Enterprise Asset Management

Transcription

1 Enterprise Asset Management Using SCADA, Workflow, CMMS and GIS Standards Certification Education & Training Publishing Conferences & Exhibits Speakers: Kerry Lee Schrank Aaron Cromer 2017 ISA Water / Wastewater and Automatic Controls Symposium August 8-10, 2017 Orlando, Florida, USA

2 Kerry Lee Schrank, B.S.E.E.T. Aaron Cromer, B.S.E.E., P.E., M.B.A. Kerry Executive Solutions Consultant for GrayMatter 35 of years experience of providing solutions leveraging leading edge technology Water/Wastewater, O&G, Power & Energy Aaron Director of Strategic Partnerships with GrayMatter 20 years of experience implementing technology to improve Operational and Business processes Water/Wastewater, O&G, Power & Energy 2

3 Presentation Outline Let s Challenge Assumptions (three examples) Using Condition Based Monitoring of equipment to improve operations and maintenance performance Electronic Standard Operating Procedures (Workflow) Data driven work process (two examples) Work Order Automation into a CMMS SCADA Events/Limits auto create work orders GIS Location Data of Asset Performance for SCADA 3

4 Let s Challenge Assumptions The following three examples demonstrate the importance of data and its impact to improved operating and maintenance performance Over loading or under loading haul trucks? Flow meter problem or stuck valve? Extreme high turbidity due to what? 4

5 Let s Challenge Assumptions Is this truck over loaded or under loaded? 170 TON Caterpillar Haul Truck 5

6 Let s Challenge Assumptions: Condition Based Monitoring Solution By monitoring motor signals through a math model one is able to calculate the material weight in the bucket, display to the operator and then tally each dipper to minimize overloads and prevent catastrophic events! An equally important benefit of condition based monitoring is maximizing material throughput. 6

7 Let s Challenge Assumptions: Flow Meter failed or stuck valve? Flow Meter indicates no flow to RO train some work had been done previously on the valve so maintenance assumed the flow meter needed to be replaced. Flow Meter Valve 7

8 Let s Challenge Assumptions: Condition Based Monitoring Solution One is able to sense the flow in the line by feeling the pipe or by simply listening for flow. A simple solution is to add a vibration sensor at the flow exit of the valve! What other data could have helped determine the problem? And there is a cost Vibration Sensor 8

9 Let s Challenge Assumptions: WTP Filter Gallery (problem & solution) 26 Filters Intake from Lake VFD Controlled Pump Common Manifold (Header) Intermittent Extreme High Turbidity On Only One Filter Hired Divers to inspect expensive problem not found Replaced media expensive problem not solved Problem Existed for Two Years Turned to Data Analysis to troubleshoot Problem Identified in 15 Minutes Found Relationship Between Turbidity and VFD Speed Pipe Section From Manifold To Filter Was Scaly/Rusty (resonance) Interim Solution Reprogram VFD to not run at bad speed range Ultimate Solution Replace Pipe Section at planned Filter Rehab Final Step Normal up VFD program

10 Let s Challenge Assumptions: WTP Filter Gallery (problem & solution) 10

11 IIoT Industrial Internet of Things - collaboration of people, data and machines More and more machines have sensors and are automated so the time is now to exploit that data to improve operations and maintenance efficiency and SCADA will get you there! People Data Machines 11

12 How do we leverage SCADA data? How do we get the data to the right person? esop Electronic Standard Operating Procedures (Workflows) Filter Effluent Turbidity at City of Haverhill Ensure Safety, Security and Compliance at Orlando Utilities Commission 12

13 Electronic Standard Operating Procedures 13

14 City of Haverhill Filter Effluent Turbidity esop 14

15 City of Haverhill Filter Effluent Turbidity Workflow: 1. Sensor sends data to SCADA on filter effluent turbidity level 2. SCADA reads out of spec limit, which triggers a Workflow 3. Workflow guides operator through steps to determine cause of out of spec condition Workflow records operator input and actions Senior team notified, as required, for additional consultation Workflow records date/time of resolution Benefits of Digitizing Process Reduce paperwork burden Ensure operators take the correct steps Ensure compliance with regulatory requirements 15

16 City of Haverhill Filter Effluent Turbidity 16

17 City of Haverhill Filter Effluent Turbidity 17

18 City of Haverhill Filter Effluent Turbidity 18

19 City of Haverhill Filter Effluent Turbidity 19

20 City of Haverhill Filter Effluent Turbidity 20

21 City of Haverhill Filter Effluent Turbidity 21

22 City of Haverhill Filter Effluent Turbidity 22

23 City of Haverhill Filter Effluent Turbidity 23

24 City of Haverhill Filter Effluent Turbidity 24

25 City of Haverhill Filter Effluent Turbidity 25

26 Orlando Utilities Commission Conway Chlorine Leak Example (esop) 26

27 Orlando Utilities Commission Digitizing Standard Operating Procedures to: Ensure Safety, Security, and Compliance at Orlando Utilities Commission Chlorine Level Water Injection Rate Human Exposure Limits of Exposure Normal Injection ppm ppm Less than 15 mins Small System Cleaning ppm 5-15 ppm Immediately Irritating System SHOCK ppm ppm Fatal after 30 mins For municipalities across the country that deal with potentially hazardous chemicals on such a frequent basis, like Orlando Utilities Commission (OUC), keeping operators safe is the top priority. 27

28 Orlando Utilities Commission 28

29 Orlando Utilities Commission Conway Chlorine Leak Example 29

30 Orlando Utilities Commission Conway Chlorine Leak Example 30

31 Orlando Utilities Commission Conway Chlorine Leak Example 31

32 Orlando Utilities Commission Conway Chlorine Leak Example 32

33 Orlando Utilities Commission Conway Chlorine Leak Example 33

34 Orlando Utilities Commission Conway Chlorine Leak Example 34

35 Orlando Utilities Commission Conway Chlorine Leak Example 35

36 Automated Work Order Generation Succes Stories 36

37 Collier County Project Objectives Automation of Work Orders based on conditional data Standardized Operator Responses to Standard, repetitive events occuring in SCADA What are the actions for operators? Leverage SCADA data current and historical to drive performance When X happens, the operators shall do Y Shall be recorded for training and operational improvements

38 Collier County Project Plan Develop list of Events/Alarm Types Quantify the amount of Events/Alarms Well Site Template Approach Pump Station RO Skid Process Building All Pressure Transmitters or All VFDs All Pumps All Actuators Implement This or This Develop the templates within Workflow 38

39 SCADA Real Time Data o Cyclical Counters o Run Times o Counters o Faults (VFDs ) o Alarm Limits o Sequence of Events o Major Events o Grouping of Events o Hardware Faults o Software Changes Instrumentation o 4-20 ma o DI o DO o PSUEDO Tags/Points Don t Get Stuck in a Rut Learn the True, Real-Time Condition of an Asset

40 SCADA Enhanced Data Sets o o o o HART PROFIBUS ModBus Ethernet Actuator o Data set that is available VFD o Data set that is available Instrumentation o Data set that is available Don t Get Stuck in a Rut Learn the True, Real-Time Condition of an Asset

41 Enhancing CMMS with esops Real-Time Condition-Based Asset Management SCADA sends data to Workflow Data Threshold triggers Workflow Workflow requests CMMS to create new work order Workflow sends esop, work order # and GIS details to operator SCADA Data & Events Workflow Monitors Data Real-Time CMMS New Work Instructions Pump Runtime Hits an Operational Threshold! Data triggers Pump Runtime workflow CMMS sends work order # and GIS information to Workflow Operator goes to specific pump station, performs 5 task steps, and completes workflow, which closes the work order Central SCADA SOA Workflow Water Operations SOA CMMS

42 Collier County Project Objectives Integration of SCADA OQ and Training LIMS HISTORIAN KPI/ Dashboard CIS SCADA Workflow CMMS Capital Forecasting Hydraulic Modeling GIS 42

43 Collier County Project Objectives Integration of SCADA Workflows with CMMS OQ and Training LIMS HISTORIAN KPI/ Dashboard CIS SCADA Workflow CMMS Capital Forecasting Hydraulic Modeling GIS 43

44 Predictive, Real-Time Maintenance Strategies 44

45 Predictive, Real-Time Maintenance Strategies What to do and When o Prioritize work based on o Asset Criticality o Business Risk Exposure Asset Criticality o Defined by Process Mapping o Static Value doesn't change Business Risk Exposure o o o o BRE = COF * POF * RMF COF Consequence of Failure o Values does not change once set RMF - Risk Mitigation Factor o Amount of redundancy o Duplex Pump stations POF Probability of Failure o Condition * Reliability * Operational Performance SCADA DATA the only data that is Dynamic Don t Get Stuck in a Rut Learn the True, Real-Time Condition of an Asset

46 Predictive, Real-Time Maintenance Strategies Operational Performance: o o o o Does the performance meet the specs? Pumping Capacity RPM speed? Volume throughput Reliability o o o What is the uptime How are you capturing the data? Are you capturing the data? Don t Get Stuck in a Rut Learn the True, Real-Time Condition of an Asset

47 Real-time Condition Based Monitoring of GIS GIS Location Data of Asset Performance for SCADA Collier County Success 47

48 Real-time Condition Based Monitoring of GIS How to Link SCADA to GIS and here is why! Drive Performance of SCADA Assets We know break per foot/mile of pipe Reportable We don t show pump up time or availability Increased vision will create more funding More appropriate work strategy and not just same 48

49 Wrapping it Up! Condition Based Asset Performance Monitoring Know your assets Are you sure? Electronics Standard Operating Procedures Consistency Standardization Auditing performance Efficiency SCADA Integrated with CMMS Data Driven Decisions Optimized Asset Life based upon performance 49

50 Leveraging SCADA Data Why Not??? Where are YOU in YOUR SCADA journey? Where are YOU in YOUR CMMS journey? Where should your SCADA journey take YOU? What outcomes are you looking for with: SCADA? CMMS? What s YOUR plan for getting there? 50