资产健康管理 (AHM)

Chinese chemical subsidiary of multinational corporation serves customers throughout the world. Sales offices and research and technology centers are strategically located to provide rapid response to customer requests. Just two workers were assigned to maintain thousands of intelligent instruments in three production units, so they could do little more than react to device issues as they appeared. This costly maintenance method inevitably led to unexpected downtime when a critical instrument failed. Plant management recognized the need to change from reactive to predictive maintenance for all assets, including instruments and control valves, but help was needed in implementing such a technology-based initiative.

Doug Gilroy and Mark Bayrock of Advanced Audio Concepts, a Vancouver-based systems integrator, were given free reign to design, install and operate River Rock's complex surveillance system. Gilroy had freedom to design the system with several unique aspects, such as the use of video balun technology to integrate quickly, and an innovative design in the tech room that makes it easier for the operator to spot problems. The integrators also had a long-standing relationship with Honeywell and chose to use Honeywell products almost exclusively throughout the installation.

Between 2005 and 2010, Aluar went through a substantial growth phase where most of the production facilities were upgraded. As a result of this expansion, the number of PLCs increased from 100 to 300. When it came to managing the control program software, however, flaws and cracks began to show in the established workflow and version control procedures that had prior to the growth phase, been based on manual backups and documentation. A rapid growth in the number of automation and maintenance staff (>100 users) also coincided with increasing accounts of infrequent and incomplete documentation of software versions, which then required an increasing effort where bug tracing and detection were concerned. This increased the risk of incidents that could not only affect operation, but that could also result in stoppages at the mid-term. It also increased the risk of safety risks remaining undetected.