Introduction
Maintenance costs can pose a considerable challenge in the realm of water and wastewater plants. However, with the evolution of industrial communications technology and the implementation of IoT, these costs can be significantly reduced. In this blog post, we will discuss how industrial communications can revolutionize maintenance practices in water and wastewater plants, resulting in improved operational efficiency and cost savings. Let's explore the potential of IoT and its impact on maintenance. So, keep reading to learn more!
Understanding the Maintenance Challenges
Water and wastewater plants encounter numerous maintenance challenges, including equipment breakdowns, inefficient resource allocation, unplanned downtime, and the exorbitant costs associated with emergency repairs. Traditional maintenance approaches often rely on reactive measures, leading to increased expenses and operational inefficiencies. According to a survey conducted by ABB, the Water & Wastewater industry bears a staggering cost of $98,222.22 per hour due to unscheduled or unplanned downtime.
The Role of Industrial Communications in Maintenance
Through the utilization of industrial communications and IoT, water and wastewater plants have the opportunity to revolutionize their maintenance practices. Here are several essential ways in which IoT can effectively tackle the challenges associated with maintenance:
Secure Remote Access
With secure remote access, you can conveniently connect to any field control system for programming, diagnosing, updating, calibrating, or monitoring purposes as if you were physically present. One great example is the Ewon and Talk2M Service, which not only saves time and money during commissioning but also throughout the installation's life cycle. By enabling faster problem response, reducing downtime, and increasing system availability, this solution ensures that responsible individuals receive immediate alert notifications on their mobile phones, regardless of their location. It's estimated that this approach can save 30 to 80% of unnecessary trips and even identify the root cause of issues before a trip is required. Take the example of Apliclor, a Spanish company that effectively employs remote access for the initiation of remote installations. They also provide remote support, proactively anticipating potential issues. Additionally, Ewon COSY is also utilized by UK Power Networks Limited to establish connections between Siemens power-quality measurement devices and the central control room. This facilitates improved maintenance and troubleshooting, enabling seamless collaboration between on-site and remote engineers.
Remote Monitoring and Real-time Data Collection
The Internet of Things (IoT) empowers vendors and plant managers by enabling remote monitoring of critical equipment. This allows real-time data collection on performance, operating conditions, and maintenance requirements. Adopting this proactive approach helps identify issues early and take timely action, minimizing downtime and optimizing maintenance efforts for smooth operations and maximum productivity. With IoT, plant managers gain a comprehensive understanding of equipment health, enabling informed decisions and efficient resource allocation.
Siwatec, a German company, excels in decentralized drinking water supply. They specialize in container-based treatment plants, ensuring high-quality water remotely without on-site operators. Leveraging remote monitoring technology, Siwatec guarantees uninterrupted water quality, optimizing maintenance costs through predictive maintenance and automated spare parts ordering. By harnessing external data, Siwatec efficiently estimates water demand, maximizing system running time.
Predictive Maintenance and Condition Monitoring
With IoT sensors and advanced analytics, plants can use predictive maintenance strategies. By continuously monitoring equipment health and detecting anomalies, maintenance teams can schedule repairs or replacements before failures occur. This approach reduces costs and extends asset lifespan. Studies show that implementing predictive maintenance can significantly boost productivity by approximately 25%. It also reduces breakdowns by 75%, enhancing operational efficiency. This proactive approach to maintenance can generate substantial cost savings, with maintenance expenses reduced by 25-30%.
Minimizing Downtime through Industrial Network Monitoring
Industrial Networks have revolutionized industrial automation in the Water & Wastewater industry by enabling seamless communication among devices and machines. However, along with these advantages, industrial networks bring heightened complexity, increasing the likelihood of issues. A single networking problem can have a catastrophic impact, causing the entire line to come to a standstill and resulting in costly downtime.
Solutions to monitor industrial networks online and provide alerts when anomalies occur are key to increase uptime of the plant. With diagnostic tools, issues can be promptly addressed without delay. For instance, the Rijnland District Water Control Board installed the ComBricks module from Anybus Diagnostics in their network to resolve various PROFIBUS malfunctions in the aeration tank of their wastewater purification systems. By monitoring the network with ComBricks, the PROFIBUS system is now significantly more stable and completely free of malfunctions. They are now well-prepared to take immediate action in case of any future malfunctions.
Challenges and Considerations
While Industrial communications and IoT offer significant benefits in maintenance, there are various challenges and considerations to address. These encompass:
Data Security and Privacy
Safeguarding sensitive data from cyber threats poses a significant challenge. It is crucial to establish robust encryption and access control measures to protect critical information and allow authorized access only. When selecting vendors and products, it is imperative to verify certification and choose reputable vendors with extensive experience and ample resources to consistently uphold system security and availability of the systems.
Integration with Existing Systems
Integrating IoT solutions with existing infrastructure and software systems can be a complex task that demands technical expertise and adequate resources. During implementation, careful consideration must be given to compatibility and interoperability. It's important to note that there are several Industrial networks standards in the market, and typically, they are not compatible with each other. Therefore, it is advisable to choose devices with multinetwork capabilities or utilize gateways to convert protocols and ensure seamless connectivity.
Costs and Return on Investment
IoT implementation involves upfront costs, including hardware, software, and training. A thorough cost-benefit analysis is essential to ensure a positive return on investment in the long run.
Conclusion
In an era where maintenance costs pose significant challenges for water and wastewater plants, IoT emerges as a game-changing solution. By leveraging remote monitoring, predictive maintenance, and optimized processes, plants can reduce downtime, improve resource allocation, and extend asset lifecycles. Real-life case studies demonstrate the transformative power of IoT in reducing maintenance costs and enhancing operational efficiency. As the water and wastewater industry continues to evolve, embracing IoT will be instrumental in achieving sustainable and cost-effective maintenance practices. So, take the plunge into the world of IoT and unlock a brighter future for maintenance in water and wastewater plants.