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
AMIANTIT WATER MANAGEMENT
(2) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
• 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
AMIANTIT WATER MANAGEMENT
(3) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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]
AMIANTIT WATER MANAGEMENT
(4) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
AMIANTIT WATER MANAGEMENT
(10) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
• ………
AMIANTIT WATER MANAGEMENT
(11) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
AMIANTIT WATER MANAGEMENT
(12) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
AMIANTIT WATER MANAGEMENT
(13) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
• ……
AMIANTIT WATER MANAGEMENT
(14) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
AMIANTIT WATER MANAGEMENT
(15) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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 !
AMIANTIT WATER MANAGEMENT
(16) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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 !
AMIANTIT WATER MANAGEMENT
(17) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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 !
AMIANTIT WATER MANAGEMENT
(18) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
AMIANTIT WATER MANAGEMENT
(19) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
AMIANTIT WATER MANAGEMENT
(20) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER 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)
AMIANTIT WATER MANAGEMENT
(21) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
AMIANTIT WATER MANAGEMENT
(22) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
AMIANTIT WATER MANAGEMENT
(23) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
P&I-diagram
Pipe-design
Isometrics
Layout-arrangementdesign (3D)
Functional-design
PLCPCS
Apparatus-specification
Permit-application
Consumerspecification
Cableracewaydesign
Connection-and Cable –
design
Circuitdiagram
Pipe Classmanagement
Equipment-specification
Pipe partscatalogue
Blockdiagram
Simulation
Substance-management
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 ?
AMIANTIT WATER MANAGEMENT
(24) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
- 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
AMIANTIT WATER MANAGEMENT
(25) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
AMIANTIT WATER MANAGEMENT
(26) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
AMIANTIT WATER MANAGEMENT
(27) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
P&I-Diagram
Pipedesign
Isometrics
Layout-arrangement-Design (3D)
Functional-design
PLCPCS
Apparatus-specification
Permitapplication
Consumerspecification
CableRaceway
design
Connection-and Cable
design
Circuitdiagram
PipeClass
management
Equipment-specification
PipeParts
catalogue
Block-Diagram
Simulation
Substance-management
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 ?
AMIANTIT WATER MANAGEMENT
(28) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
Process Tag Types
Plant Hierarchy
Process Tag Instances
Symbol table
Hardware Configuration
PCS7 Engineering
Integrated configuration of PCS7Hardware and Software
AMIANTIT WATER MANAGEMENT
(29) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
AMIANTIT WATER MANAGEMENT
(30) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
.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
AMIANTIT WATER MANAGEMENT
(31) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
• 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
AMIANTIT WATER MANAGEMENT
(32) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
- 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
AMIANTIT WATER MANAGEMENT
(33) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
Why industrial augmented reality ?
$
Augmented
Reality
AMIANTIT WATER MANAGEMENT
(34) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
Augmented RealityRetrieve tag information by simply viewing
AMIANTIT WATER MANAGEMENT
(35) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
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
•Nominal Power [4 kW]
•Type [Rotary pump]
•Circuit diagram
•Order ID [4711]
•Manufacturer [GrundfosAG]
•Current flow rate [0,8
m3/h]
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]
CAx
ERP
DCS
AMIANTIT WATER MANAGEMENT
(36) Konferenz für Durchgängige Anlagenplanung Nürnberg 20.März 2013 © PWT Wasser und Abwassertechnik GmbH
AMIANTIT WATER MANAGEMENTAMIANTIT WATER MANAGEMENT
Many Thanks foryour attention !