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GE
Intelligent Platforms
Implementing a Workflow Solution Leveraging SCADA and
Cityworks
2013 T-CON
Water Utilities spend over
$1,000,000,000 on controls and IT
every year with the goal of
increasing operational efficiency,
consistency and accountability.
The truth is, these solutions only
deliver so far on these goals
because they are not integrated and
unable to leverage their full potential.
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3 ©2011 GE Intelligent Platforms
All Rights Reserved
Business
SCADA
Engineering
Operations
Asset
Management
Results:
Duplicate effort, information silos,
analysis gaps operational inefficiency
and reactive operations
Manual data collaboration is
widespread even with the large level of
IT investment.
“After huge IT
investments, I still
have operators hand
creating 60 page
operational reports
every 6 hours wasting
thousands of hours
every year.”
4 ©2011 GE Intelligent Platforms
All Rights Reserved
• $ Workflow – Incorporate into financial packages for further analysis
• GIS Workflow – Real time spatial mapping of events & asset information
• Controls Proficy CMMS - Automatically Trigger work orders, capture labor and materials parameters, & real-time water efficiencies
“Platform convergence
provides staff with
collaborative
information allowing us
to better serve our
customers. ”
Maximize your investment by connecting your IT investment:
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Workflow Best friend to plant managers everywhere.
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Digitize manual and automated
processes with one tool across your
entire utility – from plant operators and
maintenance teams to field crews and
leadership
Every operator is your best with:
Manual task automation
Digitized Std. Operating Procedures
Alarm Response Management
Centralized Operator Interface
Decrease downtime,
maintenance and costs
across operations
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7 ©2011 GE Intelligent Platforms
All Rights Reserved
manual task
automation
Some processes require direct operator
interface or don’t make sense to
automate
Detailed step based
instructions fed by live
data leads operator
though dynamic
processes to deliver
best possible outcomes
Embed iFIX or 3rd
party software to
provide topical
control to the
operator
8 ©2011 GE Intelligent Platforms
All Rights Reserved
electronic
standard
operating
procedures
Scheduled, Daily, and SCADA activated
tasks keep operators focused
Improve operator
safety by digitizing
MSDS information into
central database that
also ensures they have
the latest revisions
Simplified steps for the
operator with detailed
information in the work
instructions
Connect to documents,
videos, even live feeds to
provide operators with
deeper knowledge on each
step
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9 ©2011 GE Intelligent Platforms
All Rights Reserved
alarm
response
management
Consistent alarm response
reduces troubleshooting time and
risk
Provide operators with
detailed information on
alarms including
trending
Digital alarm log entry
reduces labor and
increases the information
collected on events (No
more lost sheets of paper)
Automatic excursion
detection, begins
troubleshooting
workflow
10 ©2011 GE Intelligent Platforms
All Rights Reserved
Centralized
operator
interface
Combine SCADA, LIMS, CMMS and
Security systems into a single interface
Integration with GIS-based
CMMS for condition-based
and reliability-centric asset
management
Tasks auditing and
notification processes
ensure chain of
command
Provide detailed work order
instructions for maintenance
and calibrations
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11 ©2011 GE Intelligent Platforms
All Rights Reserved
Enhancing SCADA with eSOPs
Workflow Water
Operations
Caustic chemical out of
spec!
SCADA
Data & Events
SCADA sends data to
Workflow
Out of spec data triggers
workflow
Workflow
Monitors Data
Data triggers “Caustic
chemical feed out of spec”
workflow
Operator performs 4 steps
and sends email to
Maintenance.
New Work
Instructions
Workflow sends eSOP to
operator
Central SCADA
12 ©2011 GE Intelligent Platforms
All Rights Reserved
Enhancing CMMS with eSOPs Real-Time Condition-Based Asset Management
Workflow Water
Operations
Pump Runtime
out of spec!
SCADA
Data & Events
SCADA sends data to
Workflow
Out of spec data
triggers workflow
Workflow
Monitors Data
Data triggers “Pump
Runtime” workflow
Operator goes to specific
pump station, performs 5
task steps, and completes
workflow, which closes the
work order
New Work
Instructions
Workflow sends eSOP,
work order # and GIS
details to operator
Central SCADA
CMMS sends work order #
and GIS information to
Workflow
Real-Time
CMMS
Workflow requests
CMMS to create new
work order
CMMS SOA SOA
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13 November 2010
Point to point integration
Yesterday
CMM
S
WMS
ERP GIS
SCAD
A
CIP
DMS
LIMS
Today with GE
Service Oriented
Architecture
14 November 2010
Trigger from any system on the Service Oriented
Architecture
Work Process Management
EMS
SOA
Event
Manager
WPM
GIS
CMM
S
Field Crew
Manager
Plant
Operators
Analy
tics
Etc.
Alarms
Events
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Reporting
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Process Feedback and Reporting
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Waterford Township
Use Case
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360 Miles of Water Main and Appurtenances
19 Production Wells
2 Elevated and 1 Ground Storage Tanks
13 Iron Filtration Plants
1 High Service Pumping Station
355 Miles of Sanitary Sewer
63 Sewer Lift Stations
15 Township Buildings
5 Township Cemeteries
230 Vehicle Fleet
Waterford Township DPW Assets
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Project Objectives
• Electronic Standard Operating Procedures (eSOP) - Provide method for capturing real-time events and documenting best practice processes to resolve them while codifying institutional knowledge
• Provide a workflow component for SCADA – Auto task generation
• Integration of SCADA workflows with Cityworks (CMMS) via Work Order API to further leverage business platforms and capture labor and material used to resolve issues
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Project Overview SCADA
Facilitates efficient monitoring, control and optimization of water and sewer operations.
Alarms generated are large proportion of CMMS work orders
No eSOP procedures and not linked directly to SCADA
Workflow
Event Based, Process-Centric
• Manual task automation
• Digitized eSOP
• Alarm Response Management
• Direct Integration with SCADA and CMMS
• Service Oriented Architecture – Key to Integration
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Project Overview
Cityworks
•Work Order API provides developers a supported set of web services to generate work orders in Cityworks.
•Utilizing the inherent Cityworks business logic, data values sent to the service can trigger both routine and emergency work orders.
•The web services follow the JSON standard making them language independent and able to support requests generated from a variety of environments including .Net and Java.
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Project Items
Phase I
Automated workflows based on SCADA condition events
• Pump number of starts
• Pump runtimes
• Standalone workflow to document Sanitary Sewer Overflow (SSO)
reporting process
Automated workflow based on time event
• Site Inspection – 5-7 inspections per day as part of a 2 week cycle
Incorporation of Cityworks Work Order API for automatic work order
generation
Phase II • Integration of Document Management System (OnBase)
• Development of additional workflows by internal staff
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Workflow Overview
Workflow is made up of four main components
•Equipment Model – Models site/equipment and linkage of SCADA values
•Events – Conditional expressions or time based events that trigger workflows
•Workflow Templates – Configured Templates that contain automated process and manual steps
•Schedules – Combines events with workflow templates to initiate workflows
These components create a process driven workflow for managing by exception
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Workflow Equipment Model
Model of site and equipment
Stores real-time SCADA values for evaluation
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Workflow Equipment Model
Model of site and equipment
Stores real-time SCADA values for evaluation
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Workflow Events – Conditional
Conditional Expression – Uses values stored in Equipment to evaluate expressions
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Workflow Events – Conditional
Conditional Expression – Uses values stored in Equipment to evaluate expressions
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Workflow Events – Time Based
Time Based Expression – Uses date/time expression to determine when event should be triggered
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Workflow Template
Configured steps and processes that are executed automatically and/or with user interaction
Steps can be modified by workflow authors and services can be added by administrator
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Workflow Template
•Series of predefined methods are used to create and populate the work order when the work order is generated
•Template can be modified so that a work order is not automatically generated at the start of the workflow, it can be chosen as an option in one of the steps
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Workflow Template
Workflow presents pre-configured services that can be added as a method
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Workflow Schedule
Combines workflow template with events, either conditional or time based to determine if a workflow should be generated
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Workflow Deployed
When a workflow is triggered, either manually or automatically as part of a conditional or time based event a series of processes occur:
An email is triggered, notifying appropriate personnel of the workflow and supplying a work order number if generated
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Workflow Deployed
Appropriate users can view details of the workflow and begin processing it
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Workflow Deployed
Information from SCADA is displayed in the workflow, along with specific eSOP information for troubleshooting
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Workflow In Action Steps guide users through resolution of the issue
Steps have expiration timers, if steps are not processed in time escalation processes occur (notifications)
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Workflow Deployed
Users can view list of completed workflows and can view details of workflows
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Workflow Manager View Managers can view complete list of pending workflows
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Workflow In Action Managers can develop workflows based on functions of their group
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Workflow Labor Hour Report
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Workflow Work Order Type Report
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Workflow % Work Orders by Site
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Thank You!
Terry Biederman, P.E.
Global Industry Manager- Water
GE Intelligent Platforms
Questions?
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Backup
eSOP
Solution Components
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GIS
Busines
s
CMMS DMS AMI Payroll AVL W-WAN
Automation & Control
SCADA PLC
Modeling
Standalone and Disconnected Platforms
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eSOP Solution
Solution components: Proficy Workflow and Reporting eSOP Editor – Global Display eSOP System Configuration – Global Display eSOP Template – Workflow Template eSOP Step – Workflow Template Form Email – Custom Activity eSOP User Activities Solution Objects Service Provider
What you will need to have… One of the supported Workflow Operating Systems SQL Server 2005 (or greater) SSRS – SQL Server Reporting Services SQL Server Business Intelligence Development Studio Microsoft Office 2007 (or greater)
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47 November 2010
One common method to communicate about assets
Standard Models (CIM, ISA95)
SCAD
A
SOA
LIMS
ERP
GIS
Noriu Kitas vienas alus, prašome
Желим Још једно пиво молим
Event Information and data
私はもうビールはお願いしたいと思います
Jeg ønsker en annen øl vennligst
48 November 2010
Location Context ISA-95 Equipment Models