presentation jkr melaka web (iscada application)

8/6/2019 Presentation Jkr Melaka Web (Iscada Application)

1/16

Implementing eMaintenanceImplementing eMaintenance

usingusing iiSCADASCADA technologytechnology

for Wisma Persekutuanfor Wisma Persekutuan

MelakaMelaka

By Nurhaizan

JKR Mekanikal Melaka

Case StudyCase Study

Published by permission and courtesy of JKR mekanikal Meleka.


2/16

BackgroundBackground

The Fire Protection System in WismaThe Fire Protection System in Wisma

Persekutuan Melaka was upgraded inPersekutuan Melaka was upgraded in

December 2003December 2003

At the same time, a WebAt the same time, a Web--based SCADAbased SCADA((iiSCADASCADA) system was installed to) system was installed to

monitor the Fire Alarm, Hose Reel,monitor the Fire Alarm, Hose Reel,

Sprinkler, Chiller and Lift Systems.Sprinkler, Chiller and Lift Systems.

We implemented Electronic MaintenanceWe implemented Electronic Maintenance

((eMaintenanceeMaintenance) to enhance our) to enhance our

Maintenance Management processMaintenance Management process


3/16

GatewayGatewayInternetInternet

ServerServer UserUser

1.1. AGateway collects failure events fromAGateway collects failure events from

our equipment and transmits them to aour equipment and transmits them to a

server on the Internet.server on the Internet.

2.2. When a failure occurs, techniciansWhen a failure occurs, technicians

automatically receive an SMS and emailautomatically receive an SMS and email

3.3. JKR and the FM contractor can accessJKR and the FM contractor can access

the data in real time from any PCthe data in real time from any PC

HowHow iiSCADA worksSCADA works


4/16

Mobile Alerts

Tel Line

Internet

iSCADA Server

Embedded

InternetGateway

Real-time Monitor / AlarmOnline Reports / Statistics

Embedded

Internet

Gateway

ArchitectureArchitecture

Site 1

Site N


5/16

Monitor by SystemMonitor by System (Data from JKR melaka)(Data from JKR melaka)

See Status of ALL systems on the same screenSee Status of ALL systems on the same screen Systems in good condition are inSystems in good condition are in YellowYellow FolderFolder

Systems with Failure Events are inSystems with Failure Events are in REDRED FolderFolder

Click onClick on REDRED folder to see details of Failuresfolder to see details of Failures


6/16

Monitor by LocationMonitor by Location (Data from JKR melaka)(Data from JKR melaka)

See Status of ALL sites/buildings at onceSee Status of ALL sites/buildings at once Buildings in good condition are inBuildings in good condition are in YellowYellow FolderFolder

Buildings with Failure Events are inBuildings with Failure Events are in REDRED FolderFolder

Click onClick on REDRED folder to see details of Failuresfolder to see details of Failures


7/16

Site 1

Melaka

Site 2

Perak

Site 3

Johor

Internet

iSCADA Server

Global Reach

Kawalselia


8/16

Real Time MonitoringReal Time Monitoring screen shot showing that ascreen shot showing that a

Fault occurred in the Fire Alarm System onFault occurred in the Fire Alarm System on

26 May 2005 at 7:54 pm26 May 2005 at 7:54 pm

An email and SMS was sent to Nurhaizan andAn email and SMS was sent to Nurhaizan and

Zulhelmi when the failure occurredZulhelmi when the failure occurred


9/16

ReportingReporting screen shot showing that the samescreen shot showing that the same

fault kept repeating since 13fault kept repeating since 13thth May 2005May 2005


10/16

StatisticsStatistics screen shot showing overall systemscreen shot showing overall system

availability from 1availability from 1stst Jan 2004 to 31Jan 2004 to 31stst Dec 2004Dec 2004

Overall Functionality Index (Up Time) = 98.24%Overall Functionality Index (Up Time) = 98.24%

Fire Alarm Up Time was lowest at 88.3%Fire Alarm Up Time was lowest at 88.3%

Total Down Time of all systems = 511.72 HoursTotal Down Time of all systems = 511.72 Hours


11/16

TTransparencyransparency

How JKR has benefited fromHow JKR has benefited from

implementation of eMaintenanceimplementation of eMaintenance

Everything was recorded automatically without humanEverything was recorded automatically without human

intervention. Reports & statistics are available online tointervention. Reports & statistics are available online to

top management in real time.top management in real time.

EEfficiencyfficiencyReduces manpower for fault detection and paper workReduces manpower for fault detection and paper work

AAvailabilityvailabilityAutomatic detection and SMS enables quick actions to beAutomatic detection and SMS enables quick actions to be

taken. This improves the overall availability of ourtaken. This improves the overall availability of our

systems.systems.


12/16

Reporting Concept: eMaintenanceReporting Concept: eMaintenance

Vs Conventional MaintenanceVs Conventional Maintenance

Central AuthorityCentral Authority

Lower AuthoritiesLower Authorities


Assets /Assets /Data SourceData Source

ConventionalConventionalMaintenanceMaintenance

Central AuthorityCentral Authority



Assets /Assets /Data SourceData Source

Query /Login

Information

ElectronicElectronicMaintenanceMaintenance

ReportsReports

ReportsReports

ReportsReports


13/16

Reactive & Predictive Components of eMaintenanceReactive & Predictive Components of eMaintenance

Reactive Maintenance:Reactive Maintenance:

React to a system failure, and attempt to restore normalReact to a system failure, and attempt to restore normalfunctionality in the shortest time possible.functionality in the shortest time possible.

iSCADAs role in Reactive Maintenance:iSCADAs role in Reactive Maintenance:--

(1)(1) Detecting Failures automatically, and sending alerts toDetecting Failures automatically, and sending alerts to

technicians instantly and automatically by email & SMS.technicians instantly and automatically by email & SMS.

(2)(2) Logs all events and produces statistical analysis that can point toLogs all events and produces statistical analysis that can point to

the root cause of problems (See next slide)the root cause of problems (See next slide)

Predictive Maintenance:Predictive Maintenance:

Anticipate system failures before they happen by using ConditionAnticipate system failures before they happen by using Condition

Monitoring toolsMonitoring tools

iSCADAs role in Predictive Maintenance:iSCADAs role in Predictive Maintenance:--

(1) Monitoring analogue signals from the site in real time(1) Monitoring analogue signals from the site in real time

(2) Analyzing Trending data to detect abnormal behavior.(2) Analyzing Trending data to detect abnormal behavior.


14/16

iSCADA helps point to root cause of failuresiSCADA helps point to root cause of failures

Due to Leaks inDue to Leaks in

the Sprinklerthe Sprinkler

System pipingSystem piping

Screenshot of actual site data from JKR Melaka

After the Fire Protection

system at Wisma

Persekutuan Melaka wasupgraded, we used the

iSCADA system to monitor

the performance of the

new installation.

We found that there was

over 500 events reportedby the Sprinkler System.

We drill deeper into the

iSCADA statistical

analysis report and it

showed that the Jockey

Pump ran for 443 times in

a very short period oftime, which is not normal.

This indicated a leak in

the piping system,

which was subsequently

fixed by the contractor.


15/16

iSCADA helps in Predictive MaintenanceiSCADA helps in Predictive Maintenance

Conditioning Monitoring

allows maintenanceengineers to detect

abnormal behavior. Action

can then be taken to

prevent an actual failure.

Eg 1. If a temperature

sensor is embedded intothe shaft of the Lift Motor,

the temperature profile

may indicate abnormalities

in bearings or load.

Eg 2. Taking periodic

readings of peak current

consumption of a

compressor, and

observing the trend over a

period of time may point to

deteriorating efficiency.


16/16

Moving ForwardMoving Forward

1.1. Implement eMaintenance in all JKRImplement eMaintenance in all JKR

buildings statebuildings state--wide and nationwidewide and nationwide

2.2. This allows consolidation ofThis allows consolidation of

maintenance management data andmaintenance management data andcentral supervisioncentral supervision

3.3. Performance of FM contractors can bePerformance of FM contractors can be

monitored objectively with Keymonitored objectively with Key

Performance Indicators (KPIs)Performance Indicators (KPIs)

4.4. Ensure that Maintenance budgets areEnsure that Maintenance budgets are

managed prudentlymanaged prudently

5.5. Enables JKR to perform PredictiveEnables JKR to perform Predictive

MaintenanceMaintenance

presentation jkr melaka web (iscada application)

Documents