INTEGRATED PLANT ENGINEERING IN WATER TECHNOLOGY

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1 INTEGRATED PLANT ENGINEERING IN WATER TECHNOLOGY Konferenz für Durchgängige Anlagenplanung 2013 Integrated Plant Engineering Conference 2013 Nürnberg Achim Ewig, PWT Wasser und Abwassertechnik GmbH (1)

2 Integrated Plant Engineering in Water Technology Introduction PWT Aspects of Plant Engineering Approaches to higher Efficiency Implementation of Integrated platform Integrated 3D- Plant Engineering Integrated Process Control and Automation Integrated Operations and Maintenance (2)

3 Wasser und Abwassertechnik GmbH Company data: Management Board: Employees: 225 Headquarter: Dipl.-Ing. Rüdiger Böckle Dipl.-Ing. Klaus Dickhoff Zwingenberg / Germany Company history: 1965 Start of activities in water technology with PREUSSAG AG Location Zwingenberg until 1998 branch of Preussag Wasser & Rohrtechnik 1998 Merger of the Preussag Group s water activities in Preussag Wassertechnik GmbH 2001 Company renamed in PWT Wasser- und Abwassertechnik GmbH, Company Headquarter Zwingenberg 2004 PWT takeover by Saudi Arabian Amiantit Company Group (SAAC) Branch Offices and Subsidiaries: Leipzig, Hamburg Istanbul / Türkei, Bukarest / Rumänien Ashgabat / Turkmenistan Baku / Aserbaidschan Dammam / Saudi Arabien info@pwt.de (3)

4 Business Areas and Activities WATER Planning, Realization, Commissioning and Operating Drinking water Water treatment plant, Sea water desalination, Decontamination, Groundwater treatment, Net water pumping stations Process water Cooling tower make-up water treatment, Bypass filtration, Condensate polishing, Boiler feed water treatment, Flue gas washing water treatment, Process water treatment, Rinse water treatment Waste Water Automation and Process Control Technology (4) Communal und Industrial waste water treatment Landfill-leakage water treatment Pumping stations Process Control Systems, Automation- and Telemetry systems Medium- and Low voltage switch gears for all kind of water treatment facilities and networks

5 Plant Engineering WATER Systematic usage of knowledge in the design, creation and optimization of plants Cooperation of different disciplines (process-, civil-, mechanical- electrics and automation engineering) Planning steps be carried out in one or more project related, consecutive phases Multiplicity of individual interdependent activities Procedure model for project activities Procedure model for project independent activities Key factors are Quality, Expenses and adherence to schedules (10)

6 Project phases and related activities WATER PROJECT Process & Basic design Block diagram Process flow diagram Substances, Substance streams Simulation data Power demand calculation P & I- diagram Pipe Classes Equipment& Instrumentation specification Functional design specification General layouts. (11) Detail design Layout and Arrangement design Piping and Supports design Isometrics Bill of materials Circuit line diagrams Functional charts PLC and PCS Configuration Realization Operation, Maintenance Revision, Overhaul Procurement Logistics Quality Assurance Surveying As Built Documentation Documentation Maintenance Spare parts Revision management Inspection Inspections ant tests Modernization / Overhaul Extension Commissioning.. Shut down management

7 Plant Engineering conventional workflow (formerly) WATER Everyone receives a data package and throws his packages to the next desk Simulation Blockdiagram Process flow diagram P&Idiagram Substancemanagement Permitapplication Pipe class management Pipe parts catalogue Pipedesign Apparatusspecification Equipmentspecification Layout arrangement Design (3D) Instrumentation and control specification Functionaldesign Electrical consumer specification Electrical cabinet design Cable raceway design Connection & Cable design PLC PCS Circuit diagram e.g. formerly used Systems PWT Isometrics PDS AUTOCAD Add- On s PDS (12) E-PLAN WS CAD Excel/Access Word VISIO

8 The way to higher efficiency WATER Integration and continuity of disciplines Seamless and continuous workflows across all phases of life cycle Data consistency and prevention of multiple data entering Continuous data model of engineering tools Common description language Artefacts which can be reused across projects. VDI/VDE- Guideline 3695: Engineering of industrial plants Evaluation and optimization represents basics and procedures vividly and clearly VDI/VDE 3695 (November 2010): Part 1 Fundamentals and procedure Part 2 Processes Part 3 Methods Part 4 Tools (13)

9 VDI/VDE 3695 Integration and continuity of disciplines; Tools WATER for an efficient engineering workflow, integrated tools are essential The four steps to increase efficiency: Target D INTEGRATED ENGINEERING Target C HOMOGENEOUS ENGINEERING Target B HETEROGENEOUS ENGINEERING Target A Immanent data exchange with integrated interfaces Availability, using of computer added engineering tools with standardized data exchange between software tools Availability, using of computed aided planning software with computer processable data Data and information of the plant are available in electronic, documented oriented form (14)

10 System to System Interfaces or Instructions on how to being unhappy! WATER Worst case: All Systems are connected to each other Deployment and maintenance of n*(n-1) interface connections A n B F C E (15) D

11 Allrounder Integration Platform End in itself and a Chimera! WATER Better: Each system use a allrounder Integration platform Deployment and maintenance von n*2 interface connections A n B Integration platform F C E (16) D

12 Integrated Integration Platform The comprehensible solution! WATER Obvious: The system with greatest Integration capabilities becomes Integration Platform Deployment and maintenance von (n-1)*2 interface connections A n B D+ EE F ++ FF Integration & platform Integration platform F E (17) C D

13 Integration of Engineering activities allows shorter planning process WATER Formerly Project phases/activities serial Today Future serial, shortened by tools parallel Process Mechanical Piping Electrical Automation Time Time Time further optimization of individual tools very elaborate Only an integrated view across all engineering activities enables a shorter and more efficient planning period Source: Siemens /Bruns 2011 (18)

14 Cumulative valuationlife Cycle Asset Management WATER Quality, Quantity of Plant Asset Information Benefits for the organization EPC Owner-operator ERP- Integration CMMS- Integration PCS- Integration Information loss Integrated during handover Software solution Structured plant information with integrated software solution Information erosion EPC Minimum statutory requirements for Plant Information Owner-operator Tender (19) E P C Commissioning Operation & Maintenance Refurbishment Operation & Maintenance

15 Typical objections (deal breaker) WATER Owner- operator EPC lack of awareness of digital Plant uncertain benefits Sorge vor zusätzlichen Kosten Missing hand-over strategy Pure concentration on CAPEX not on OPEX low requirements regarding the disclosure of information Engineering is not fully integrated Lack of reuse of information Resistors Unclear O/O requirements Unclear EPC requirements Unclear market requirements Lack of standards Lack of ressources Vendor (OEM) (20)

16 IT SYSTEM STRUCTURE WATER Smartphone Tablet Head mounted display Mobile Devices external access / VPN MIS Server... Internet Branch Subsidiary Engineering Company Site Office Citrix Server CAE - Server Database SQL (21) Working station 1 Working station.n Desktop User Desktop User n

17 Integrated Integration Platform WATER Object orientated thinking realized in COMOS Integrated assessment from the project design up to the service and maintenance P&I diagram Object orientated Planning Software & Integrated platform Single line Seamless transition of data in the entire life-cycle of the plant Real Life Cycle Integration platform for all technical aspects of the plant Circuit diagram Piping isometry Optimization of the operation and maintenance of the plant Plant information system Multilingual support Prevention of multiple interfaces & media discontinuity 3D- Model Function chart Data sheets/ Lists (22) Assessments / Service/ Maintenance

18 Integrated Plant Engineering with COMOS WATER.. What is still needed? Simulation Block diagram Process flow diagram P&Idiagram Instrumentation and Controlspecification Substancemanagement Permitapplication Pipe Class management Pipe parts catalogue Automation Process Control Pipedesign Apparatusspecification Equipmentspecification Layoutarrangement design (3D) PLC PCS Functionaldesign Consumer specification Electrical cabinetdesign Cable raceway design Connectionand Cable design Isometrics Circuit diagram Used Tools 3D Integration MicroStation COMOS Excel/Access Miscellaneous Word (23)

19 COMOS 3D Integration WATER Comos P&ID Isometrie Comos Plant Modeler AVEVA PDMS Microstation Comos PipeSpec Comos Platform - seamless connection of P&ID, Isometrics und 3-D - bidirectional isometrics 3D engineering - standards-based or user-defined pipe class and pipe parts catalogues - Intelligent and interactive Isometrics taken off the 3-D-Modell - overall material take off (MTO s) and bill of material (BOM s) management - Integration of all 3-D Detail engineering documents (24)

20 Comos Plant Modeler / MicroStation Integration- Architecture P&ID Isometrie Comos (25).. HVAC Comos Plant Modeler Cable Raceway Comos Steel Structures User Interface Integration Civil Structures WATER Bentley Microstation Microstation Bentley / MicroStation Platform Using Microstation, this common, open platform allows seamless integration of other application areas

21 Comos Integrated pipe parts and pipe class management WATER Bidirectional Planning P&I -Isometric 3D Comos P&ID Comos Isometrics Comos PipeSpec Designer PipeSpecs PPC / special parts standardization standards / codes Comos Viper Visual Plant Engineering Comos Plant Modeler (26)

22 Integrated Plant Engineering with COMOS WATER.. What is still needed? Simulation BlockDiagram Process Flow Diagram P&IDiagram Instrumentation controlspecification Substancemanagement Permit application Pipe Class management Pipe Parts catalogue Automation Process Control Pipe design Apparatusspecification Equipmentspecification LayoutarrangementDesign (3D) PLC PCS Functionaldesign Consumer specification Electrical cabinet design Cable Raceway design Connectionand Cable design Isometrics Circuit diagram used Systems 3D Integration MicroStation COMOS Excel/Access Miscellaneous Word (27)

23 Integrated configuration of PCS7 Hardware and Software WATER PCS7 Engineering Process Tag Types Plant Hierarchy Process Tag Instances Symbol table Hardware Configuration (28)

24 Integrated configuration of SIMATIC S7 und WIN CC WATER SIMATIC S7 / WIN CC Object data Face plate type Process Tag Instances Symbol table Hardware Configuration (29)

25 Conclusions Plant Engineering WATER The world of the interfaces is drastically simplified but still to improve!! A1 A2.XML n1 COMOS MicroStation ISO PCS7 TIA MIS AR (30) DMS n2 DMS

26 Conclusions Plant Engineering WATER Integrated Engineering ( Target D) achieved but not fully developed Efficiency- and Productivity improvements be achieved with increasing use Improvement of Quality and Functionality only with the participation and experience of the user Tools are not used by some users as intended Improvement of existing tools more important rather than create new versions Standardization for interoperability and exchange with other systems based on ISO Hand-over strategies for the exchange and transfer to operators. (31)

27 - Next Step to integrated operation WATER Further improvements in plant life cycle requires the use of new methods and technologies in dealing with planning- and asset data The challenge is not alone anymore to have plant data digital available, but also enormous data location-, personal- and task dependent to use and to keep them up to date. Optimization of processes in the plant life cycle only with the help of mobile application Augmented Reality in Life Cycle Integrated Asset Management (32)

28 Why industrial augmented reality? WATER $ ed Augment Reality (33)

29 Augmented Reality Retrieve tag information by simply viewing WATER (34)

30 Data Consolidation with UBIK WATER Data Sources TAG: P617 PWT (Mobile) OP- Assist TAG: P617 Nominal Power [4 kw] Type [Rotary pump] Circuit diagram Order ID [4711] Manufacturer [GrundfosAG] Current flow rate [0,8 3/h] UBIK Server (Consolidation) Nominal Power [4 kw] Delivery height [5,5 m] Manufacturer [Grundfos] Type [Rotary pump] Circuit diagram CAx TAG: P617 Nominal Power [4 kw] Type [Rotary pump] Circuit diagram Order ID [4711] Manufacturer [GrundfosAG] Current flow rate [0,8 m3/h] TAG: P617 Order ID [4711] Manufacturer [GrundfosAG] Supplier ERP TAG: P617 Current flow rate [0,8 m3/h] Current torque [147 N] (35) DCS

31 WATER Many Thanks for your attention! (36)