Smart ICA What do Water Companies Want to Monitor and Control Their Assets?

Transcription

1 Smart ICA What do Water Companies Want to Monitor and Control Their Assets? Speaker: Mike Booth Severn Trent Water Standards Manager ICA & Electrical 1.0 Synopsis Intelligent motor control and networks such as Profibus have been deployed across the UK water industry, and these systems provide enhanced data to improve asset (Pump) performance. Severn Trent Water is now deploying low cost Smart ICA Architecture which also includes Smart ICA Apps that self-optimise assets to give approximately 30% operational cost savings. This session will present an overview Severn Trent s approach. 2.0 Business Requirements for Smart ICA Smart ICA was developed to align with Severn Trent s Smart Networks Vision: 'Imagine a world where we are able to predict and prevent failures of our network so that all our customers receive reliable water and waste water services' The vision is overlaid with the requirement for TOTEX reduction, and a target of 30% capital efficiency was set with the requirement for significant operational cost efficiencies. 3.0 Severn Trent s Approach to Developing Smart ICA Severn Trent has implemented several Community of Practice groups (Wenger) to develop and manage standards. (See Figure 1) Within the Instrumentation Control and Automation arena the ICA Community of Practice (ICA COP) is in place and includes subject matter experts from across Severn Trent and it s Tier 1 and Tier 2 supply chain. Severn Trent has a strategic Tier 2 supplier framework for ICA & Telemetry that includes motor control centres and control panels. Representatives from the Tier 2 suppliers are essential members of the ICA COP to provide technical input, template designs and software development. Strategic component frameworks are also in place for PLCs, HMIs and Drives and only tested devices that can be fully integrated are included in the Severn Trent Standard ICA Hardware List. Controlling the variation of devices significantly reduces TOTEX and risk by reducing the cost to manage firmware version compatibility and general system support.

2 Figure 1: Severn Trent ICA Community of Practice Model Severn Trent has found that the development of the Smart ICA Apps is the most important activity to release the operational cost savings. The Apps are focused on automatically do something about it rather than creating data. The Apps are specified, produced and tested by the Severn Trent ICA Specialists working with the ICA & Telemetry Framework supplier s software engineers. The key skills required to deliver Smart ICA Apps are understanding: Organisation s culture and capability Water and Waste Water Treatment Process Asset performance and failure modes. PLC Programming & Intelligent Systems High level data requirements for effective asset management

3 4.0 What is Severn Trent s Smart ICA? Smart ICA is the Severn Trent integrated architecture overlaid with the bespoke software Apps. A close analogy is a Smartphone with Apps Installed for the user s requirements. Figure 2: Analogy of a Smartphone 4.1 Architecture Device Layer - Ethernet Network - Motor Starters and Field Inputs and Outputs Framework Intelligent Fixed Speed & Variable Speed Starters Low Power Drives Framework Modular Starters Ethernet Site-Wide Network Full remote support capability Device replacement 4.2 Software Infrastructure Code Continuous Data (Power Trends etc.) Base Intelligent Starter Functions (Jam, Stall, Warnings etc.) Smart ICA Apps (STW Patent Pending) o Active Energy Management o De-Ragging o Auto Reversing o + 15 Apps and more in development 4.3 Modular Motor Starters - MCC Cost Reduction (Figure 3) Wall Mounted Variable Speed Drives or DOL Starters in a Box Up to 15kW Allows Expansion Beyond 2 Starters Ethernet Connected to ICA Section Factory Built Pre-Wired Back Board & Kiosk for New Build Civil Costs - No MCC Cable Trench or Plinths External Distributed Starter Option

4 Figure 3 Modular Starters 4.4 Telemetry Signals Telemetry PLC on Site Wide Ethernet Network Modbus Comms Link to Telemetry Outstation WITS Card Trial PLC Direct to Telemetry 4.5 Detailed Data Factory (Large) Sites SCADA with Archive / Historian Local HMI Standard Faceplates / Graphics 5.0 Smart ICA Benefits The majority of new systems installed within the capital programme deploy Smart ICA architecture. The Severn Trent Innovation team are also carrying out a project to deploy Smart ICA in Sewage Pumping Stations (Ballard Panels) and have funded the development of Apps. The early indications show the following benefits. 5.1 Capital Cost Reduction 30% Capital Cost Savings ICA & MCC Steelwork Size / Cost Reductions Kiosk Size Reductions Programme Time Reduction Plug and Play Package Off Site Build ICA & MCC Kiosks Performance Based Capital Investment Targeting 5.2 Operational Cost Reduction Smart ICA Apps 30% to 50% OPEX Reduction Energy Cost Active Energy Management Apps Call out reduction Fix Before Failure Proactive Asset Management New Asset Benchmarking

5 6.0 Smart / Intelligent Systems in the UK Water Industry A recent WIMES / Profibus International review presented a wide variation of strategies across the UK water industry. Ranging from trial installations of a small number intelligent motor control centres to wide scale deployment and use of intelligent motor control and instrumentation systems. The UK water companies have a variety of supplier frameworks in place for PLCs and Drives, and they also deploy their chosen network type. The Smart Phone Analogy Android V s ios debate... does it really matter? All of the major component vendors (Siemens, Mitsubishi, Schneider, Rockwell etc.) and network types (Profibus, Profinet, Devicenet Ethernet etc.) can be used for Smart or Intelligent Systems. When an organisation has resourced and upskilled to support selected components and a network type, the variation and approval of components needs to be carefully controlled. Severn Trent achieves this via supplier framework agreements for strategic components. Another key consideration for the industry is the engineering skills shortage, hence the capability to develop and support operation technology is limited. A collaborative approach involving the end users and support teams is essential to ensure successful deployment. The need for full remote device support is also an essential requirement. The UK Water Companies need to ensure that they consider the people, process and technology aspects to ensure they have a successful deployment of intelligent and Smart ICA and share their experiences via industry wide groups WIMES! Mike Booth M.Sc. MIET Severn Trent Water ICA & Electrical Standards Manager