innovation in asset management - pennongroup.co.uk · innovation in asset optimisation reliability...
TRANSCRIPT
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