Asynerlytics, LLC. The Water and Wastewater Industry Specialist

Transcription

1 Asynerlytics, LLC The Water and Wastewater Industry Specialist

2 PAS 55 Certified Reliability Sustainability - Synergy 2 2 2

3 55000 & ISO Standards The WRF achieved PAS 55 Certification on May 2012 PAS 55 is an International Specifications or Standards Focusing on Continuous Improvement, Strategy and Risk Management Demonstrated we had established and are continuing to improve a Quality Asset Management System (QAMS) for the entire lifecycle of our assets and infrastructure Member of TE2AM at the University of Wisconsin School of Engineering Selected to develop an outline for the Asset Management and the Energy Management ISO Standards Commissioned by the U.S Department of Energy in Washington, DC

4 Benefits of PAS 55 Certification Use the 28-point checklist for better overall long-term planning Monitor and improve the way you manage your physical assets Achieve legal and regulatory compliance and better customer service Enjoy increased support for risk and sustainability management Prepare for the full lifecycle with more control over costs

5 Des Moines Metropolitan WRA Case Study

6 DMMWRA - Case Study

7 Asset Sustainability Roadmap Destination Objective Reduced Annual Energy Cost Reduced Carbon Footprint Benchmark against Carbon Emissions Effective Energy Management Program Implement Energy Optimization Program Benchmark Energy Cost & Carbon Emissions Evaluate Energy Footprint & Prioritize Assessments Actions Evaluate Footprint & Prioritize Actions Determine GHG Emissions Inventory Develop Energy Reduction Strategy (Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved. 7

8 Initial Project Goals Identify target equipment Establish basis for condition monitoring (flow/kwh) = efficiency Verify availability of data and add instrumentation, network wiring, and data point as required Develop data integration to Infor Asset Sustainability Configure Infor Asset Sustainability capabilities to support Condition based Monitoring (earliest possible notice that we are on the failure curve)

9 CbM Data Points Establish Condition based Monitoring profile Equipment Level Data Run Time Hours Amps KWH System Level Data Flow (SCFM or MGD) Equipment Operating Mode (i.e., single or multiple equipment running)

10 Infor EAM Asset Sustainability Enable energy performance monitoring & measurement Identify cost reduction & conservation opportunities Enable continuous commissioning & peak demand analysis Determine if new energy initiatives are actually succeeding Audit utility information to identify billing anomalies Enable energy cost reductions of 10 25% Enable greenhouse gas, water, and waste reporting

11 Manufacturing & Industrial Electric motor-driven systems in industrial processes consume 63% of all electricity used in U.S. industry U.S. Dept. of Energy

12 Be a First Responder Asset Sustainability Alert Management * Equipment DEGRADES Consumptive Maintenance $$$$$ * PM/PdM $$$ Asset Sustainability OEM Service EAM * Run to FAIL

13 Actionable steps to achieve energy savings (cost savings) Example: Consumption is exceeding design Consumption

14 Various Monitoring Strategies Utility Bills Building Processes and Systems Assets Utility Meters Sub Meters Sensors 14

15 DMMWRA Technology Stack Infor EAM Asset Sustainability Integrated/Warehoused Asset and Management Data Analytics/Visualization/Alerts Enterprise Level Business Application HACH/WIMS Data Repository Archival/Aggregation Database Rockwell RSViewSE SCADA Factory Talk Real Time Collection Sensors/Instrumentation/PLC

16 Optimization Information Network All of these business enterprise solutions collect data and transmit it to the Infor EAM Asset Sustainability Condition based Monitoring program. The synergy of this integration provides the industrial business intelligence necessary for a truly sustainable production environment. 1 i.lon, or PI System, or other Infor ION 2 BMS, Utility Bill Agg, or other Infor EAM Database CSV File FTP CSV File XML Web Service Alerts

17 Energy Management Optimization Install metering devices o Provide essential real-time and historical information Use System to understand what loads contribute to the peak Notify key personnel when the plant is setting a new peak for the period o Make sure only essential loads are running during the peak Establish granular energy saving goals using Energy Metrics as a tool to help drive the reduction Train and Leverage Energy Champion to use AS and engage employees

18 WRF Peer Process Systems

19 WRF Peer Process Systems

20 EAM Alert Management

21 What Does Alert Management Provide? Actionable steps to achieve energy savings (cost savings) For example: Consumption is exceeding design consumption From: To: Bill Miller Subject: (ASE Alert) KWH Spike on GAS Tracked Asset Notice: The most recent KWH reading on Equipment: 35-PAB-3 [PROCESS AIR BLOWER #3, 35- PAB-3] has exceeded 2 standard deviations of the mean hourly KWH for this unit's peer equipment. Last Reading:1, Avg for this Equipment: Avg for Peer Equipment: Warning Level (2 Sigma) for this Equipment: Warning Level (3 Sigma) for peer Equipment: Please notify appropriate personnel for investigation.

22 GHG/CO2 Emissions Management Track carbon footprint Reporting Benchmark to improve

23 2010 PAB Energy Usage Report

24 2013 PAB Energy Usage Report

25 Initial Identified Savings Process Air Blowers (2,000 HP) Main Raw Water Pumps (700 HP) Return Sludge Pumps (100 HP) Total Run Hours 3,552 3,552 3,552 Days of Data High Cost per Hour $ $ $ 0.82 Low Cost per Hour $ $ $ 0.63 Cost per Hour Delta $ $ 6.30 $ 0.19 Maximum Potential Savings $ 43, $ 16, $ Annualized Savings $ 142, $ 55, $ 1,664.40

26 Peak KW vs. Cost KW Facility Level Demand KW s

27 WRA 2013 Energy Stats Consumed an average of 92,300 kwh/day for a total of 33,800 mwh (33,800,000 kwh) of electricity 60% of CDM local government energy cost from WRA Facility WRA rates ranged from $0.0404kWh to $0.069kWh Average monthly electrical cost of $100, Lowest monthly electrical cost to date: $65,000.00

28 Managing Consumption The key to controlling electrical cost is demand Drive the consumption to the lowest rate through minimizing Peak Demand Controlling Peak Demand by; Constant online monitoring of demand and making process and equipment decisions based upon current Demand Peak

29 Controlling Demand Establish equipment operational rotation based upon current peak demand Reduce or curtail energy consumption within selected processes Use longer operational runs with lower energy vs. shorter operational runs resulting in higher energy usage Offset demand with Electrical Generation

30 Asset Sustainability provides WRA the structural framework from policy to the plug to ensure optimal operating performance while continually improving their energy performance saving money, improving operational effectiveness, and being a good steward of the environment. When enterprises can link efficiency to expense reduction and profitability it s a win-win

31 What Happens When Assets Fail to Receive Sufficient Attention? Significant profit potential is left on the table Costly operating surprises can arise Unoptimized assets mean lost opportunity for bottom-line improvement and decreased asset performance & reliability

32 Global Solution Single Database Facility 1 Facility 2 Facility 3 Organization Specific: Organization Specific: Organization Specific: People People People Processes Processes Processes Data Data Data Multiple Locations / Departments Multiple Locations / Departments Multiple Locations / Departments User Focus: User Focus: User Focus: Role Based Role Based Role Based Mobile / Tablet / Desktop Mobile / Tablet / Desktop Mobile / Tablet / Desktop Language Language Language Share Common Best Practices Reports Analytics Data Processes

33 EAM Analytics Starting With the End in Mind

34 Equipment Management Report Snapshots

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38 Gartner EAM Magic Quadrant Maintenance : A Strategic Road Map Level 7 - Financial Optimized Level 6 - Reliability Centered Maintenance Level 5 - Predictive Forecasting Level 4 - Based on Condition Level 3 - Preventative Planned on Usage Level 2 - Preventative Planned on Time Level 1 - Run to Failure It was thought that no one has achieved greater than Level 5 The DMMWRA has achieved all 7 Levels

39 The Direction of DMMWRF Today Work is a web based analytics tool that helps customers make tactical and strategic decisions about their motor-driven assets. Work (Motor Master+ in the cloud) capturing near real-time detail energy and equipment data, will provide continuous equivalency evaluation and procurement engineering capabilities to enable repair vs. replacement and non-conformance analytics. Embedded Technologies incorporating Self-Diagnostic PLC s with transducers at the sub-component level of key critical assets. The data is then transmitted digitally to SQL Databases such as a Hach Wims data repository or Factory Talk Transaction Manager, where is can be easily accessed by the Infor EAM/AS or other relative programs.

40 TM Copyright Infor. All Rights Reserved. 40

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43 World Class Organization

44 It s Time To Make A Difference Being Energy Efficient is Simply Smart! Asynerlytics.com