managing totex in amp6...can usually be justified based on the potential for operational performance...

Managing TOTEX in AMP6 An Information Driven approach

2 Commercial In Confidence ©Copyright RIVENTA 2015

1.0 Purpose of this Document The following document aims to outline how products and services provided by Riventa,

through its authorized delivery partner Deritend Ltd, can support the optimal

management of TOTEX.

Deritend is a UK based, multi-site service provider

specialising in managing customers’ mechanical &

electrical assets to the highest standards

Riventa is a leading provider of pump efficiency

measurement and station optimisation expertise,

serving the Water & Waste Water Industry


2.0 The benefits of an Information driven approach to TOTEX A fundamental requirement of managing TOTEX is that decisions must then be made

based on quantitative measures in order to optimize the “Total cost of ownership”.

Therefore a pre-requisite of any TOTEX reduction initiative must be the acquisition of

data that is reliable, accurate and current.

Therefore TOTEX can best be minimized through an Information driven approach,

where the base-line data is trusted in order to make decisions which will have positive

long-term implications on TOTEX outcomes.

One critical measurement for Water distribution companies is that of “Pump Efficiency” ,

for two reasons; i) because Pump Efficiency degrades naturally with use/time and ii)

Pump Efficiency changes with system characteristics/head. The latter is often the cause

of hidden costs in terms of excessive energy costs and potentially a greatly reduced

useful life of the pump.

Until the last 10-years, historically pump efficiency has been very difficult to measure in

situ. Today the maturing of technology has led to the availability of pump Efficiency

Measurement systems that are accurate, reliable and durable. The proliferation of this

technology has been accelerating over recent years due to i) the increasing imperative

for asset owners to achieve cost reduction and ii) the availability of information systems

which make it possible to utilize the resulting information.

Data-driven decision making is defined not only by collecting data, but also by how and

if it is used in making crucial decisions – such as when and how to improve the

performance of a pump, motor or ancillary equipment. Riventa has focused not on the

measurement technology as the deliverable to the client, but, moreover, we continue to

be focused on the “Outcomes” in terms of “Total Cost Reduction” that can be achieved

by Utilizing the information.


Blue-chip clients who have used Riventa have without exception gained confidence in

making business decisions based mainly on “data and analysis” provided by Riventa

and shifting away from decisions made on “experience and intuition.”

For pump repair, replacement or refurbishment the best decision in terms of TOTEX can

be made with a full set of data - ideally over a 12-month period, so as to take account of

seasonal variations as well as short-term 24-hour demand variation.

In smaller assets (nominally less than 100kW) this can be cost prohibitive as the annual

running costs are relatively low compared to the cost of monitoring, analyzing and

managing the data. In these cases, Pump Testing provides a snapshot of performance

in terms of pump condition and the efficiency curve. Pump Testing can also deliver a

static system curve which gives an indication of the actual efficiency achieved under

real operating conditions.

For larger pump (above 400kW) the business case for high precision pump monitoring

can usually be justified based on the potential for operational performance

improvements alone. It is not uncommon to identify energy savings in the order of 10%

by optimizing the operational decision making within a given pumping station. This

includes Pump Selection, Pump Scheduling and the timing of decision-making.

Using the same pump monitoring data, it is then possible to reliably characterize the

dynamic system performance as well as pump condition. This provides the opportunity

to optimize the capital decision-making by refurbishing or replacing with new assets in

order to significantly improve the suitability of the pump for the system in which it

operates. Riventa have seen numerous instances where an over-sized pump has been

refurbished and the outcome is an even higher energy bill and shorter than expected

asset life.


3.0 Measurement Technology Riventa have a range of technology manufactured for the measurement of pump

performance in a wide range of industries and applications, however our focus [and

reputation for delivering successful cost reduction projects] is on maximizing short-term

and long-term cost reduction for our clients in the Water and Waste water industry.

Riventa will recommend the utilization of existing site instrumentation - where it has the

potential to provide data of the required integrity. In some cases, particularly high-

energy pump sets, the overall saving that can be achieved is significantly influenced by

the accuracy of the measurement equipment. A site survey is always the first step to

assessing the most suitable way to achieve successful cost reduction.

A combination of existing site instruments and additional measurement technology is

also a potential solution. Riventa have the expertise and experience to make use of the

interconnectivity of intelligent sensors and measurement devices. Our ECOFLOW and

PROFLOW products are designed to leverage existing site flow meters and pressure

measurements, where appropriate.

Below the three core technologies that Riventa can offer are outlined under the broad

categories: -

Pump Testing

• On-site Service provided by Deritend LTD

• Off-site Analysis and reporting

Pump Monitoring

• Installed Equipment (Either FREEFLOW, ECOFLOW or PROFLOW System)

• Customised Real-time Decision Support Software System (Online or Offline)

• Remote support and recommendations


3.1 Pump Testing The FREEFLOW is a “Hybrid” pump testing system as it is the only product on the

market to provide the thermodynamic pump efficiency measurement method and a fully

integrated Conventional Method within the same system.

The FREEFLOW is considered the new standard for on-site testing as the

thermodynamic method exceeds the requirements of ISO 5198 and the “Conventional

Method” exceeds the standard required for BS EN ISO 9906:2012.

The FREEFLOW Portable is used by RIVENTA & DERITEND to deliver on-site testing

services.

Besides providing trained and experienced staff, to minimise the risk of poor pump test

results, the FREEFLOW system incorporated Real-time quality checks on measurement

quality. Using the statistical measurement of Standard Deviation (σ) which shows how

much variation or dispersion from the average exists for each parameter. A low standard

deviation indicates that the data points tend to be very close to the mean – which imply

low levels of measurement uncertainty.

Riventa has experience within many UK Water companies – at developing bespoke

testing equipment for specialist or non-standard applications. For example Diesel

engine driven pumps were tested using a method of Torque measurement on site. This

provided the best available methodology and results for the client.


3.2 Pump Monitoring Riventa is leading the field of installed pump monitoring in terms of reducing Costs,

Energy and Emissions. All Riventa measurement technologies provide the core data

required to optimize the pumping operations, including;

• Pump Efficiency (%)

• Pump Flow Rate (MLD, l/s)

• Pump Head (m)

• Electrical Power (kW)

Pumping system characteristics typically change with demand and station operation.

Using pump monitoring, these changes can be observed and controlled. Often, hidden

characteristics can be discovered which can lead to major improvement in overall

operating efficiency and pump lifecycle costs.

Measure, Monitor and Control: The principle benefit of pump monitoring comes from

enhanced plant Information. The ability to Measure, Monitor and Control can lead to

major enhancement in station performance. Monitoring solutions from Riventa are

essential tools for reducing the downsides associated with pumping including:

• Energy consumption

• Carbon Emissions

• Pump failure

• Premature wear

Trending Pump Degradation: To schedule your Capital Expenditure, Riventa Pump

Monitoring solutions are an essential tool. This is because real-time data is the most

comprehensive and accurate way to trend pump degradation over time.

As a real alternative to regular on-site pump testing, it also enables easier maintenance

planning. Using trend data, it becomes possible to predict the most cost-effective time


for pump replacement, refurbishment, coating or other remedial maintenance.

The reliable and accurate data ensures that the best decisions are made with respect to

asset improvement – as the real operating conditions are captured in the Database for

analysis at any time.

The three measurement solutions are outlined below including: -


3.2.1 (Motors rated 400kW+) Based on the same core technology as the Portable FREEFLOW pump testing system,

the FREEFLOW is also available as a “Thermodynamic pump monitoring” System.

Designed for permanent installation, it provides real-time pump performance

measurements within the industrial pumping environment. It will measure hydraulic

performance of each individual pump and can be installed without any costly

modification to pipe work. It is also capable of delivering accurate and reliable Flow rate

and Pump Efficiency.

HIGHLIGHTS • Measure Pump Head, Flow, Efficiency and Power

• High Precision to identify every 1% of saving

• A Total Information-based Maintenance Solution

• Detection of Cavitation / NPSH problems

• Track Reduction in pump efficiency

• Integrates with Existing PLC/SCADA System

• Remote Consultancy, support & Analysis available

PLC / SCADA INTERFACE


The FREEFLOW Pump Monitoring system can monitor hydraulic performance, pump

efficiency and in conjunction with our Operator Interface Software, the real-time

effectiveness of each pump can be evaluated. Because a pump is usually part of a

dynamic system, its contribution will vary with demand and system characteristics.

FREEFLOW technology provides the tools to measure, evaluate and maximise system

performance.

Where FREEFLOW Pump Monitoring system is installed, real-time pump data is

captured, processed and provided to managers and operators. Every minute of the day

and night the “Enhanced Information” available from FREEFLOW can be used to

reduce station operating costs.

This industry-leading measurement solution uses state-of-the-art measurement

technology [which is exclusive to Riventa] and exploits the principles of the

Thermodynamic method to calculate hydraulic performance; using differential

temperature, suction pressure, delivery pressure and Electrical power to each motor in

order to provide the key hydraulic measurements: -



• Pump Head (m)


FREEFLOW data can be integrated with your PLC to enhance control system regime.

Data can be viewed using SCADA, GSM modem or uploaded through its integrated

web-server to a secure SQL database.

COST MANAGEMENT is achieved by monitoring Head, Electrical power, Pump

Efficiency and Flow Rate enables us to trend and characterize hydraulic KPI’s to reduce

Operational expenditure and Capital Expenditure. Real-time Operator guidance is

available to standardize least cost station operation where manual decisions are made


about pump operation. Where different operator shifts are utilized, the Freeflow system

can provide the same decision support across 24-hour shift patterns.

3.2.2 (Motors rated <400kW)

The PROFLOW Station Performance Monitor provides real-time data on each individual

pump, deriving pump efficiency from the station flow meter. Designed specifically for

smaller water pumping stations with Pumps typically below 400kW.

HIGHLIGHTS

• Measure Pump Head, Flow, Efficiency and Power

• Utilizes Station Flowmeter to calculate individual Pump Performance







This novel measurement solution uses the patented ECOFLOW algorithm which is able

to divide the common station flow meter into the individual contributions of each pump

with 100% accuracy. Secondary measurements of suction and discharge pressure and

electrical power enable the computation of pump efficiency, to each motor in order to

provide the key hydraulic measurements: -



• Pump Head (m)


ECOFLOW data can be integrated with your PLC to enhance control system regime.




Efficiency and Flow Rate enables us to trend and characterize hydraulic KPI’s to reduce

Operational expenditure and Capital Expenditure. Real-time Operator guidance is

available to standardize least cost station operation where manual decisions are made

about pump operation. Where different operator shifts are utilized, the Freeflow system

can provide the same decision support across 24-hour shift patterns.


3.2.3 (Any waste water application) NEW PRODUCT In addition to the functionality of the ECOFLOW, the PROFLOW Station Performance

Monitor is a real-time protection device providing alarm out of imminent problems with

the pump, motor or system. Designed specifically for the harsh environment of waste-

water pumping stations. PROFLOW monitors all the essential mechanical and

hydraulic parameters to detect the onset of problems or degradation of performance.

HIGHLIGHTS

• Measure Pump Head, Flow, Efficiency and Power

• Utilizes Station Flowmeter to calculate individual Pump Performance







Through advanced accelerometer technology, the pump and motor set can be

benchmarked for mechanical performance against ISO standards and historic data.

This data can also be cross referenced to the changing performance of the pump

through the patented PROFLOW algorithm which is able to divide the common station

flow meter into the individual contributions of each pump with 100% accuracy.

Secondary measurements of suction and discharge pressure and electrical power

enable the computation of pump efficiency.

The mechanical signature of a pump and motor will change with different operating

points (through variable speed or system changes), therefore it is important not to

confuse these variations with the onset of mechanical problems; therefore reconciling

mechanical and hydraulic data is an essential part of assessing pump and motor health.

PROFLOW data can be integrated with your PLC to enhance control system regime.




Efficiency and Flow Rate enables the customer to trend and characterise hydraulic and

mechanical KPI’s to reduce Operational expenditure and Capital Expenditure.

CONDITION-BASED MAINTENANCE Using RMS velocity, enveloped acceleration and

Fast Fourier Transforms processing methods enable detection of pump, motor and

system problems like rolling element degradation, looseness, cavitation, misalignment,

imbalance / unbalance and air entrapment. Prediction of degradation and failure

enables scheduled, rather than out of hours, maintenance resulting in reduced damage

and lower maintenance costs


4.0 INFORMATION SYSTEM Riventa understands the essential need to capture, back-up and secure your data. Our

systems are compatible with existing site PLC and SCADA systems and can therefore

be readily integrated with your existing systems (including control room applications).

Alternatively or additionally, we can provide fully-secure remote support and data

services over the internet using a secure 256 bit AES tunnel over the internet and

provides a very robust Information system.

Remote access enables Riventa to provide outstanding support and services. Our

Hydraulic engineering consultants can review your data and provide a report at any

time. Our technical support staff can diagnose any system faults and arrange repair

without the need for a site visit.

USERS ACCESS SERVER VIA ENCRYPTED

TUNNEL

RIVENTA SECURE SERVER

AUTHORISED CLIENT USERS

VPN NETWORK SECURED BY ENCRYPTION


5.0 Methodology

Our Methodology is best developed with and customised to suit the objectives of each

customer, however, some of the key factors are outlined below: -

1. Define Hierarchical priorities: (Top-down v. Bottom up / Sub-network v. Station v.

Pump-Level TOTEX Management)

2. Define Strategic Priorities: Finite Investment resources will require priority

decisions with respect to Security of supply v. Short-term payback)

3. Define the mission critical information and data required to manage TOTEX

4. Develop a Management Information System (MIS) to apply business case to

each project. Also required to manage long-term assessment of TOTEX

reduction.

5. Test methodology at a pilot site to test methodology.

AUDIT ASSETS & PRIORITISE

PRECISION PUMP MONITORING

CLEAN WATER PUMPS

CLEAN WATER

PUMPS

LOWCOST PUMP MONITORING

HIGH ENERGY USERS LOW

SHORT, MEDIUM & LONG TERM CAPITAL IMPLEMENTATION BASED ON GPX INDEX & FINANCIAL CASE

REACTIVE MAINTENANCE

OPTIMISED ‘REAL-TIME’ OPERATION

OTHER TESTING FRAMEWORK PUMPS

MEDIUM

PORTABLE PUMP TESTING

WASTE WATER

PUMPS

PUMP MONITORING & PROTECTION


6.0 Deliverables Riventa will guarantee to find all significant sources of saving relating to pumping

operations and asset performance within a given pumping station.

Each site will be evaluated individually and the best course of action outlined and

proposed to the client for consideration.

To do this, through our delivery partners Deritend, and with our mix of products and

services, we will deliver the following benefits: -

• Ascertain the current condition of assets

• Ascertain site constraints with respect to operations

• Real-time Operator Guidance (Train and Standardise best operation practice)

• Provide predictive and preventative maintenance data (from accurate real-time

data, through real-time communication)

• Provide data visibility to key stakeholders (Authorised Manager, Operators &

partners)

• Optimize future decision-making based on accurate Pump Monitoring data

• Identify dynamic system curve in order to minimize operation & ensure asset

changes are “Fit for purpose”.

• Inform on demand changes with time (Historic station duty v. current v. future –

prevent like-for-like replacement of incorrectly sized assets)

• Accurately determine the benefit of Asset replacement based on dependable

benchmark data

• Demonstrate savings in OPEX and CAPEX in a methodology agreed with by

Riventa, Deritend and the client.


Bespoke Solutions: Most clients choose Riventa Pump Monitoring solutions in order to

optimise plant operation and save energy. Therefore as part of the FREEFLOW system

Riventa usually provide plant optimisation software as standard. As our software

systems are modular, we can rapidly produce a software user Interface which is

customised to your application.

Training: We also provide training to make sure your organisation can fully utilise this

powerful system. Riventa shares the aim of its clients – which is to maximise plant

performance and minimise payback period. Training is always carried out with local staff

to support the long-term benefits of whichever system we provide.

Support: In most applications, Riventa utilise remote communications to monitor the

ongoing performance of the plant. This means that our consultants have access to data

and can identify ongoing plant improvements – based on historic data and the most

common operating conditions. This has become an essential tool for maximising

ongoing energy and cost saving.

Quality and Reliability: Designed for use in an industrial environment; our Pump

Monitoring solutions are very low maintenance and requires only periodic calibration in

most applications. Developed and built by Riventa designers - quality and reliability are

a key focus in all Riventa products.

Partnership: Riventa are working with Deritend Ltd across the UK water industry.

Deritend have strong relationships with many UK Water Companies and have

experience at installing and maintaining our products through their network of engineers

based in West Bromwich and Luton.


RIVENTA UK Riventa Ltd ǀ Pool Innovation Centre Trevenson Road ǀ Pool ǀ Redruth ǀ Cornwall ǀ TR15 3PL T +44 (0)1209 311244 +44 (0)1404 548016 M +44 (0)7798 780950 [email protected] www.riventa.com RIVENTA KOREA Riventa Korea Co. Ltd ǀ Prugio Building 4 Office 207 ǀ 499 Cheonghak-dong ǀ Yeonsu-gu Incheon Metropolitan City ǀ Republic of Korea 406-831 T +82 (0)32 814-9929 M +82 (0)10 4000-9929 [email protected] www.riventa.com

managing totex in amp6...can usually be justified based on the potential for operational performance...

Documents