Slide 1

© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners. Juan Collados AV-11 Condition-Based Maintenance

Slide 3 Overview Introduction What is Condition Manager? The Niche The Solution Value Proposition Case Study: VECTREN Power

Slide 4 Condition Management Challenges Moving From Re-active to Pro-active Operations Maximize Reliability and Availability, Balanced with Utilization while managing complexity Managing the huge number of devices and assets from many different suppliers Building and maintaining operations expertise as workforce ages Provide Collaboration environment for Operations and Maintenance

Slide 5 The Opportunity Reduce unplanned outages What is the cost of one hour of downtime? 5% average production loss per annum due to unscheduled downtime Reduce downtime More timely and effective responses to issues More effective shutdown/turnaround Reduce unnecessary preventive maintenance 30 to 50% of preventive maintenance is unnecessary Can represent 10 to 20% of total maintenance cost Source: ARC

Slide 6 What is the Invensys Condition Manager Solution? An easy-to-use, rules-based asset condition manager that intelligently and automatically raises alerts to actual or potential problems.

Slide 7 Condition Manager Allows organizations to move beyond simple calendar based maintenance Proactive condition-based maintenance Empowers operators by providing the ability to track maintenance activity associated with an asset Increases asset availability by reducing unplanned downtime

Slide 8 Well Connected Aggregates real-time data from leading plant floor systems Plant Historians Modeling Engines Field Device Monitoring solutions Standard OPC client interface simplifies integration with other advanced monitoring technology

Slide 9 Solid Foundation Employs MSMQ and Web Services for exchanging data with the Enterprise Asset Management system Option to send BizTalk alerts when conditions are triggered

Slide 10 Value Proposition Improved Asset Availability and Reliability Ensures necessary availability to support production goals Avoids unplanned outages through early detection and improved planning Delivers availability at the lowest possible cost Extends equipment life Improves resource utilization The CM

Slide 11 Key Messages Unique, intelligent real-time condition management solution that collects and analyzes real-time diagnostics from all plant production assets Provides early failure detection to increase asset availability, reduce costs and avoid unnecessary maintenance and downtime Supports continuous improvement through integrated workflow management driving appropriate action to improve overall asset performance Provides operations, engineering, and maintenance with easy access to current asset information for better decision making to help optimize asset contribution over its full lifecycle

Slide 12 Operations (asset utilization) Maintenance (asset availability) Process Control Loop Logic Control Production Management Operations Management Supply Chain Management Industry Unit 1 Solution Industry Unit 2 Solution Industry Unit n Solution Industrial Energy Management System Condition Monitoring Plant Asset Management Enterprise Asset Management Instrument Condition Tracking Valve Condition Tracking Pump Condition Tracking Other Device Condition Tracking Performance Convergence Alarm Management Loop Management Loop Analysis Security Analysis Operation Dashboards The Layers ERP MES Plant Business Control Focus at the Business Level Driving economic performance measurements and improvements from all plant resources. Plant Operational Control Focus around equipment sets or groups Driving asset availability and asset utilization measurements to achieve local optimum. Asset Management Focus around field device/equipment Driving asset availability and asset utilization measurements and improvements in component assets.

Slide 13 Think of CM in 3 Simple Stages 1. Collect – Data Sources include intelligent field devices, historians, asset performance models, and OPC diagnostic sources 2. Analyze – Single to multi-variable rules based engine, simple and complex expressions, advanced statistical process control (WER), thresholds, etc… 3. Act – Automatic generation of Work Orders, Work Requests, Equipment Activity Records, s, MS BizTalk, Workflows, etc…

Slide 14 Condition-Based Maintenance Approach Configuration Engine Asset Register

Slide 15 CM Configurator Runtime Hours Starts & Stops Device Status Device Parameters Avantis Entity The CM Configurator is used to associate Real Time Points, Models and Intelligent Devices with Avantis Entities for the purpose of generating maintenance events. This is accomplished with drag 'n’ drop ease of use.

Slide 16 Condition Manager Components Repair: Operations \ Event View Maintain: Asset Registry The Maintenance View Inspect: Configuration Environment One Integrated Business Process

© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

Slide 18 Understand the Starting Point Culture –Willing and ready to change –Recognize the issues Business Processes –Current, optimized –Built on best practices and benchmarks? –Measurement Systems in place Corporate Knowledge –Available, Accessible Technology Base

Slide 19 Case Study ●Vectren Corporation (NYSE:VVC), is a progressive energy-holding company headquartered in Evansville, Indiana ●Delivers gas and/or electricity to more than 1 million utility customers in Indiana and Ohio Challenge –Streamline Maintenance work and Equipment processes –Drive down the cost of unplanned work Reasons for choosing Avantis –Ability to integrate a condition based maintenance strategy –Windows look and feel –With the wide range of users – Janitors, mechanics, supervisors, skills development was required

Slide 20 Condition-Based Maintenance - BEFORE Over 15,000 separate equipment readings archived in Honeywell PhD data historians at two power plants. Temperature Vibrations Gallons RPMs Temperature Hours Data Historian

Slide 21 Condition-Based Maintenance - AFTER Readings Work Request Work Order Page Data Historian Condition Manager

Slide 22 How has CM Changed Vectren’s Overall Business? ●Time and money saved because PM work done by need and not by schedule ●Fewer outages ●Improved responsiveness to bad situations ●“Automated eyeballs” do work formerly done by engineers allowing them to do other work ●Users given autonomy to determine entities, monitoring points, details and outputs ●No regulatory or safety compliance issues ●Pages or s sent on all triggering events ●Work requests automatically created ●Statistics passed to Avantis

Slide 23 Types of Equipment Monitored ●Motors: hours, temperature, RPMs ●Pumps: amps, hours ●Fans: temperature, vibrations ●Filters: hours ●Air compressors: hours, temperature ●Monitors: PPM, pH ●Generators: temperature ●Air blowers: hours ●Turbines: vibrations ●Storage tanks: gallons

Slide 24 Voice of the customer: Vectren “Automated Eyeballs. Instead of wasting an engineer’s time reviewing charts, that engineer is freed-up to do other tasks.” “If you are creative, you can have CM create a Work Request well ahead of anyone noticing the change.” “CM is a tool that provides a very cost effective way to optimize PM programs. Through its creative application we have improved reliability and avoided costly emergencies.” “The PM functionality alone provides enough savings to pay for the CM implementation.” “The value added proposition is in the early detection of change, well ahead of any problem. Forewarned is forearmed. You can plan, schedule and in some cases budget for the problem. You own the problem, instead of the problem owning your operation.”

Slide 25 Copyright 2009 ExperTune, Inc. Questions?