Maintenance in instrumentation Maintenance with concept and technology focusing on results www.andritz.com Specific knowledge for reliable instruments. Analytical instrumentation Due to its close relation with operation and process control, Instrumentation is a fundamental discipline to In Analytical Instrumentation, Maintenance continued process industries. Maintenance Solutions Division of ANDRITZ offers to Clients maintenance Solutions Division of ANDRITZ offers ser- contracts, as assuming the responsibility of managing and implementing conventional Instrumentation, as vices ranging from factory’s analyzers to managing specialized modules, such as analytics, metrology, automation and valves. a complete maintenance structure. MS Division can also assume full responsibili- Conventional instrumentation ty of the function, from the management of analyzers’ performance to the purchase Differentials and importation of spares. The purpose is to provide even more reliability to analytical ▪ Active in the management of contracts since 1993 process and environmental variables. ▪ Experience in major projects: “greenfield” and “brownfield“ Scope of the function ▪ Large specific instrumentation training bank ▪ Control loops in general ▪ Technologies integration capacity, ranging from pneumatic ▪ Field instrumentation and accessories nstrumentation through Fieldbus ▪ Primary measuring elements: sensors, Differentials ▪ Technological exchange between the diverse hired contracts Scope of the function detectors and meters ▪ Pioneer in Brazil in analytical instrumentation contracts, active in ▪ Management systematics and remote support ▪ Field instrumentation: pneumatic, analogical, this modality since 1992 ▪ PH meters digital, intelligent and radioactive ▪ Largest number of contracts of this nature, catering to more than ▪ Conductivity analyzers 3,500 process analyzers and 3,200 pieces of laboratory equipment ▪ Control valves ▪ Gas analyzers ▪ Application engineering team of engineers and technicians with ▪ Image systems: cameras and monitors wide experience in Analytics ▪ CEMs ▪ Electronic and pneumatic instrumentation ▪ Sindus PAC - online predictive monitoring system for all factory analyzers ▪ Chromatographs laboratory ▪ Technological support and parts from the analyzers’ division, which has been ▪ Sampling systems ▪ Valves workshop developing and manufacturing analyzers and sampling systems since 1988 ▪ Opacimeter ▪ Web learning, through interchange between MS Division’s various contracts and partnerships with strategic suppliers ▪ Turbidimeters Structuring activities: Routine activities: ▪ Specialty certified through ISO 9001 since 1998 ▪ Silica analyzers ▪ Definition of assets criticality ▪ Maintenance strategies ▪ Consistency analyzers ▪ Definition of families of equipment ▪ Routine and shutdown planning ▪ Kappa, whiteness and ▪ Structuring of maintenance software: CMMS ▪ Implementation of improvements Activities residual analyzers (Computerized Maintenance Management System) ▪ Time and condition-based preventive maintenance ▪ Strategies of maintenance and service ▪ Refractometers, etc. ▪ Definition of maintenance policies per families ▪ Planned and emergency corrective maintenance ▪ Preventive maintenance plans and inspection routes of equipment ▪ Detective and predictive maintenance and inspection routes ▪ Preventive, predictive, corrective and proactive maintenance ▪ Elaboration of maintenance plans and procedures ▪ Technical-managerial reports ▪ Tuning of control loops ▪ Engineering of maintenance and application ▪ Issuing of ISO 9001 and 14001 working manuals ▪ 24h assistance with technicians on call support and instructions ▪ Metrological management ▪ Online predictive monitoring of analyzers ▪ Monitoring and support in audits ▪ Definition of spare parts ▪ 24 hour assistance ▪ Technical procedures and checklists of calibration and maintenance ▪ Improvements in problematic sampling systems ▪ Registration of technical information ▪ Technical management of materials ▪ Spare parts lists and technical management of stocks ▪ Suppliers research, purchasing, imports and ▪ Organization of technical documentation ▪ Issue of technical and managerial reports ▪ Control indicators and monitoring systematic nationalization of spare parts Valves Metrology As a final control element extremely critical to Maintenance Solutions Division of ANDRITZ the productive process, the specialized ma- strives to provide greater reliability in nagement of the Maintenance Solutions Divi- measurements, additionally to meet me- sion of ANDRITZ in the Valves function ma- trological requirements of ISO 9001 and kes a tremendous impact on the product’s ISO 14001 regulations, in issues related to quality, energy and chemical consumption, monitoring and measuring. as well as operational availability. Furthermo- To ensure that systems provide accurate re, a large part of the instrumentation budget information, it is necessary to have syste- goes to this category of equipment. matic metrological control over them, by means of calibrations with results that are traceable and with estimated uncer- tainties, so as to control and maintain measurement errors of systems within the acceptable levels for measuring purposes. Differentials Scope of the function ▪ Experience: active in this segment since 1993 Differentials Scope of the function ▪ Instruments registration ▪ Managerial approach (peace of mind for the customer) ▪ Control valve’s management since 1993 ▪ Physical identification of instruments ▪ Control and on/off valves ▪ Orientation for measurement reliability (gains in quality ▪ Valves Technical Center: repairs in valves, actuators and positioners, carrying out ▪ Safety valves and productivity) ▪ Management of standards calibration analysis of failures root cause and control of valve signatures ▪ Exclusive software for metrological management purposes ▪ Manual valves ▪ Planning of calibration interventions ▪ Maintenance Solutions Division of ANDRITZ guarantees to clients access to the ▪ Specialty certified through ISO 9001 since 1998 best technological solutions from each supplier, assisting in the choice of the best ▪ Actuators ▪ Calibrations execution alternative from cost and performance’s point of view. ▪ Conventional and intelligent ▪ Critical analysis of suppliers’ calibration certificates ▪ Activities Over 12,000 control valves under MS Division’s responsibility positioners ▪ Maintenance of calibration registers ▪ Proprietary offline valve analysis system ▪ Implementation and maintenance of routines for the metrological control of instruments ▪ Indicators surveys Sindus-OPP valves ▪ Definition and documentation of quality procedures ▪ Periodicity adjustments in instruments Valves module with capacity of performing predictive online monitoring even in valves associated to metrology ▪ Communication of non-conformities identified without an intelligent positioner. ▪ Control of instruments calibration expiring date in instruments ▪ Calibration scheduling ▪ Participation in quality audits of second and Activities ▪ Calibration with proprietary methodologies third parties ▪ Emission of calibration certificates ▪ Maintenance and application engineering ▪ Planned and emergency corrective maintenance ▪ Selection and follow-up of calibrations carried out ▪ Organization of calibration registers and other associated ▪ Failures analysis / continuous improvement ▪ Management of online valve predictive networks by other suppliers documents ▪ Routine and shutdown planning ▪ Redimensioning and reliability of stock ▪ Critical analysis of calibration registers ▪ Emission of non-conformity reports ▪ Predictive maintenance and inspection routes ▪ Technical management of services in the workshop ▪ MSA (Measurement Systems Analysis) studies (trends, ▪ Improvement of existing measurement systems ▪ ▪ Monitoring and support in audits Time and condition-based preventive maintenance R&R, stability and linearity) ▪ Monitoring and support in audits Automation Automation In the area of Automation, Maintenance Solutions Division of ANDRITZ is active in digital systems for process control, invol- ving maintenance, configuration and im- plementation of improvements in several groups of equipment and processes. Differentials Scope of the function ▪ Industrial communication boards ▪ Configuration and maintenance ▪ Automation management experience in big industrial groups since 1993. and networks ▪ Programmable Logic Controllers (PLC) ▪ Automation projects development capacity integrating several technologies ▪ Distributed Digital Control Systems and manufacturers. ▪ Control CPU (DDCS) ▪ Existing contracts with full remote access to engineering stations or PLCs ▪ Engineering stations ▪ Information systems networks, thus expanding the capacity of remote technical support by experts. ▪ Wide range of specific trainings in automation. ▪ Operation stations ▪ Plant Information (PI) software ▪ Technological interchange systematic between contracts. ▪ Video monitors ▪ Supervisory ▪ Use of the Sindus OPP tool. ▪ Peripheral devices ▪ I/O units Automation Activities ▪ Establishment of preventive and ▪ Corrective maintenance ▪ Maintenance engineering, predictive maintenance plans ▪ Interlocking diagnosis improvements and failure analysis ▪ Planning and scheduling of ▪ Control loops tuning ▪ Maintenance record management interventions on equipment ▪ Review of control strategies ▪ Maintenance of technical documentation and programs ▪ Configuration activities ▪ Specification and approval of ▪ General