Asynerlytics, LLC The Water and Wastewater Industry Specialist

2 2 2 Reliability – Sustainability - Synergy

PAS 55 Certified

• The WRF achieved PAS 55 Certification on May 2012

• PAS 55 is an International Specifications or Standards Focusing on Continuous Improvement, Strategy and Risk Management

• Demonstrated we had established and are continuing to improve a Quality Asset Management System (QAMS) for the entire lifecycle of our assets and infrastructure

• Member of TE2AM at the University of Wisconsin School of Engineering

• Selected to develop an outline for the 55000 Asset Management and the 50001 Energy Management ISO Standards

• Commissioned by the U.S Department of Energy in Washington, DC

55000 & 50001 ISO Standards

Benefits of PAS 55 Certification

• Use the 28-point checklist for better overall long-term planning

• Monitor and improve the way you manage your physical assets

• Achieve legal and regulatory compliance and better customer service

• Enjoy increased support for risk and sustainability management

• Prepare for the full lifecycle with more control over costs

Des Moines Metropolitan WRA Case Study

DMMWRA - Case Study

(Confidential – For Internal Use Only) Copyright © 2008 Rockwell Automation,

Inc. All rights reserved. 7

Asset Sustainability Roadmap

Develop Energy Reduction Strategy

Determine GHG Emissions Inventory

Evaluate Footprint & Prioritize Actions

Implement Energy Optimization Program

Destination…”Objective”

• Reduced Annual Energy Cost

• Reduced Carbon Footprint

• Benchmark against Carbon Emissions

• Effective Energy Management Program

Benchmark Energy Cost & Carbon Emissions

Evaluate Footprint & Prioritize Actions

Energy Assessments

Initial Project Goals

• Identify target equipment

• Establish basis for condition monitoring (flow/kwh) = efficiency

• Verify availability of data and add instrumentation, network wiring, and data point as required

• Develop data integration to Infor Asset Sustainability

• Configure Infor Asset Sustainability capabilities to support Condition based Monitoring (earliest possible notice that we are on the failure curve)

CbM Data Points

• Establish Condition based Monitoring profile

– Equipment Level Data

• Run Time Hours

• Amps

• KWH

– System Level Data

• Flow (SCFM or MGD)

• Equipment Operating Mode (i.e., single or multiple equipment running)

Infor EAM Asset Sustainability

Enable energy performance monitoring & measurement

Identify cost reduction & conservation opportunities

Enable continuous commissioning & peak demand analysis

Determine if new energy initiatives are actually succeeding

Audit utility information to identify billing anomalies

Enable energy cost reductions of 10 – 25%

Enable greenhouse gas, water, and waste reporting

Manufacturing & Industrial

Electric motor-driven systems

in industrial processes consume

63% of all electricity used

in U.S. industry

U.S. Dept. of Energy

Be a First Responder Asset Sustainability Alert Management

Run to FAIL

*

* PM/PdM

DEGRADES

*

OEM Service

$$$ EAM

Consumptive Maintenance

$$$$$

Asset

Sustainability

Equipment

Actionable steps to achieve energy savings (cost savings) Example: Consumption is exceeding design Consumption

Various Monitoring Strategies

14

Utility Bills

Utility Meters

Sub Meters

Sensors

Assets

Processes and

Systems

Building

DMMWRA Technology Stack

• Integrated/Warehoused Asset and Management Data

• Analytics/Visualization/Alerts

• Enterprise Level Business Application

Infor EAM Asset Sustainability

• Archival/Aggregation

• Database

HACH/WIMS Data Repository

• Real Time Collection

• Sensors/Instrumentation/PLC

Rockwell RSViewSE SCADA Factory Talk

Optimization Information Network

All of these business enterprise solutions collect data and transmit it to the Infor EAM Asset Sustainability “Condition based Monitoring” program. The synergy of this integration provides the industrial business intelligence necessary for a truly sustainable production environment.

Infor EAM

Database

Infor ION

i.LON, or

PI System,

or other 1

Web

Service

Alerts

2

FTP

FTP

BMS,

Utility Bill Agg,

or other

XML

CSV

File

CSV

File

Energy Management Optimization

Install metering devices

o Provide essential real-time and historical information

Use System to understand what loads contribute to the peak

Notify key personnel when the plant is setting a new peak for the period

o Make sure only essential loads are running during the peak

Establish granular energy saving goals using Energy Metrics as a tool to

help drive the reduction

Train and Leverage “Energy Champion” to use AS and engage employees

WRF Peer Process Systems

WRF Peer Process Systems

EAM Alert Management

What Does Alert Management Provide?

Actionable steps to achieve energy savings (cost savings) For example: Consumption is exceeding design consumption

From: InforEAM@dmgov.org

To: Bill Miller

Subject: (ASE Alert) KWH Spike on GAS Tracked Asset

Notice: The most recent KWH reading on Equipment: 35-PAB-3 [PROCESS AIR BLOWER #3, 35-PAB-3] has exceeded 2 standard deviations of the mean hourly KWH for this unit's peer equipment. Last Reading:1,342.14 Avg for this Equipment:1060.370979 Avg for Peer Equipment:871.748302 Warning Level (2 Sigma) for this Equipment: 1253.7672008363033 Warning Level (3 Sigma) for peer Equipment: 1197.7073075641322 Please notify appropriate personnel for investigation.

GHG/CO2 Emissions Management

Track carbon footprint Reporting Benchmark to improve

2010 PAB Energy Usage Report

2013 PAB Energy Usage Report

Initial Identified Savings

Process Air Blowers

(2,000 HP)

Main Raw Water Pumps

(700 HP)

Return Sludge Pumps

(100 HP)

Total Run Hours 3,552 3,552 3,552

Days of Data 148 148 148

High Cost per Hour $ 47.62 $ 17.97 $ 0.82

Low Cost per Hour $ 31.40 $ 11.67 $ 0.63

Cost per Hour Delta $ 16.22 $ 6.30 $ 0.19

Maximum Potential Savings $ 43,210.08 $ 16,783.20 $ 506.16

Annualized Savings $ 142,087.20 $ 55,188.00 $ 1,664.40

Peak KW vs. Cost KW Facility Level

Demand

KW’s

WRA 2013 Energy Stats

• Consumed an average of 92,300 kWh/day for a total of 33,800 mWh (33,800,000 kWh) of electricity

• 60% of CDM local government energy cost from WRA Facility

• WRA rates ranged from $0.0404kWh to $0.069kWh

• Average monthly electrical cost of $100,000.00

• Lowest monthly electrical cost to date: $65,000.00

Managing Consumption

• The key to controlling electrical cost is demand • Drive the consumption to the lowest rate through

minimizing Peak Demand

• Controlling Peak Demand by; Constant online monitoring of demand and making process and equipment decisions based upon current Demand Peak

Controlling Demand

• Establish equipment operational rotation based upon current peak demand

• Reduce or curtail energy consumption within selected

processes • Use longer operational runs with lower energy vs.

shorter operational runs resulting in higher energy usage

• Offset demand with Electrical Generation

• Asset Sustainability provides WRA the structural framework from policy to the plug to ensure optimal operating performance while continually improving their energy performance – saving money, improving operational effectiveness, and being a good steward of the environment.

• When enterprises can link efficiency to expense reduction and profitability it’s a “win-win”

What Happens When Assets Fail to Receive Sufficient Attention?

Unoptimized assets mean lost opportunity for bottom-line improvement and decreased asset performance & reliability

Significant profit potential is left on the table

Costly operating surprises can arise

Facility 1 Facility 2 Facility 3

Global Solution Single Database

Share Common

Reports Analytics

Organization Specific:

People

Processes

Data

User Focus:

Role Based

Mobile / Tablet / Desktop

Language

Multiple Locations / Departments

Organization Specific:

People

Processes

Data

User Focus:

Role Based

Mobile / Tablet / Desktop

Language

Multiple Locations / Departments

Organization Specific:

People

Processes

Data

User Focus:

Role Based

Mobile / Tablet / Desktop

Language

Multiple Locations / Departments

Data Processes Best Practices

EAM Analytics Starting With the End in Mind

Report Snapshots

Equipment Management

Gartner EAM Magic Quadrant

Maintenance : A Strategic Road Map

• Level 7 - Financial Optimized • Level 6 - Reliability Centered Maintenance • Level 5 - Predictive Forecasting • Level 4 - Based on Condition • Level 3 - Preventative – Planned on Usage • Level 2 - Preventative – Planned on Time • Level 1 - Run to Failure

• It was thought that no one has achieved greater than Level 5

• The DMMWRA has achieved all 7 Levels…

The Direction of DMMWRF Today

• Motors @ Work is a web based analytics tool that helps customers make tactical and strategic decisions about their motor-driven assets.

• Motors @ Work (Motor Master+ in the cloud) capturing near real-time detail energy and equipment data, will provide continuous equivalency evaluation and procurement engineering capabilities to enable repair vs. replacement and non-conformance analytics.

• Embedded Technologies incorporating Self-Diagnostic PLC’s with transducers at the sub-component level of key critical assets. The data is then transmitted digitally to SQL Databases such as a Hach Wims data repository or Factory Talk Transaction Manager, where is can be easily accessed by the Infor EAM/AS or other relative programs.

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