enhanced training methods for operations staffnysawwa.org/docs/pdfs/session_6_4.pdf · 1 20 october...
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© ARCADIS20 October 20151 © ARCADIS20 October 20151
Enhanced Training Methods
for Operations Staff
Ways to make training stick
September 24, 2015
September 24, 2015
© ARCADIS20 October 20152
Authors
• Suman Bopaiah, ENV SP
‒ ARCADIS, Commissioning/Training Coordinator (CMJV)
• Edward G Kowalski, PE, PMP
‒ ARCADIS, Control Systems Commissioning Leader (CMJV)
• Jim Hanratty, PE
‒ NYCDEP BWS, Eastview Regional Manager
© ARCADIS20 October 20153
What We’ll Be Covering
• Enhanced staff training provided during the
commissioning phase at the Catskill/Delaware
Ultraviolet Facility (CDUV)
• Benefits of augmenting traditional training with
immersive training
• Lessons learned and current use of enhanced
training tools at CDUV
© ARCADIS20 October 20154
Project Background: Water Flow & UV Facility
Rendering
Hillview
Reservoir
UV
Catskill Aqueduct
City Tunnels
Kensico
Reservoir
Delaware Aqueduct
Shafts 19
Future Pressurized
Catskill Aqueduct
North Forebay
UV Building
Shaft 19Generator
Building
© ARCADIS20 October 20155
Project Background
• Location: Town of Mt. Pleasant, NY
• Largest UV water disinfection facility in the world
• Largest unfiltered surface water system in the U.S.
• Serves ~9 million customers
• Can disinfect (UV) up to 2.4 BGD of water
• Project Cost ~$1.6B
© ARCADIS20 October 20156
Project Background: Key Facility
Components
• Forebays / Influent Gates
• 56 UV Units (cap. 60 MGD each)
• 4 Quadrants
• 16 Energy Dissipating Valves
• 5 Generators
• 6 Venturis144”
Venturi
Diameter
© ARCADIS20 October 20157
March 30,
2011
Enclose UV
Building
March 17,
2012
Electrical
Substation
August 3,
2012
1st UV
Quadrant
October 29,
2012
Plant Fully
Operational
February 2013
BWS
Turnover/Acceptance
August 31,
2012
2nd UV
Quadrant
November 8,
2012
Commissioning
Period Ends
2014
BWS Full
Facility
Operations
CMJV Operation + BWS Staff Support, Engagement & Training
Facility Commissioning:
Milestones (~ 2 years Training)
© ARCADIS20 October 20158
Facility Commissioning: Team
Collaboration (CDUV Staff)
• SEW, Welsbach, LJ Coppola and Sub-Contractors
• Hazen & Sawyer / CDM Smith
• ARCADIS / CH2MHill
• DEP(BEDC/BWS)
NYCEP
Construction Management Joint Venture
ContractorsDesign
Joint Venture
25 Operations & Supervisory Staff
15 Maintenance, Instrumentation, SEE, &
Computer Specialists
6 Administration Staff & Others
© ARCADIS20 October 20159
Vendor Training (Contractor)
Systems Training
(DJV)
Systems O&M Manual Training
(DJV)
Health & Safety and Other
(DEP)
Traditional Training
Facility Commissioning:
Traditional Training
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Recognizing Enhanced Training
Opportunities
• Meeting testing and meet water demand
Flow Demand
• Complex coordination upstream and downstream
• Transition from manual to complex auto control strategies
Flow Control/Automation
• UV Units in and out-of-service
• DOH reporting needs
Disinfection
• Troubleshooting at “live” facility
• System response: e.g. takes 40 minutes to open north forebaygates
Construction & Testing
• First UV system for the DEP
• Hiring and rapid on-boarding
Staff
• Power savings, UV dose, instrument calibrations
System Optimization
© ARCADIS20 October 201511
Operations EngagementConstruction Tracking
Engagement
Communication
Coordination
Vendor Training (Contractor)Systems Training
(DJV)
Systems O&M Manual Training
(DJV)
Health & Safety and Other
(DEP)
Traditional Training
Computer-Based Simulation
En
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Enhanced Training Approach:
Augmenting Traditional Methods
© ARCADIS20 October 201512
Operations Engagement:
Control Room
• On-the-job training (OJT) during 24/7 Control
Room Operations:
‒ Trained small groups by witnessing CMJV staff
operate initially (CMJV – 2; BWS – 3)
‒ Performed walk-through of facility
‒ Provided training on Control Room duties -
recognizing PMCS data and alarms
Operations
© ARCADIS20 October 201513
Operations Engagement:
Control Room
• On-the-job training (OJT) during
24/7 Control Room Operations:
‒ Process monitoring forms
‒ Routine/Round Forms
‒ Targeted training (UV basics,
alarm management, etc.)
Operations
© ARCADIS20 October 201514
Construction Tracking Engagement
• Increase familiarity of system components and
ensure uninterrupted water supply:
‒ WARF/Process
‒ Incident
Notifications
Construction Tracking
Work Activity Registration Form
© ARCADIS20 October 201515
Communication Coordination
• Institute Communication Plan to ensure effective
information transfer between shifts
‒ Flow Control Oversight
‒ Daily Planning Meetings
‒ Email Notifications
‒ White-board updates
‒ Daily conference calls
Communi-cation
© ARCADIS20 October 201516
Communication Coordination
• Monitoring
‒ PMCS & Equipment
• Issues Notification
‒ Startup & Commissioning
• Beginning & End of Shift
Reporting
‒ Flow Testing Status
Communi-cation
Equipment Monitoring Form
Flow Testing Status Form
© ARCADIS20 October 201517
Communication Coordination
Beginning and End of Shift Reports
Communi-cation
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Communication Coordination
• DOH Reporting
‒ Collected input from commissioning team members to
configure Historian
‒ Reformatted the report, adjusted the HMI to simplify
manual data
‒ Collaborated with staff and provided training
throughout DOH refinement process
Communi-cation
© ARCADIS20 October 201519
Simulation Environment
• Simulation Environment:
‒ Full complement hardware/software
Limitation: no complete UV Vendor Unit
Panel/ or Entire Model/Quadrant
‒ Offline Control Logic Revision Testing
Modification to Control Strategies tested in
the simulator (either on site or at the
integrator facility)
‒ Implementation Planning
Methodical approach with buy-in from team
on schedule of execution of more complex
strategies
Computer-Based
Simulations
Simulator: Transition to Automation
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• Simulation set up in
software/hardware
• Operator training teams
‒ Risk, failure scenarios
‒ High level strategies
‒ Vendor panel sequences
Computer-Based
Simulations
Simulator: Set up & Training
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• Changes run through multiple times/
varying scenarios
• “Actual” reflected in control room, real
training environment
Operation Team Exercise : Simulate failure UV chemical cleaning
Computer-Based
Simulations
Simulator: Updates
© ARCADIS20 October 201522
Simulator: Updates
• Tiered Approach to Staged transition to
Automatic Operation:
‒ Level 1: Semi-Automatic
NYCEP “co-pilot” / CMJV & Contractor “pilots”
Local Auto control (UV) coupled with Remote
Manual (EDV)
• 6-8 months
• Gain familiarity with simulator/embedded logic
‒ Level 2 – Automatic: Full auto flow control
‒ Level 3 – Optimization: System-wide flow
optimization, energy optimization
Computer-Based
Simulations
© ARCADIS20 October 201523
• Increases staff engagement
• Increases knowledge of equipment/ system
operations
• Elevates confidence levels
• Fosters ownership of system
• Prepares staff for high levels of automation
and new technology
23
• Meets contract requirements
• One-size-fits-all approach
• Non-immersive
• Short-term impactsVendor Training (Contractor)
Systems Training
(DJV)
Systems O&M Manual Training
(DJV)
Health & Safety and Other
(DEP)
Traditional Training
Operations Engagement
Construction Tracking Engagement
Communication Coordination
Computer-Based Simulations
En
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nc
ed
Tra
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Traditional vs Enhanced Training
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Current Operations
>1.1
BGDNormal flow
Dose
Reduction
3%Critical Alarms
Manual/Auto
Full Auto next year
SimulatorTraining Tool
EOM,
SOP
Updates
© ARCADIS20 October 201525
Lessons Learned & Results of
Enhanced Training
• Needs to be customized to fit utility and staffing needs
• Routine Round Sheets adopted and currently in use
Operations Engagement
• Budget for additional training as early as possible
• WARF currently used by utility staff
Construction Tracking engagement
• Led to healthy collaboration
• Beginning & end of shift report currently in use
Communication Coordination
• Simulator has limitations. Costly.
• Train staff in a virtual environment (identical to control room)Computer-Based
Simulator
© ARCADIS20 October 201526
Staff Feedback
“Morning WARF
meeting was great”
“Hands-on
training is critical”
“Pilot and co-pilot
exercises helped
during commissioning”
“End of Shift reports
quickly summarized
Ops for next crew”
© ARCADIS20 October 201527
Future
• Cross-training of Operations & Maintenance staff
• Electronic Operation Manual (EOM) updates will
document system improvements and SOPs
• Dose Reduction and Energy Optimization
• Continual Improvement