Presented by The Emerging Role of the PI System in Caterpillar’s Condition Monitoring Service David Krenek – Global Petroleum Market Professional

Caterpillar Electronic Data Condition Monitoring Service Utilize Electronic Equipment Data Proactively Reduce Unscheduled Outages through Early Warning of Pending Component Failures 2 Increase Productivity Limited Resources Stranded Data Remote Sites Unattended Operation Limited Site Expertise More Complex Equipment

Background – B.P. (Before PI) Proof of Concept – Find Exceptions In Data –SmartSignal Epi-center –Validated non-parametric, multi-variate method Gaps Identified with Other Processes –Robust Data Management System to Achieve High Velocity, Scalable Solution –Additional Analysis Tools to Determine Root Cause –Effective 2-way communication between Analyst and Site Personnel is critical to cycle time and accuracy of recommendations –Quick access to related data to reduce cycle time. Events and Diagnostic Messages Component History Planned Maintenance –Automate, Automate, Automate 3

PI System Role – Initial Plan 4

Current Implementation 5

Discovered Benefits An Analytics Complement EPI-center for slow developing issues PI System for short duration, intermittent issues EPI-center for identifying unknown or obscure relationships PI System for Notifications of identified relationships 6

Discovered Benefits PI AF - Security –Network –Data PI AF - Scalability 7

Discovered Benefits Connectivity Flexibility –Cell –DSL –Customer Network –PI-to-PI Interface –Other Historian to PI System 8

Component History & KPI’s 9

The Value of High Fidelity Data Are these trends from different processes? 10 Maybe Not!

11 Events & Diagnostics TimestampCodeDescription 27-Nov-11 21:11:071045Low Intake Manifold Pressure 27-Nov-11 21:11:22242Engine Overload 27-Nov-11 21:12:02411Cylinder #11 Detonation The Value of High Fidelity Data - Transients 1-minute scan rate Provides some insight of events 1-second scan rate Provides more detail of process variability Exposes “missed” events

Link Engine Alarms to Engine Conditions 12 The Value of High Fidelity Data - Transients

Event begins and ends in 3 minutes! 13 Desired Air Pressure (Red) is less than Actual (White) Engine Commands Wastegate (Blue) to close Air Pressure Not Increasing Command Now Full Closed Low Pressure Alarm Active Increasing Air Pressure Indicates Wastegate has Closed Low Pressure Alarm Active Increasing Air Pressure Indicates Wastegate has Closed The Value of High Fidelity Data - Transients Engine Indicated Load Peaks (Cyan) and Overload Fires Conclusion Driven Equipment was not overloading engine. Event was related air management system. Recommendation to Service Provider: Inspect/Repair at next scheduled Shutdown Wastegate Bushings Linkage Actuator

Derived Data Making Data More Meaningful – PI Totalizers 14 Raw Data Combustion Time Raw Data Combustion Time Processed Data Misfire Processed Data Misfire Derived Data Visualization of Raw Data May Not Provide Much Insight A Different View of the Data May Provide Better Insight.... For example Lizard in a Pond.... Raw Data of JPEG Lizard in a Pond.... Processed View of JPEG

Data Enhancement Noisy Signal will delay persistence condition for EPI-center 15 Filtered Signal Improves visualization and analysis

Data Enhancement Improve Model Fidelity and Reduce Model Maintenance Process Gas Suction Temperature varies by day and by season 16

Signal Processing Temperature ratio is a function of Pressure Ratio Using Temperature Ratio Function Reduces Model Maintenance and Improves Visualization. 17 Cylinder #1 Suction Valve Repaired Cylinder #3 Discharge Valve Repaired Cylinder #1 Suction Valve Repaired Cylinder #3 Discharge Valve Repaired Cylinder #5 DischargeValve Repaired

Operator Engagement Operator Engagement Reduces Cycle Time and Errors Visuals Improve Operator Knowledge Increased Operator Knowledge builds Trust 18 Operator changed Air Inlet Filter with Engine Running

Filling the Gaps Robust Data Management System to Achieve High Velocity, Scalable Solution –The PI System –AF Additional Analysis Tools to Determine Root Cause –ProcessBook –PI DataLink –Performance Equations –ACE Calculations –PI Totalizers Effective 2-way communication between Analyst and Site Personnel is critical to cycle time and accuracy of recommendations –PI WebParts Quick access to related data to reduce cycle time. –Events and Diagnostic Messages PI ProcessBook, PI Notifications –Component History – AF, PI WebParts –Planned Maintenance Automate, Automate, Automate –Continuous Data Feed From Site to Analytics Modeling – PI System –Adding Assets - AF 19

Parting Thoughts – What We’ve Learned The PI System’s Emerging Role –It is THE Core, Central Time-Series Data Management Tool –It is a Critical Analytics Element Events & Diagnostics Can Be Valuable Leading Indicators Well Constructed Visualizations Improve Understanding of Events Every “Save” Counts 20

21 David Krenek Market Professional Petroleum Group Caterpillar, Inc Northwest Freeway Suite 1010 Houston, Texas Brought to you by