Implementing eMaintenance Implementing eMaintenance using using iiSCADASCADA technology technology

for Wisma Persekutuan for Wisma Persekutuan MelakaMelaka

By NurhaizanJKR Mekanikal Melaka

Case StudyCase Study

Published by permission and courtesy of JKR mekanikal Meleka.

BackgroundBackgroundThe Fire Protection System in Wisma The Fire Protection System in Wisma Persekutuan Melaka was upgraded in Persekutuan Melaka was upgraded in December 2003December 2003

At the same time, a Web-based SCADA At the same time, a Web-based 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 Maintenance We implemented Electronic Maintenance ((eMaintenanceeMaintenance) to enhance our ) to enhance our Maintenance Management processMaintenance Management process

GatewayGatewayInternet Internet ServerServer UserUser

1.1. A Gateway collects failure events from A Gateway collects failure events from our equipment and transmits them to a our equipment and transmits them to a server on the Internet. server on the Internet.

2.2. When a failure occurs, technicians When a failure occurs, technicians automatically receive an SMS and emailautomatically receive an SMS and email

3.3. JKR and the FM contractor can access JKR and the FM contractor can access the data in real time from any PC the data in real time from any PC

How How iiSCADA worksSCADA works

Mobile Alerts

Tel LineInternet

iSCADA Server

EmbeddedInternetGateway

Real-time Monitor / AlarmOnline Reports / Statistics

EmbeddedInternetGateway

ArchitectureArchitecture

Site 1

Site N

Monitor by System Monitor 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 in Systems in good condition are in YellowYellow Folder Folder• Systems with Failure Events are in Systems with Failure Events are in REDRED Folder Folder• Click on Click on REDRED folder to see details of Failuresfolder to see details of Failures

Monitor by Location Monitor 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 in Buildings in good condition are in YellowYellow Folder Folder• Buildings with Failure Events are in Buildings with Failure Events are in REDRED Folder Folder• Click on Click on REDRED folder to see details of Failuresfolder to see details of Failures

Site 1Melaka

Site 2Perak

Site 3Johor

Internet

iSCADA ServerGlobal Reach

Kawalselia

Real Time MonitoringReal Time Monitoring screen shot showing that a screen shot showing that a Fault occurred in the Fire Alarm System on Fault 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 and An email and SMS was sent to Nurhaizan and Zulhelmi when the failure occurredZulhelmi when the failure occurred

ReportingReporting screen shot showing that the same screen shot showing that the same fault kept repeating since 13fault kept repeating since 13thth May 2005 May 2005

StatisticsStatistics screen shot showing overall system screen shot showing overall system availability from 1availability from 1stst Jan 2004 to 31 Jan 2004 to 31stst Dec 2004 Dec 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

TTransparencyransparency

How JKR has benefited from How JKR has benefited from implementation of eMaintenanceimplementation of eMaintenance

Everything was recorded automatically without human Everything was recorded automatically without human intervention. Reports & statistics are available online to intervention. Reports & statistics are available online to top management in real time. top management in real time.

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

AAvailabilityvailabilityAutomatic detection and SMS enables quick actions to be Automatic detection and SMS enables quick actions to be taken. This improves the overall availability of our taken. This improves the overall availability of our systems. systems.

Reporting Concept: eMaintenance Reporting Concept: eMaintenance Vs Conventional MaintenanceVs Conventional Maintenance

Central AuthorityCentral Authority

Lower AuthoritiesLower Authorities

Lower AuthoritiesLower Authorities

Assets / Assets / Data SourceData Source

Conventional Conventional MaintenanceMaintenance

Central AuthorityCentral Authority

Lower AuthoritiesLower Authorities

Lower AuthoritiesLower Authorities

Assets / Assets / Data SourceData Source

Query /

Login InformationElectronic Electronic

MaintenanceMaintenance

ReportsReports

ReportsReports

ReportsReports

Reactive & Predictive Components of eMaintenanceReactive & Predictive Components of eMaintenance

Reactive Maintenance:Reactive Maintenance:React to a system failure, and attempt to restore normal React to a system failure, and attempt to restore normal functionality in the shortest time possible.functionality in the shortest time possible.

iSCADA’s role in Reactive Maintenance:-iSCADA’s role in Reactive Maintenance:-

(1)(1) Detecting Failures automatically, and sending alerts to Detecting 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 Logs all events and produces statistical analysis that can point to the root cause of problems (See next slide)to the root cause of problems (See next slide)

Predictive Maintenance:Predictive Maintenance:Anticipate system failures before they happen by using Condition Anticipate system failures before they happen by using Condition Monitoring toolsMonitoring tools

iSCADA’s role in Predictive Maintenance:-iSCADA’s 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.

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

Due to Leaks in Due to Leaks in the Sprinkler the Sprinkler System pipingSystem piping

Screenshot of actual site data from JKR Melaka

After the Fire Protection system at Wisma Persekutuan Melaka was upgraded, we used the iSCADA system to monitor the performance of the new installation.

We found that there was over 500 events reported by 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 of time, which is not normal.

This indicated a leak in the piping system, which was subsequently fixed by the contractor.

iSCADA helps in Predictive MaintenanceiSCADA helps in Predictive Maintenance

Conditioning Monitoring allows maintenance engineers to detect abnormal behavior. Action can then be taken to prevent an actual failure.

Eg 1. If a temperature sensor is embedded into the 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.

Moving ForwardMoving Forward

1.1. Implement eMaintenance in all JKR Implement eMaintenance in all JKR buildings state-wide and nationwidebuildings state-wide and nationwide

2.2. This allows consolidation of This allows consolidation of maintenance management data and maintenance management data and central supervisioncentral supervision

3.3. Performance of FM contractors can be Performance of FM contractors can be monitored objectively with Key monitored objectively with Key Performance Indicators (KPIs)Performance Indicators (KPIs)

4.4. Ensure that Maintenance budgets are Ensure that Maintenance budgets are managed prudentlymanaged prudently

5.5. Enables JKR to perform Predictive Enables JKR to perform Predictive MaintenanceMaintenance