INTEGRATED PLANT ENGINEERING IN WATER · PDF fileINTEGRATED ENGINEERING Immanent data exchange with integrated interfaces. AMIANTIT WATER MANAGEMENT ... Integrated Plant Engineering

AMIANTIT WATER MANAGEMENT

(1) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH

AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT

INTEGRATED PLANT ENGINEERINGINTEGRATED PLANT ENGINEERINGINTEGRATED PLANT ENGINEERINGIN WATER TECHNOLOGYIN WATER TECHNOLOGYIN WATER TECHNOLOGY

Achim Ewig, PWT Wasser und Abwassertechnik GmbH

Konferenz für Durchgängige Anlagenplanung 2013Integrated Plant Engineering Conference 2013

Nürnberg 20.03.2013




• 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

Integrated Plant Engineering inWater Technology




Wasser und Abwassertechnik GmbH

Company history:

Company data:

• 1965 Start of activities in water technology with PREUSSAG AG

• Location Zwingenberguntil 1998 branch of Preussag Wasser & Rohrtechnik

• 1998 Merger of the Preussag Group’s water activities inPreussag Wassertechnik GmbH

• 2001 Company renamed in PWT Wasser- und AbwassertechnikGmbH, Company Headquarter Zwingenberg

• 2004 PWT takeover by Saudi Arabian Amiantit Company Group(SAAC)

•Management Board: Dipl.-Ing. Rüdiger BöckleDipl.-Ing. Klaus Dickhoff

• Employees: 225

• Headquarter: Zwingenberg / Germany

• Branch Offices and Leipzig, Hamburg

Subsidiaries: Istanbul / Türkei,

Bukarest / Rumänien

Ashgabat / Turkmenistan

Baku / Aserbaidschan

Dammam / Saudi Arabien

www.pwt.de [email protected]




Planning, Realization, Commissioning and Operating

Communal und Industrial waste water treatment

Landfill-leakage water treatment

Pumping stations

Waste Water

Process Control Systems, Automation- and Telemetry systems

Medium- and Low voltage switch gears

for all kind of

water treatment facilities and networks

Automation and

Process Control

Technology

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

Process water

Water treatment plant, Sea water desalination,

Decontamination, Groundwater treatment,

Net water pumping stations

Business Areas and Activities

Drinking water




Plant Engineering

• 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

• ………




Process &Basic design

• Block diagram

• Process flow diagram

• Substances, Substancestreams

• Simulation data

• Power demandcalculation

• P & I- diagram

• Pipe Classes

• Equipment-& Instrumentationspecification

• Functional designspecification

• General layouts

• ……….

• Layout andArrangement design

• Piping and Supportsdesign

• Isometrics

• Bill of materials

• Circuit line diagrams

• Functional charts

• PLC and PCSConfiguration

•………

• Procurement

• Logistics

• Quality Assurance

• Surveying

• As BuiltDocumentation

• Documentation

• Inspections ant tests

• Commissioning

• ……………..

• Maintenance

• Spare parts

• Revision management

• Inspection

• Modernization /Overhaul

• Extension

• Shut downmanagement

• ………

PROJECT

Operation,Maintenance

RealizationDetail designRevision,Overhaul

Project phases and related activities




P & I -diagram

Pipe-design

Isometrics

LayoutarrangementDesign (3D)

Functional-design

PLCPCS

Apparatus-specification

Permit-application

Electricalconsumer

specification

Cableracewaydesign

Connection& Cabledesign

Circuitdiagram

Plant Engineeringconventional workflow (formerly)

Pipe classmanagement

Equipment-specification

Pipe partscatalogue

Block-diagram

Simulation

Substance-management

Process flowdiagram

Instrumentationand control

specification

Electricalcabinetdesign

PDSAUTOCADAdd- On ’s

E-PLANWS CAD

VISIOPDS

Excel/AccessWord

e.g. formerly used Systems PWT

Everyone receives a data package and throws his packages to the next desk




The way to higher efficiency

• 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

• ……




VDI/VDE 3695Integration and continuity of disciplines; Tools

“for an efficient engineering workflow, integrated tools are essential”

The four steps to increase efficiency:

Target A

Data and information of theplant are available in electronic,documented oriented form

Target BHETEROGENEOUSENGINEERING

Availability, using of computedaided planning software withcomputer processable data

Target CHOMOGENEOUSENGINEERING

Availability, using of computeradded engineering tools withstandardized data exchangebetween software tools

Target DINTEGRATEDENGINEERING

Immanent data exchangewith integrated interfaces




F

E D

C

A

…n B

Worst case: All Systems are connected to each other

Deployment and maintenance of n*(n-1) interface connections

System to System Interfacesor Instructions on how to being unhappy !




F

E D

C

A

…n B

Better: Each system use a allrounder Integration platform

Deployment and maintenance von n*2 interface connections

Integrationplatform

Allrounder Integration PlatformEnd in itself and a Chimera !




F

E D

C

A

…n B

Obvious: The system with greatest Integration capabilities becomes Integration Platform

Deployment and maintenance von (n-1)*2 interface connections

Integrationplatform

F&

Integrationplatform

E + F&

Integrationplatform

D+ E + F&

Integrationplatform

Integrated Integration PlatformThe comprehensible solution !




Project phases/activities

Process

Mechanical

Piping

Electrical

Automation

Time

parallelserial

Time

Formerly Future

Time

serial, shortened by tools

Today

further optimization ofindividual tools very elaborate

Only an integrated view across all engineering activities

enables a shorter and more efficient planning period

Integration of Engineering activitiesallows shorter planning process

Source: Siemens /Bruns 2011




Tender E P C Commissioning Operation & Maintenance RefurbishmentOperation &Maintenance

Qu

ali

ty,

Qu

an

tity

of

Pla

nt

As

se

tIn

form

ati

on

Be

ne

fits

for

the

org

an

iza

tio

n

Owner-operator

EPC

Information lossduring handover

Minimumstatutory requirementsfor Plant Information

Information erosion

Structured plant informationwith integrated software solution

PCS- Integration

CMMS- Integration

ERP- Integration

IntegratedSoftware solution

Owner-operatorEPC

Cumulative valuation-Life Cycle Asset Management




Typical objections (deal breaker)

Owner- operator EPC

Sorge vorzusätzlichen

Kosten

lack ofawareness ofdigital Plant

uncertainbenefits

lowrequirementsregarding thedisclosure ofinformation

Pure concentration onCAPEX not on OPEX

Engineering is notfully integrated

Missinghand-overstrategy

Unclear O/Orequirements

Resistors

Unclear EPCrequirements

Lack of reuse ofinformation

Unclear marketrequirements

Lack of standards

Lack ofressources

Vendor (OEM)




CAE - ServerDatabase SQL

Working station 1

Citrix Server

Working station ….n Desktop User

Internet

Desktop User…n

. . . . .

BranchSubsidiary

external access / VPN

EngineeringCompany

SiteOffice

MIS Server

TabletHead mounted

displaySmartphone

Mobile Devices

IT – SYSTEM STRUCTURE




Object orientated thinking realized in COMOS®Integrated assessment from

the project design up to the

service and maintenance

Seamless transition of data in

the entire life-cycle of the plant

“Real Life Cycle”

Integration platform for all

technical aspects of the plant

Optimization of the operation

and maintenance of the plant

Plant information system

Multilingual support

Prevention of multiple

interfaces & media

discontinuity

Object orientatedPlanning Software

&Integrated platform

P&I diagram

Piping isometry

Single line

3D- ModelFunction chart

Data sheets/ ListsAssessments /Service/ Maintenance

Circuit diagram

Integrated Integration Platform




P&I-diagram

Pipe-design

Isometrics

Layout-arrangementdesign (3D)

Functional-design

PLCPCS


Permit-application

Consumerspecification

Cableracewaydesign

Connection-and Cable –

design

Circuitdiagram

Pipe Classmanagement


Pipe partscatalogue

Blockdiagram

Simulation


Process flowdiagram

Instrumentationand Control-specification

Electricalcabinet-design

MicroStation COMOS

Excel/AccessWord

Used Tools

Miscellaneous

AutomationProcess Control

3D Integration

Integrated Plant Engineering with COMOS®

….. What is still needed ?




- 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

Comos® PipeSpec

Comos® Platform

Comos®

P&IDIsometrie

AVEVA PDMS

Comos®

Plant Modeler

Microstation

COMOS® 3D Integration




Comos® Plant Modeler / MicroStationIntegration- Architecture

User Interface Integration

Comos® Platform

Comos®

P&IDIsometrie

Civ

ilS

tru

ctu

res

Ca

ble

Ra

cew

ay

BentleyMicrostation

Comos®

Plant Modeler

Microstation

Using Microstation, this common, openplatform allows seamless integration ofother application areas

Ste

el

Str

uc

ture

s

……

..

Bentley / MicroStation ®

HV

AC




Comos®

Integratedpipe parts and pipe class management

Comos® Viper

Visual Plant Engineering

Comos® P&ID Comos®

Isometrics

Comos®

Plant Modeler

PipeSpecsPPC / special parts

standardizationstandards / codes

Comos®

PipeSpec Designer

Bidirectional Planning P&I -Isometric – 3D




P&I-Diagram

Pipedesign

Isometrics

Layout-arrangement-Design (3D)

Functional-design

PLCPCS


Permitapplication

Consumerspecification

CableRaceway

design

Connection-and Cable

design

Circuitdiagram

PipeClass

management


PipeParts

catalogue

Block-Diagram

Simulation


ProcessFlow

Diagram

Instrumentationcontrol-

specification

Electricalcabinetdesign

MicroStation COMOS

Excel/AccessWord

used Systems

Miscellaneous

AutomationProcess Control

3D Integration

Integrated Plant Engineering with COMOS®

….. What is still needed ?




Process Tag Types

Plant Hierarchy

Process Tag Instances

Symbol table

Hardware Configuration

PCS7 Engineering

Integrated configuration of PCS7Hardware and Software




Symbol table

Hardware Configuration

SIMATIC S7 / WIN CCSIMATIC S7 / WIN CC

Process Tag Instances

Face plate type

Object data

Integrated configuration ofSIMATIC S7 und WIN CC




.XML

ISO 15926

The world of the interfaces is drastically simplified but still to improve !!

PCS7TIA

n1…COMOS

n2…

A2

MicroStation

DMS

A1

DMSMISAR

Conclusions Plant Engineering




• 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 15926

• Hand-over strategies for the exchange and transfer to operators

•……….

Conclusions Plant Engineering




- Next Step to integrated operation -

• Further improvements in plant life cycle requires the use ofnew 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 useand to keep them up to date.

• Optimization of processes in the plant life cycleonly with the help of mobile application

Augmented Reality in Life Cycle Integrated Asset Management




Why industrial augmented reality ?

$

Augmented

Reality




Augmented RealityRetrieve tag information by simply viewing




Data Consolidation with UBIK®

Data Sources

UBIK ® Server(Consolidation)

TAG: P617

•Nominal Power [4 kW]

•Delivery height [5,5 m]

•Manufacturer [Grundfos]

•Type [Rotary pump]

•Circuit diagram

TAG: P617

•Order ID [4711]

•Manufacturer [GrundfosAG]

•Supplier

•…

TAG: P617

•Current flow rate [0,8 m3/h]

•Current torque [147 N]

•…

TAG: P617



•Circuit diagram

•Order ID [4711]


•Current flow rate [0,8

m3/h]

PWT (Mobile)OP- Assist®

TAG: P617



•Circuit diagram

•Order ID [4711]


•Current flow rate [0,8 3/h]

CAx

ERP

DCS




Many Thanks foryour attention !

Documents

INTEGRATED PLANT ENGINEERING IN WATER · PDF fileINTEGRATED ENGINEERING Immanent data exchange with integrated interfaces. AMIANTIT WATER MANAGEMENT ... Integrated Plant Engineering