profibus applications and maintenance strategies in yorkshire water chris howard. ica projects...
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Profibus Applications and Maintenance Strategies in
Yorkshire Water
Chris Howard. ICA Projects Operations Manager
Adrian Wilkinson.ICA Projects Engineer
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
Evolution of Profibus Applications in YWS
Year
‘09‘08‘07‘06‘05‘04‘03
IMCC Aldwarke
DeviceNet
YWS ICA Profibus Strategy
IMCC Clean and Waste sites DP-V0
IMCC’s 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
Key Profibus Stakeholders in YWS and Their Impact On YWS Application
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
YWS World Class Asset Management Model
Technical Applications, Developed and Applied Within
Yorkshire Water
Traditional MCC
• Best Practice and Standards Documents – Good engineering,
electrical & control specification.
– Standard Documentation for all panel manufacturers and system integration.
Application Software Change Management
• Managed the change.– PLC provider change to a IEC 61131-3 platform.
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.
Proportion of the application of Profibus on Yorkshire water sites.
75%
MCC Instrumentation
25%
• Instrument function block development initially accounted for 25% inconsistence in program development.
InstrumentationMCC
• 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.
• Normal route of a function block.
SystemIntegrator A
SI Forum
Yorkshire Water Standards
SystemIntegrator B
SystemIntegrator C
SystemIntegrator D
PLC Programming
Instrumentation
• Initial route of a instrumentation function block
SystemIntegrator A SI Forum
Yorkshire Water Standards
SystemIntegrator B
SystemIntegrator C
SystemIntegrator D
PLC Programming
Instrumentation
Real Inputs
Control and
Status
Real Outputs
Traditional Function block
Data Inputs
Control and
Status
Data Outputs
Profibus Function block
MCC Instrumentation
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.
HMI PLC Intelligent Motor Control device
MCC
Parameterisation of Simocode unit.
• Have we created a conflict in backup version control !
• Have we re engineered the wheel !
• Technical achievement !
Parameterisation of Simocode unit.
MCC
ICA Maintenance Strategy
ICA Profibus Knowledge Model
Skill by Generic Training
Education by Promotion
Application by Request and Need
Specific YWS Awareness by Co-ordinated Scheme Training
KN
OW
LED
GE
MEUK ProfibusPresentation
ICA Projects Team Input to initial Company Profibus Guidelines
Education by PromotionApril 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 07 April 08
2 off Profibus Installer and Maintenance Course
Skill by Generic TrainingApril 06 April 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 DVD’s for self training on Profibus Network Integrity testing
Specific YWS Awareness by Specific Scheme Training
April 06 April 07 April 08
Harlow
Loftsome
LangsettScheme 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
April 09
Application by Proactive Request and Business Need
April 06 April 07 April 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 3rd 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
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?
Summary of ICA Initial Integrity testing at scheme handover.
√
?
x
Acceptable.Acceptable, but not to standard.Not acceptable, needs attention.
Sustainability of the knowledge and skills.
Current Skill base!
ICA Technician LOI’s
SCADA
Instrumentation
Electrical Devices
PLC’s
Future Skill base!
• Profibus and the ICA Technician.
PLC’s
LOI’s
SCADA
Instrumentation
Electrical Devices
YWS – Department Responsibilities of Data and Control
IT ElectricalICA
Electric Valves
MCC’s
PID Controllers
PLC’s
InstrumentsTelemetry
VSD’sSCADA Hardware
Corporate Network
SCADA software
ETHERNET – Office / Industrial CommsETHERNET – Office Comms
Hardwired 4 / 20mA and DigitalsProfibus
Training and Developing of Maintenance teams
• Ownership of the training!
ICA Electrical
Profibus
Competency Measure of ICA Personnel on Profibus
0
5
10
15
20
25
30
35
Not a
ware
Aware
Min
imal S
kill
Compe
tent
Profic
ient
Highly
Skil
ful
Knowled
geable
Highly
Kno
wledg
eabl
e
Exper
t
Competency
No
.of
ICA
Tec
h's
/En
g's Estimated "K" on Previous Comms Netw orks
Profibus - Expected spread of K w ith No ManagedKnow ledge/Skill gain
Profibus - Desired K and Skill gain w ith ManagedKnow ledge/Skill gain
Profibus - Measured K and Skill gain w ith ManagedProgram
Summary
• At end of all
Thank You
Questions?