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Innovation in Asset OptimisationReliability and Efficiency

Bob Trivett

Alan Burgess

Asset Reliability - Evolution

1st Generation Maintenance – Breakdown2nd Generation Maintenance – Preventative (scheduled service)3rd Generation Maintenance – Reliability (RCM)

Failure can be predicted

• Asset age or ‘time in service’ information can assist

• Conditional maintenance inspections can check for wear

• Need more data and better data

• No one data source can be used to predict failure

•Manufacturers

•Operators

•Maintenance

•Repairers

• Best data is real time, real asset condition monitoring

Sourcing data to predict failure

• Installed at more than 180 SWW sites

• ‘Vibcode’ Studs are fitted to machines

• Planned Maintenance Operatives collect

readings once a month.

• Bearing condition data collected using a

‘Vibscanner’

• Data is downloaded onto specialised

software package – Omnitrend.

Manual CBM Data Collection

On-line vibration monitors

All faults produce a specific signature

CBM - Facts and Figures

• 180 sites with CBM monitoring

covering 4,375 assets

• 42 strategic sites with on-line

vibration monitoring systems

• On-line system automatically

emails warnings

• Monitoring of key plant items with

an asset value of £381m

Thermographic Surveys

• Hand-held thermal

imaging camera

• Surveys with

intervention

Summary benefits of RCM and CBM

• Enhances diagnostics

• Delivers efficiency savings

• Improves reliability of service

• Extends asset life

• Minimises catastrophic failures

• Allows planned downtime for repairs

• iSCADA compatible technology

SWW Annual Energy Consumption

•£20m expenditure; 250GWh consumption

•Pumping ~80%

•Process/other ~20%

Pumps - monitoring

• Energy reduction and efficiency strategy

• Benchmarking of pump performance

• Fixed monitoring covering 25% of energy usage

• Portable testing programme, 300+ pumps

Pumps – improvements

•Repair/restoration

•Use of modern coatings including nano-materials

•Better than new efficiencies

•Extended life

•Increased reliability

•Reduced Opex and avoided Capex

• Employee engagement

• AMR metering project management

• Submetering programme

• Process optimisation

• Lighting/heating enhancements and

controls

• 2010 Devon Environmental Business

Initiative winner, jointly with MIRES

Generation - existing

• 5.6 MW Hydro electric generation

• 1.7 MW Sewage gas CHP generation

• Generating ~6% requirements

• On site energy use with ROCs & LECs

• Performance and efficiencyimprovements in K5 ongoing

Generation - pumps as turbines

“KSB and South West Water together

are delivering a unique and

innovative solution of using

centrifugal pumps to generate

electricity”

Distribution micro generation

“We are delighted to be working

with South West Water; this is

our first significant installation

and it takes a confident,

forward-thinking company to

be ahead of the curve in a

rightly conservative Water

Industry.”

Duncan Collins, MD

Zeropex UK Ltd installed its first UK Difgen at South West Water in May 2011

Generation plans

Up to 20 new schemes and 4MW extra

capacity in K5

Target 20% self-generated renewable

energy by 2020

Solar PV

•Polmaugan 5GWh

•Potential SWW sites 2GWh

Wind

•Potential SWW sites 20GWh

Sludge

•Potential Advanced Sludge Treatment

Programme 25GWh

Efficiency summary

Application of new technology is achieving:

• 5 years of reducing energy consumption

• 5 years of reducing carbon emissions

• Growth in renewable generating capacity

• On track to meet 2015 carbon reduction target