1. Proactive Asset Management Survey
Creates Roadmap to Parts Inventory
and Obsolescence Plan
Session: 1B-5133

2. Photography & Video Recording Policy
Photography and audio/video recording is not permitted in any sessions or in the
exhibition areas without press credentials or written permission from the Emerson
Exchange Board of Directors. Inquiries should be directed to:
EmersonExchange@Emerson.com
Thank you.

3. Presenters
 Angelo Angeleri
 Joe Hawkins
 Zachary White

4. Agenda
 Presentation Overview
 APS: Palo Verde Nuclear Generating Station
 Drivers for Building Asset Database
 Objectives and Requirements
 Challenges
 Data Gathering
 Database Utilization
 Results and Benefits
 Summary
 More Information Services

5. Presentation Overview
 Inconsistent installed base data was impacting service
and parts inventory requirements.
 Storage reduction forced parts consolidation, illustrating
the importance of an asset management program for
proper inventory planning.
 A comprehensive asset survey done by Caltrol and
Emerson provided the asset benchmark needed to allow
data driven parts inventory and outage planning.
 Survey data utilized for inventory reduction, parts
procurement, and outage planning.
 Asset survey paved the way to a proactive management
program for process control assets.

6. APS: Palo Verde Nuclear Generating Station
 Owned by consortium of seven Southwest utilities and operated by
Arizona Public Service Co. (APS)
 Member of STARS Alliance
– Promotes consistency and implement best
practices across 7 member nuclear facilities
 Palo Verde Nuclear Generating Station
is the largest power producer in the US.
– 3 Pressurized Water Reactors on 4,000 acres
– Generates 30 million megawatt-hours annually
– Serves more than 1.1 million customers
– Recycles 20 billion gallons of wastewater annually

7. Drivers for Building Asset Database
 Inconsistent data
 Obsolete product - obsolescence planning
– Older technology affecting efficiency and reliability
• Moving from reactive to proactive maintenance program
 Extensive parts lead time
 Inventory management – reduce footprint of warehouse
 Target maintenance budget for best use, planning,
technology upgrades and optimization
 Data driven decisions
 Strategic reduction of taxable
inventory over 12 month period

8. Objectives & Requirements
 Comprehensive asset database
– Turnkey system networked into existing
digital infrastructure
– “As-Found” images of equipment
– Serial records
– RSPPLs
– Bill of Materials (BOM)
– Flagging obsolete equipment for upgrades and optimization
 Documenting plant instituted modifications
• Cross reference to serial cards as updates occur - evergreen

9. Challenges
 Inconsistent asset data was impacting service and parts
inventory requirements and
– Proper inventory planning required accurate asset database
– Reaction to unplanned downtime was inefficient and labor
intensive
 A storage reduction forced a parts
consolidation
 Comprehensive asset survey
needed to provide installed base
benchmark
 Data driven decisions for parts
inventory and outage planning
 40-60 week delivery on key safety related parts
– Stepping up pre-outage planning

10. Challenges
 Proactive maintenance and timely parts ordering for future
outages
 Repetitive parts ordering hard and soft costs
 Nuclear facility
 Nuclear qualified and badged technicians
with proper safety and security clearances
 Potential radiation exposure in plant hot areas
 Baseline set of deliverables changed once value
recognized, deliverables were increased at
request of Palo Verde
 Setup and usability of data set

11. FieldSource - iPads
 Internal tool developed by Caltrol IT Group
– No paper, enter data straight from the field
 Remote data gathering using iPads
– Private logons to update data from service
and maintenance activities
 Navigation and menus with pull-downs streamlines
data entry and minimizes key strokes and human error
 Nightly uploads from iPads
 Fisher®
serial records, BOM, RSPPLs provided
 Field survey and outage planning

12. Data Gathering
Valve Database
Full accessibility to view or update valve data 24/7/365.

13. Data Gathering
 Walk-down of plant for Fisher equipment (initially)
– Scope expansion to include all assets (Phase 2)
 “As-Found” images of equipment
 Serial records pulled, reviewed and updated
 Recommended Spare Price Parts Lists - RSPPLs
 Bill of Materials (BOM)
 Obsolete equipment flagged
for upgrades and optimization
during future outages

14. Database Utilization
 More efficient outage planning and scheduling
– Calendar reminders for planning and key parts pre-ordering
for tags in each future outage
 Obsolescence program
– Strategically planned plant-wide
upgrades and optimization
 Support for plant modification
– Detailed and documented asset database
 “Best Practice” for increasing efficiency
of future outages

15. Business Results Expectations
 Proactive approach to maintenance and repair
 Database access anywhere using iPad or iPhone
– Private access to secure web-portal
(https:service.caltrol.com/CompanyName)
 Database helped identify control valves to receive
new part numbers and update serial cards
 Data-driven proactive approach to parts ordering,
outage and obsolescence planning
– Simplification of recommended spare parts inventory
– Live access to replacement parts lists

16. Business Results Expectations
 Database substantially increases interdepartmental
communication and coordination of asset information
– Ability to view data in multiple formats
 Single data source creates alignment and
standardization of product information
– Live field updates directly into asset database
 Maximization of plant reliability for optimal uptime
– Ability to send email for parts directly from iPad or iPhone
 Reallocation of capital budget savings from inventory and
obsolescence planning

17. Where Are The Potential Cost Savings
 Where are the cost savings?
– Better Planning
– Obsolete product replacement
– Obsolete inventory
– Labor searching data
– Engineering, maintenance and supply chain collaboration
– Pricing agreements – identify high use parts and provide
fixed costs reducing internal PO processing costs by 50%
 Reduction in state taxes paid on obsolete inventory
– State taxes = 15%
– $50 Million in inventory
– Current estimation of savings $4-6 Million

19. Where To Get More Information
 Visit the Fisher and Instrument & Valve Services stand
inside the Emerson Exchange
 www.APS.com
 www.Caltrol.com
 www.EmersonProcess.com/IVS
 www.EmersonProcess.com/Fisher
 Caltrol provides this service as part of service agreements
to manage or survey process control equipment

20. Thank You for Attending!
Enjoy the rest of the conference. Remember to stop by and
go through the featured stand on Integrated Turnarounds.