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Profibus Applications and Maintenance Strategies in Yorkshire Water

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1 Profibus Applications and Maintenance Strategies in Yorkshire Water
Chris Howard. ICA Projects Operations Manager Adrian Wilkinson. ICA Projects Engineer Adrian and myself are part of the ICA working community within YWS, servicing both the Clean Water and Environmental (Waste to you) parts of the Business We are in the Projects team that delivery minor ICA related Projects within the Business – dependant on their source of Business Need and funding. Part of our role is also to give ICA Technical Support on behalf of the Business on the Major Capital investment streams within the the two Business Units. A major function of that role on individual schemes is to ensure that the Future ease and efficient Maintenance on all ICA Equipment is achievable and therefore we represent the interest of the ICA Maintenance teams within our same Community.

2 Contents Evolution of Profibus in YWS
Key Profibus Stakeholders in YWS and their impact on YWS application Technical Profibus Applications Developed and Applied within YWS Profibus Maintenance strategies in YWS Sustainability of the Technical Knowledge and Skills within YWS related to Profibus 30secs

3 Evolution of Profibus Applications in YWS
New YWS PLC Framework YWS Profibus Best Practice Guidelines Field Network Installations “FFD” Driver Profibus Valves at Esholt WwTW Filters IMCC Aldwarke DeviceNet IMCC Clean and Waste sites DP-V0 YWS ICA Profibus Strategy Formation of Profibus “Asset Standards” Document IMCC’s Installations Clean and Waste sites DP-V1 45secs (1.15) YWS “FFD” Strategy Team YWS MCC Forum ‘03 ‘04 ‘05 ‘06 ‘07 ‘08 ‘09 Year

4 Key Profibus Stakeholders in YWS and Their Impact On YWS Application

5 Key Profibus Stakeholders within YWS
Eng’ Spec’ Standards Teams Maintenance Strategy & Asset Team ICA Maintenance Teams M&E Maintenance Teams Engineering Consultants MCC Framework Partners 2mins (3.15) FFD - seeks to protect those fresh water bodies identified by Member States as waters suitable for sustaining fish populations seeks to protect those fresh water bodies identified by Member States as waters suitable for sustaining fish populations Project Delivery Partners FFD Strategy Team

6 YWS World Class Asset Management Model
0.30 secs (3.45secs) Disjointed across ALL stakeholders. Same slide mixed up

7 Technical Applications, Developed and Applied Within Yorkshire Water

8 Traditional MCC Best Practice and Standards Documents
Good engineering, electrical & control specification. Standard Documentation for all panel manufacturers and system integration. Good engineering, electrical & control specification. Because the MCC’s and the PLC control code had evolved slowly over a long period of time. In the PLC World YW developed standard programming practices, including standard block of PLC code for Standard items of control and automation.

9 Application Software Change Management
Managed the change. PLC provider change to a IEC platform. When we changed YW main framework PLC provider, the change was straight forward as all of the programming practices changes to a IEC compliant PLC provider, all the standard blocks of PLC code be changed in a planned and proactive manner, the main block of work carried out before any of the new PLC were installed on site.

10 Intelligent MCC Best Practice and Standards Documents
Good engineering, electrical & control specification. Standard Documentation for all panel manufacturers and majority of System Integration Profibus PLC function block methodology and application. Yorkshire Water had a rapid drive towards intelligent MCC’s. Even though a traditional MCC all documents and practices where in place. It sounds a simple task of realigning the preset function blocks to Profibus.

11 Proportion of the application of Profibus on Yorkshire water sites.
MCC Instrumentation 75% 25%

12 MCC Instrumentation No previous instrument function blocks, as we only used the analogue signal and a fault contact from Instruments. We didn’t have a good understanding of what extra information Profibus instrumentation could give us and how useful that information was. Instrument function block development initially accounted for 25% inconsistence in program development.

13 Normal route of a function block.
Instrumentation Normal route of a function block. System Integrator A SI Forum PLC Programming System Integrator B Yorkshire Water Standards System Integrator C System Integrator D

14 Initial route of a instrumentation function block
System Integrator A SI Forum PLC Programming System Integrator B Yorkshire Water Standards System Integrator C System Integrator D

15 Real Inputs Data Inputs Control Control and and Status Status
MCC Instrumentation Traditional Function block Profibus Function block Real Inputs Control and Status Real Outputs Data Inputs Control and Status Data Outputs We have always tried to keep the Control and status section as near as possible the same. Simple task of changing the real inputs and outputs to Profibus data input and outputs. No problem. We are used to change management in Yorkshire Water, in the MCC world the function blocks changed from traditional function blocks to Profibus function blocks. Although the change was not as proactive as we would of liked, the change took place short period of time. 70% of function blocks where changed over a short period of time. The 30% left can be split 25% to new instrument function blocks and 5 % to intelligent motor control device parametisation.

16 Parameterisation of Simocode unit.
MCC Parameterisation of Simocode unit. Background & reasons! The Intelligent Motor control device is a electrical device. Existing contractual reasons with E & M Maintenance partner. 5% of the inconsistence came about due to the need to parameterisation of the Intelligent Motor Control Units. As the System Integrator and Yorkshire Water got a better understanding of the technology, the goal posts kept moving, We have ended up with many different versions on different sites. No Laptops.

17 Parameterisation of Simocode unit.
MCC Parameterisation of Simocode unit. HMI PLC Intelligent Motor Control device Via the HMI the PLC saves the parameterisation of the Intelligent Motor Control device

18 Parameterisation of Simocode unit.
MCC Parameterisation of Simocode unit. Technical achievement ! Have we re engineered the wheel ! Technical achievement at what cost – We think a excellent technical achievement by our System Integration partner BUT have we re engineered the wheel.? We went though various versions of the parameterisation function blocks to overcome different requirement mainly due to the increased knowledge gained from the work on the previous function block. This is the 5% inconsistency Have we created a conflict in backup version control ! One copy on the HMI memory, one stored in a central version control, 2 different teams doing the same backup! Have we created a conflict in backup version control !

19 ICA Maintenance Strategy

20 ICA Profibus Knowledge Model
Education by Promotion Skill by Generic Training KNOWLEDGE 1min (13mins) Created early 2006 – We have managed our Knowledge Gain Eg Education-MMU-Installers&MAint’ Courses-Final 1 in MArch09-All original identified will have attended- Business as usual for new starters etc MMU Engs Course – 8 persons just passed and certified E.g. Skill – Simocode training at TCS 1 yrish ago-Health Check training E.g. Awareness- Cap schemes- Link into model shown previous of Proj Engs defining what needed from the training E.g. Application request- Thro individuals owne development requests ie. Certain techs requesting to go on Health Checks on Cap schemes. E.g. Application need – When SAP order requests to attend eg Ian Lupton at Esholt Filters – Profibus Network devices not working due to xxxxxx Specific YWS Awareness by Co-ordinated Scheme Training Application by Request and Need

21 Education by Promotion
April 06 April 07 April 08 April 09 Internal ICA Profibus Presentation pre ICA/TCS Simocode & Profibus Data Course Renew Company Membership Profibus UK Profibus UK Seminar attendance Profibus UK Seminar Presentation ICA Projects Team Input to initial Company Profibus Guidelines ICA Projects Team Review of Company Profibus Guidelines E&H and ABB Hosted Profibus Days 2mins (15mins) PLC Framework Supplier Technical expert Introduction – ‘06 Qtr 1 Profibus UK Membership – which membership Company Membership Profibus UK Formation of Internal ICA Profibus Group Internal ICA Workshops to share ‘K’ and self development on TCS panel and Profibus Instrument Network MEUK Profibus Presentation ICA & Maint’ Strategy Team Sponsor & Endorse Delivery of Simocode/Profibus Valve Training Course for WBU & EBU Carillion Electricians

22 Skill by Generic Training
2 off Profibus Installer and Maintenance Course April 06 April 07 April 08 April 09 Bus’ Plan 2 off Profibus Installer & Maint’ Course Development & Delivery of IMCC Profibus related Training to Electricians Profibus Installer and Maintenance Course Bus Plan Further Profibus Installer & Maint’ Courses Bus Plan Training . “A Comms Course?” 2 off Profibus Installer and Maintenance Course Receive Profibus Engineers course 8 Delegates Profibus Networks and Instrumentation Training 2mins (17mins) Research, Liaison Development & Delivery of ICA/TCS Simocode & Profibus Data Course by Internal ICA Profibus Group Development, Distribution of DVD’s for self training on Profibus Network Integrity testing

23 Specific YWS Awareness by Specific Scheme Training
April 06 April 07 April 08 April 09 Lundwood FFD Haisthorpe WTW Esholt Ph1 FFD Blk Mds Incin’ Neily FFD Scheme Training pre ICA initiative to support Cap schemes Harlow Langsett Copley Main Works FFD 1min (18mins) Loftsome Naburn FFD Copley Sludge FFD

24 Application by Proactive Request and Business Need
April 07 April 08 April 06 April 09 High Royd & Harlow Hill Intelligent MCC. Problematic Network Investigation with Newly purchased Profitrace supported by 3rd Party. Specialist. Faults found and Reported Profitrace Tests on all new Profibus Networks from schemes. Project Level at request and/or Post handover. Future Template Increased Technical Input to SI Forum & Large Capital schemes by ICA Project Engineers Loftsome Intelligent MCC. Single Motor &/or Simocode Network Problem Rectification by Simocode YWSICA Corporate Licence Software diagnosing loose field connection Langsett WTW Intelligent MCC. Single Motor &/or Simocode Network Problem Rectified by trial and error 2mins (20mins) Blue is fault finding Yellow is Proactive input Early days – Rectifiication by trial and error – but no skill or knowledge increase – other than general Utilisation of Instrument tools and increased awareness Utilising of Profitrace and Simocode software on faults– initially utilising a 3rd party expert and then our own staff Profitrace software for integrity tests. Haisthorpe WTW IMCC & Field Network. Problematic Network Investigation with Newly purchased Profitrace. Faults found and reported to Project Team High Royd Intelligent MCC. Intelligent starter will not reset Rectification by both AMBS/ICA Cycle the Power Blk Mds Incin’ Intelligent MCC. Several Simocode devices not recognised and not working. Rectification by Multimeter and Profibus Technical Knowledge

25 Current and Future Profibus Maintenance Applications
Initial Integrity tests on Application handover Annual Integrity tests Version control of associated Devices Future Centralised Profibus data? Predictive Maintenance? Link into SAP generated work requests? 3mins (23mins) ACTION – Need to put titled doc into here to fae in just after aw1 but fade away at same time Utilising Technology, Business Ways of Working & Infrastructure FUTURE – Asychlic data

26 Summary of ICA Initial Integrity testing at scheme handover.
Installation – wiring of network in starter cubicle is designed for tradional starter, then the simocode unit replaces devices in the same location of the cubicle. Should the cubicle layout change to a standard to get the best layout for the network cable? Removing tight bends, increase cable spaceing, gettting the cable length correct, e.g not too short if the connector needs reconnecting, not too long to have cable spacing issues. Speed / Length list sites ? x Acceptable. Acceptable, but not to standard. Not acceptable, needs attention.

27 Sustainability of the knowledge and skills.

28 Current Skill base! ICA Technician PLC’s LOI’s Instrumentation SCADA
Electrical Devices In general YW ICA had a policy of setting on the best Electricians available and via training and work experience turned these people into ICA engineers. We liked people from this background as you could get involved in a range of electrical control and instrumentation tasks. In recent times as more specific technical knowledge is required, we have set on instrumentation technician with only instrumentation as a background. They are used to more complex instrumentation, but tend to lack skills in electrical control systems. Profibus and the ICA engineer. What skills are required?

29 Profibus and the ICA Technician.
Future Skill base! Profibus and the ICA Technician. SCADA PLC’s LOI’s Electrical Devices Instrumentation Profibus and the ICA engineer. What skills are required? LOI interface problems. Business as usual SCADA interface problems. Business as usual Instrumentation. Business as usual plus a few profibus communication settings. Electrical Devices VSD’s, Business as usual, plus a few profibus communication settings. VSD have already programmable settings for commissioning. Plus they are a electrical device, not ICA? FSD, new electrical programmable control device in Yorkshire Water, they are a electrical device, with a programmable setup! Valves, Business as usual, plus a few profibus communication settings PLC Knowledge to get to know how the PLC is controlling Business as usual PLC Knowledge and the profibus master card, how does the comms interface all hang together How complex is the understanding required, is it as simple as which are the target addresses for the profibus device input and outputs, Is it how a complex function block for Acyclic comms works. Do they need to know the setting for each device, do they need to know understand the setting for each device and what effect for example on the intelligent starter these setting have? Is it good enough to say the last device they set up the trip class as 30, do they need to know this was a special setup, will they put a trip class of 30 in the next intelligent starter they setup. I think NOT So now the ICA engineer needs to know about and understand all the devices on the Profibus network, which is a massive change compared to the traditional non intelligent installations.

30 YWS – Department Responsibilities of Data and Control
ICA Electrical ETHERNET – Office Comms ETHERNET – Office / Industrial Comms Hardwired 4 / 20mA and Digitals Profibus PID Controllers Electric Valves 1min (5mins) From a Maintenance aspect – why in ICA did we decide to do something about profibus? Profibus network and the skill base required. IT have the expertise in Ethernet in Yorkshire Water. Call outs are contracted out to external company, fix in x days. ICA have not got the in-depth knowledge of Ethernet, IT have but this leads to difficulties out of normal working hours. Within Profibus ICA have always taken the lead and are actively controlling the skill base. Purchase Profibus network analysis hardware and software. SCADA software VSD’s SCADA Hardware PLC’s MCC’s Corporate Network Telemetry Instruments

31 Training and Developing of Maintenance teams
Ownership of the training! Profibus Electrical ICA How do we increase the skill base in Yorkshire Water, traditionally give the engineers a bit of training and a few breakdown later, you have a expert, who then can pass that knowledge on to others. But what if the system rarely goes wrong, we think the answer is to give more regular training, to make up for the lack of on the job breakdown training. We have a small 4 cubicle intelligent MCC at a central location. This has been configured to Yorkshire Water standards. We have also acquired from instrumentation and valve partners various devices, we connected on a external profibus network on to this MCC. We have already undertaken many training courses on the MCC and there are plans to give regular training session based around the panel. As part of the training around the checks of Profibus network, we have developed training videos on how to use the health check software. Even though the health check can be quite boring (especially when every thing is health), we have implemented annual health check on all our Profibus network. The annual health check in a few years time may be change to for example a bi annual health check, we will not know this until we have collated health check data. The second benefit of the health check is that it is giving the ICA Technicians practise on how to analyse the Profibus network, very useful when things go wrong! As a extra bonus to the business we have trained our electrical contract partners on the intelligent motor control devices, this in turn should reduce the number of maintenance requests that are passed on to the ICA engineer from electrical partners .

32 Competency Measure of ICA Personnel on Profibus
1min.30 (30mins) ICA Maintenance teams ICA Asset team involved in supporting large schemes/ Regional team Geographically located N,S,E,W. Show and discuss – remote teams-isolated workers-passing of knowldege through individuals Then considered the Electricians Circa 50 across yws

33 Summary At end of all 1min (31mins)

34 Thank You Questions?


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