can save 20 million
Euros a year by
2020.
© Copyright 2016 OSIsoft, LLC 13
Mastering
the
High Seas
Through the
PI System, Petronas
collects real-time data
to monitor the health of
offshore platforms
remotely. No more
flying out IT on
helicopters. The
PI System prevented
five unplanned
shutdowns in the first
year.
© Copyright 2016 OSIsoft, LLC 14
Plugging the
Leaks
San Francisco
Public Utilities
Commission
predicts it will save
about 9,600 hours of
labor and reduce the
risk of accidental
discharge by
monitoring 100
critical pumps with
the PI System.
© Copyright 2016 OSIsoft, LLC 15
Getting Good
Vibrations
Flowserve gives
customers real-time
performance
insights through the
PI System. One
customer avoided
$630,000 in losses
when a welder’s
blanket almost
clogged a pump.
© Copyright 2016 OSIsoft, LLC 16
Keeping The
Lights “On:
FINGRID
implemented a real-
time condition
monitoring system
and they have
avoided major
transformers
failures and several
proactive SF6 leak
detections
© Copyright 2016 OSIsoft, LLC 17
Navigating
the Polar
Vortex
Columbia Pipeline
Group has saved $9.6
million since 2002 by
using the PI System to
help manage its
15,000 mile natural
gas network. The
PI System also helped
Columbia avoid
potential outages
during the 2014 Polar
Vortex.