Performance up, costs down

Industrial plants develop over many years. Measuring points are supplemented, modernized or adapted to new process requirements, often under high time pressure and with changing suppliers. The documentation of these changes often cannot keep pace with technical developments. Over time, this results in gaps, inconsistencies or outdated information about the installed devices. In practice, this has a noticeable impact on plant operation. Maintenance teams have to make decisions based on incomplete or scattered data. Maintenance strategies are based more on empirical values than on the actual condition of the devices.

As long as the measuring points are working, there is often no reason to systematically scrutinize these issues. It is only when a device fails, a replacement is needed at short notice or an intervention is required that it becomes apparent that components are no longer available, manufacturer-specific expertise is lacking or responsibilities are not clearly defined. In such situations, maintenance costs increase significantly, repairs are delayed and unplanned downtime can hardly be avoided.

Endress+Hauser's Dynamic Analysis of the Installed Base (DIBA) closes this gap by systematically recording, digitizing and continuously evaluating the installed base. All relevant information on the installed measuring devices is thus available in a structured and up-to-date form. On this basis, decisions in maintenance and lifecycle management can be
can be made on a sound basis, risks can be assessed in a targeted manner and measures can be planned comprehensibly throughout the entire life cycle.

Digital twins as a data basis

A central element of DIBA is the creation of digital twins of all assets in the system, regardless of the manufacturer. Each measuring device is uniquely recorded and enriched with relevant information. This includes device type, manufacturer, year of manufacture and installation, current condition, maintenance history, criticality, spare parts availability and the importance of the measuring point for system operation.
These digital twins represent the real installed base as it actually exists in the field. For operators, this creates a consistent, central database for the first time that can be accessed by various functions - from maintenance to engineering and purchasing. This significantly reduces the loss of information due to isolated solutions or outdated lists. For the first time, spare parts strategies, for example, can be defined on a risk-based and device-specific basis rather than across the board.

In the next step, the recorded data is analyzed and classified. This dynamic evaluation of the installed base makes it possible to switch from a reactive to a proactive maintenance strategy. Risks to system availability and compliance can be identified at an early stage and minimized in a targeted manner. At the same time, the cost of maintenance and spare parts inventory is reduced as measures are prioritized and easier to plan.

The digitally prepared installed base also forms an important foundation for standardization, automation and further steps in the digital transformation. Specific questions can be answered on this basis: Where is there a need for action in the short term? Which devices can continue to be operated without taking risks? And where is standardization worthwhile in order to simplify maintenance and spare parts management?

Updating during operation

A key practical aspect of DIBA is its dynamic nature. Systems change, requirements increase or shift, and productivity targets do not remain static either. This is why the analysis is updated regularly. New devices are incorporated, as are changes in condition or altered framework conditions. This means that the installed base is not just documented, but remains alive. Operators can track developments, adapt maintenance and migration strategies and make consistent decisions over several years.

Practical experience shows that with a transparent, digitally mapped installed base, many problems can be identified at an early stage. Unplanned downtimes are less frequent because critical devices can be identified and prioritized. At the same time, the cost of maintenance and spare parts is reduced as measures can be planned in a more targeted manner. The DIBA therefore does not provide a short-term effect, but supports systematic handling of the installed measurement technology. It provides orientation in established system structures and helps operators to operate their systems safely, efficiently and in compliance with regulations in the long term.

Simone Gerig, Product Manager Services at Endress+Hauser

Maintenance, Stand 313