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Profibus Applications and Maintenance Strategies in Yorkshire Water Chris Howard. ICA Projects Operations Manager Adrian Wilkinson. ICA Projects Engineer.

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Presentation on theme: "Profibus Applications and Maintenance Strategies in Yorkshire Water Chris Howard. ICA Projects Operations Manager Adrian Wilkinson. ICA Projects Engineer."— Presentation transcript:

1 Profibus Applications and Maintenance Strategies in Yorkshire Water Chris Howard. ICA Projects Operations Manager Adrian Wilkinson. ICA Projects Engineer

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

3 Evolution of Profibus Applications in YWS Year 09080706050403 IMCC Aldwarke DeviceNet YWS ICA Profibus Strategy IMCC Clean and Waste sites DP-V0 IMCCs Installations Clean and Waste sites DP-V1 Formation of Profibus Asset Standards Document New YWS PLC Framework YWS MCC Forum YWS FFD Strategy Team Profibus Valves at Esholt WwTW Filters YWS Profibus Best Practice Guidelines Field Network Installations FFD Driver

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

5 Key Profibus Stakeholders within YWS Eng Spec Standards Teams ICA Maintenance Teams Engineering Consultants Project Delivery Partners M&E Maintenance Teams MCC Framework Partners FFD Strategy Team Maintenance Strategy & Asset Team

6 YWS World Class Asset Management Model

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.

9 Application Software Change Management Managed the change. –PLC provider change to a IEC 61131-3 platform.

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 MCCs.

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

12 Instrument function block development initially accounted for 25% inconsistence in program development. Instrumentation MCC No previous instrument function blocks, as we only used the analogue signal and a fault contact from Instruments. We didnt have a good understanding of what extra information Profibus instrumentation could give us and how useful that information was.

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

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

15 Real Inputs Control and Status Real Outputs Traditional Function block Data Inputs Control and Status Data Outputs Profibus Function block MCC Instrumentation

16 Parameterisation of Simocode unit. Background & reasons! MCC –Existing contractual reasons with E & M Maintenance partner. –The Intelligent Motor control device is a electrical device. –No Laptops.

17 HMI PLC Intelligent Motor Control device MCC Parameterisation of Simocode unit.

18 Have we created a conflict in backup version control ! Have we re engineered the wheel ! Technical achievement ! Parameterisation of Simocode unit. MCC

19 ICA Maintenance Strategy

20 ICA Profibus Knowledge Model Skill by Generic Training Education by Promotion Application by Request and Need Specific YWS Awareness by Co-ordinated Scheme Training KNOWLEDGE

21 MEUK Profibus Presentation ICA Projects Team Input to initial Company Profibus Guidelines Education by Promotion April 06 Company Membership Profibus UK ICA Projects Team Review of Company Profibus Guidelines ICA & Maint Strategy Team Sponsor & Endorse Delivery of Simocode/Profibus Valve Training Course for WBU & EBU Carillion Electricians Profibus UK Seminar attendance Renew Company Membership Profibus UK Internal ICA Workshops to share K and self development on TCS panel and Profibus Instrument Network April 09 Profibus UK Seminar Presentation Formation of Internal ICA Profibus Group E&H and ABB Hosted Profibus Days Internal ICA Profibus Presentation pre ICA/TCS Simocode & Profibus Data Course April 07April 08

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

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

24 Application by Proactive Request and Business Need April 06 April 07April 08 Langsett WTW Intelligent MCC. Single Motor &/or Simocode Network Problem Rectified by trial and error Loftsome Intelligent MCC. Single Motor &/or Simocode Network Problem Rectification by Simocode YWSICA Corporate Licence Software diagnosing loose field connection Blk Mds Incin Intelligent MCC. Several Simocode devices not recognised and not working. Rectification by Multimeter and Profibus Technical Knowledge Increased Technical Input to SI Forum & Large Capital schemes by ICA Project Engineers High Royd Intelligent MCC. Intelligent starter will not reset Rectification by both AMBS/ICA Cycle the Power High Royd & Harlow Hill Intelligent MCC. Problematic Network Investigation with Newly purchased Profitrace supported by 3 rd Party. Specialist. Faults found and Reported Haisthorpe WTW IMCC & Field Network. Problematic Network Investigation with Newly purchased Profitrace. Faults found and reported to Project Team Profitrace Tests on all new Profibus Networks from schemes. Project Level at request and/or Post handover. Future Template

25 Current Initial Integrity tests on Application handover Annual Integrity tests Version control of associated Devices Current and Future Profibus Maintenance Applications Future Centralised Profibus data? Predictive Maintenance? Link into SAP generated work requests?

26 Summary of ICA Initial Integrity testing at scheme handover. ? x Acceptable. Acceptable, but not to standard. Not acceptable, needs attention.

27 Sustainability of the knowledge and skills.

28 Current Skill base! ICA Technician LOIs SCADA Instrumentation Electrical Devices PLCs

29 Future Skill base! Profibus and the ICA Technician. PLCs LOIs SCADA Instrumentation Electrical Devices

30 YWS – Department Responsibilities of Data and Control ITElectricalICA Electric Valves MCCs PID Controllers PLCs Instruments Telemetry VSDs SCADA Hardware Corporate Network SCADA software ETHERNET – Office / Industrial CommsETHERNET – Office Comms Hardwired 4 / 20mA and DigitalsProfibus

31 Training and Developing of Maintenance teams Ownership of the training! ICA Electrical Profibus

32 Competency Measure of ICA Personnel on Profibus

33 Summary At end of all

34 Thank You Questions?


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