So you have a SCADA.What s Next?

Transcription

1 So you have a SCADA.What s Next? Using Facility Tools To Drive Efficiency And Effectiveness Standards Certification Education & Training Publishing Conferences & Exhibits Speakers: Grant Van Hemert 2012 ISA Water & Wastewater and Automatic Controls Symposium August 7-9, 2012 Orlando, Florida, USA

2 About the Presenter Grant Van Hemert, P.E., is a water wastewater applications specialist for the Schneider Electric Water and Wastewater Competency Center. He has 17 years experience in water and wastewater automation, and another five years in automation and control engineering. He is a registered P.E. in the state of North Carolina and is the past chairperson for the AWWA Instrumentation and Control Committee. Mr. Van Hemert can be reached at (919) or grant.vanhemert@us.schneider-electric.com

3 Agenda What information should my SCADA provide? Can industry improvement metrics be adapted to W/WW? Software solutions above the SCADA level How can I finance the upgrades? Application examples

4 I Need To Read Meters

5 What is SCADA What SCADA is designed to do View real time data Allow for set point change Short term trending Alarming What it is not designed to do In depth analysis Complex trending In depth Efficiency Calculations In depth Effectiveness Calculations Maintenance

6 LIMS I Need To Read AMR Meters Asset Management GIS Homegrown Spreadsheet or Hand Calculations

7 The Situation Lots of Data Each software has unique features No coordination between them Correlation requires looking at each software individually ISA WWAC Symposium 2012 Manpower Intensive Aug 7-9, 2012 Orlando, Florida, USA REAL LIFE EXPERIENCE: A southern California water utility would take 3 to 4 weeks to determine the mass balance for a given point in time.

8 The Challenge Utilities need to Optimize Rising Energy Prices Reduced Tax Revenue Restricted Funding

9 The Concept Use New Tools to Determine Efficiency Determine Effectiveness Correlate the data from a variety of sources

10 Concepts to Consider

11 TCGW Total Cost for Good Water Cost to produce and deliver / discharge 1 gallon of good water. Energy cost Maintenance cost Staff Cost Chemical Cost Vehicle Cost Fines GOOD WATER Meets Permit Reaches Consumer (Water) Discharged from Facility (Wastewater)

12 Efficiency The comparison of what is actually produced or performed with what can be achieved with the same consumption of resources. (money, time, labor, etc.) Efficiency means doing the thing right

13 Effectiveness The degree to which objectives are achieved and the extent to which targeted problems are solved. In contrast to efficiency, effectiveness is determined without reference to costs. Efficiency means doing the right thing

14 Improving your Overall Facility or Equipment Effectiveness (OEE)

15 What is OEE? Overall Equipment Effectiveness A measure of how healthy your production process is relative to your planned production schedule A Standard Metric for Production Loss (OEE is referenced in Introduction to TPM by Seiichi Nakajima, Productivity Press, Cambridge, MA) Primary reference site:

16 How Does it Work OEE = A*P*Q A = Availability (%) P = Performance (%) Q = Quality (%)

17 Determine Planned Production Time (PPT) Look at the total time in operation Deduct known downtime Such as lunches, evening shutdown Result is Planned Production Time Water and Wastewater Facilities cannot shut down Sub systems like Basins and Pumps can

18 Determine Factors Availability Operating Time/ Planned Production Time Performance (Total Pieces/Operating Time) / Ideal Run Rate Quality Good Pieces / Total Pieces PIECES IN WATER WASTEWATER? Water and Wastewater plants produce gallons of water. A gallon of water can be thought of as a produced piece

19 UV Example Given 100 MGD plant 2% off spec water Lights on 24/7 Plant problem means a 50% run rate Time frame of 1 day OEE PPT = 24 Hours A = Operating Time / PPT = 1/1 = 100% P = (Total Pieces/Operating Time) / Ideal Run Rate = (50MGD/1)/100MGD = 1/1 = 50% Q = Good Pieces / Total Pieces = 49 MGD/50 MGD OEE = A*P*Q = 100% * 50% *98% = 49% WORLD CLASS OEE Availability >= 90% Performance >= 95% Quality >= 99.9% Overall OEE >= 85%

20 What does improving OEE mean Increase in Effectiveness Improved Downtime more production time Less water that does not meet permit Lower Consumables use

21 OEE and TCGW Will help you determine the best operating point for your facility. Easy parameters to judge the entire utility operation or sub systems Used by traditional manufacturing Adaptable to water and wastewater

22 The Tools

23 Software Tools OEE TCGW Efficiency Effectiveness More then just SCADA More then just a Data Historian Can analyze plant performance

24 How does it work Software looks into all data bases Consolidates and Contextualizes data Creates easy to understand reports Leakage data Hydraulic Modeling Maintenance troubleshooting tool Asset Management Energy Efficiency

25 What is Contextualized Data? Given: Need to to know Minimum and Maximum Turbidity Scenario #3 #1 Over the past five Years days Filter Answer out = Unreliable SCADA data Bad instrument Scenario #2 Unreal spikes (High during backwash) Over the past year Show Answer results = Historian by Year, Month, and Week CONTEXTUALIZE Ability to automatically determine and remove anomalous data that can skew a desired measurement.

26 Original situation Utility took weeks to do Mass Balance Took weeks to find leaks With Advanced Process Control Can do Mass Balance 1 Hour before present After just a few clicks Leaks found after a few hours Filter behavior and DAF used together to optimize chemical usage Interesting Facts REAL LIFE EXPERIENCE: A southern California water utility would take 3 to 4 weeks to determine the mass balance for a given point in time. APC proved that 30 year operational rules of thumb were not necessarily correct. The software retrained the staff on how the system behaved.

27 Definitions: LIMS: Laboratory Information System AMR: Automatic Meter Reading LIMS MS-SQL Other databases ODMS/HISTORIAN Financial, and other enterprise wide software SWAN GIS AMR GIS: Geospatial Information System SCADA: Supervisory Control And Data Acquisition SWAN: Smart Water Network SCADA Reports, Other Std. Software Inside Fence SCADA Std. Software Outside Fence Application Software (MS-SQL only) Power Metering MANUAL DATA ENTRY Controllers, Instrumentation

28 Example Belo Horizonte - Brazil - Utility Name: Copasa million people served (3.1 Belo Horizonte) - Over miles of distribution pipes SCADA Operational data Maintenance - Improved response on outage events - ( 14% outage times) - Improved maintenance policies - ( 33% repair times) Real time data Simulated data Predicted data Maintenance Data - Improved network control - Improved planning Hydraulic Model GIS - Improved public image Geodata - Increased ROI on all these investments

29 Smart Water Networks Smart Water Network solutions improve the efficiency, longevity, and reliability of the underlying physical water network by better measuring, collecting, analyzing, and acting upon a wide range of network events. Source: SWAN Smart Water Networks Forum Use of information technology to optimize the utility s capacity at a minimum CAPEX cost Data Information Decisions Actions Smart Water Networks Solutions More Better Accurate Smarter

30 SWAN: Fundamentals Smart Water Network s fundamentals - The 3 I s: Information: Realizing your full potential - SWN makes use of information that you might not know you have Integration: Make the best of your investments - SWN are able to make the best of the current IT installed base: your current investments Innovation: The constant future SWN are flexible enough to take over the utility s challenges as they come. Phase 1 Information Phase 2 Integration Phase 3 Innovation

31 Optimising W/WW Efficiency using Advanced Process Control Data-driven model of process behavior Capture relationship between process variables Build multivariate correlation between variables and actuators, causes and effects Use model to identify opportunities for improvement in process control Develop predictive controller to exploit those opportunities Volume TSS COD BOD P NH 4 ph TOC DO Residence Process Volume TSS COD BOD P NH4 ph Energy OpEx CapEx

32 Optimising W/WW Efficiency using Advanced Process Control Data-driven model of process behavior Capture relationship between process variables Build multivariate correlation between variables and actuators, causes and effects Use model to identify opportunities for improvement in process control Develop predictive controller to exploit those opportunities Upper Constraint Predictive Control Process Optimisation Process Variable eg Energy σ $ Time Predictive Engine: predicts the impact of process disturbances

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34 What is Performance Contracting? Before Utility Bills Reinvested in Facilities After Guaranteed Savings Maintenance Utility Bills Maintenance Operations Budget Operations Budget Definition: Construction vehicle and financial tool which uses the cash flow from energy savings to pay for the improvements, typically without the use of upfront capital.

35 Connecting Process Automation with Energy Monitoring to Optimize Energy Process Automation Goals: Optimize Production Maximize availability & utilization of assets. Process MES Process SCADA Process Control Devices & I/Os Energy Control Energy MES Energy SCADA Energy Monitoring Energy Control & Monitoring Goals: Optimize Consumption Maximize availability & utilization of energy. Collaborative architecture bridging silos to yield optimized plants & processes. Production energy optimization: Reduced energy consumption per unit of production & improved emissions reporting. Better consumption forecasting, critical for engaging in demandresponse programs.

36 What should you expect? Deliver real-time access to plant and business information Enable management to identify and act on opportunities to maximize performance, and to correct problems Analyze energy use and environmental impact to reveal energy saving scenarios Reveal opportunities for improved business performance and increased profit margins.

37 T hanks for your attention