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Confidential Property of Schneider Electric
IIoT in Pumping
How IIoT and intelligent pumping can contribute to solving the global water crisis
Hussain Ahmed
Program Manager, Schneider Electric
Page 2Confidential Property of Schneider Electric |
1 The global water crisis
2 Challenges
3 Solutions
4 Energy efficiency
5 System efficiency
6 Pump efficiency
7 Start small, start smart
AgendaAGENDA
Global water shortages, growth in urban
population, environmental regulations, and
process inefficiencies are all contributing to
a crisis in the Water & Wastewater industry.
It is estimated that the amount of energy
wasted as a result of traditional methods
of water processing and delivery can be cut
by up to 25%.
Page 3Confidential Property of Schneider Electric |
The global water crisis
Introduction
Page 4Confidential Property of Schneider Electric |
Challenges
Driving factors for the pump industry
24.8%
13.7%
15.8%
6.7%
12.2%
22.5%
4.3%
Pumps Fans
Compressed Air Refrigeration
Material Handling Material Processing
Other
Industrial motor energy use1. Energy efficiency
2. System efficiency
3. Pump efficiency
4. Traceability
Object model increases
system efficiency
IIoT incorporates machine learning and big data
technology, harnessing sensor data, machine-to-machine
(M2M) communication and automation technologies that
have existed in industrial settings for years. The driving
philosophy behind IIoT is that smart machines are better
than humans at accurately, and consistently capturing
and communicating data.
The concept of “smart pumping”, also referred to
as an “intelligent pumping system”, combines greater
efficiencies with sensors and software to drive the
ability to regulate and control flow or pressure.
This approach results in energy savings, increased
equipment lifetime, and maintenance cost reductions.
Page 5Confidential Property of Schneider Electric |
Solutions
Smart pumping
Industrial Internet of Things
Two major pillars
Page 6Confidential Property of Schneider Electric |
Electricity costs account for 40% of the total cost of ownership
(TCO) of a pump.
By following energy management best practices, a manufacturer
can decrease the electrical consumption of its pumping system by
at least 30%, yielding a 20% reduction in TCO and a return
on investment within 24 months for the pump operators.
Challenges
Energy efficiency
50.5%
10.0%
27.0%
12.5%
Pumps Fans Compressed Air Other
Potential energy savings
A smart pumping system along with IIoT enables
energy efficient systems through:
a.Monitoring of pumps, which helps operators to
detect higher energy usage
b.Libraries and algorithms to ensure that pumps are
running in energy efficient manner
c. Pumps driven by variable speed drives which can
save up to 30% energy compared to fixed speed
pumps
Page 7Confidential Property of Schneider Electric |
Solutions
Energy efficiency
Energy per liter
Deviation
+ 0.57 Wh
2.89 Wh
Weekly Report
Energy per liter
AVERAGE
2.89
Wh
Dec, 21st, 2010 –
18:05:02
An “inefficient “ system can result in:
a.Frequent breakdowns
b.Increased operational and maintenance costs
c. EPA issues
A pumping system is considered “efficient” if it is:
a.Available
b.Reliable
c. Compliant
Page 8Confidential Property of Schneider Electric |
System efficiency
Reduced revenue
and profits
Excessive
maintenance
costs
Increased
fuel costs
Reduced
margins
Decreased ROA
Unnecessary
maintenance
costs
EPA issues
Environmental
credit purchase
Maintenance
cycles too short
Unneeded
OEM rebuilds
Forced outages
and derates
Catastrophic
failure
Heat rate
increases
Environmental
equipment
issues
Pump performance
• Reliability
• Availability
• Compliance
• Efficiency
Challenges
A smart pumping system along with IIoT enables
an efficient system by:
a.Establishing preventive maintenance plans for
systematic inspection to detect potential failures
b.Enabling condition-based maintenance by
monitoring pumping system data for an accurate
status and risk assessment
c. Deploying corrective maintenance measures
as needed in response to an unanticipated
problem or emergency
Page 9Confidential Property of Schneider Electric |
Solutions
System efficiency
By monitoring operational parameters, an
operator can ensure smooth operations and
adjust maintenance schedules as needed.
Wireless
sensors
Intelligence
programmed
in controllers
Pump info
from drive
Gateways
Remote
monitoring
platforms
HMI edge box
With data storage
/IIoT
Page 10Confidential Property of Schneider Electric |
Solutions
System efficiency
Data from boosters in
multiple locations (1, 2, n…)
Keep talking to your boosters
Source: EuroPump
Are you sure the pump is running
at an optimal point?
It is estimated that 75% of pump systems
are oversized, many by more than 20%.
Page 12Confidential Property of Schneider Electric |
Challenges
Pump efficiency
“House of efficiency”
Covered range
of requirements on ŋpump:
75 – 110% QBEP
A smart pumping system along with IIoT enables
pump efficiency by:
a.Monitoring operating curves in real time
b.Ensuring, with intelligent algorithms, that pumps
operate at their most optimized point – which is
defined as Q(bep) by EuroPumps
c. Enabling pump system manufacturers and
operators to ensure that the pumps used
are the appropriate size
Page 13Confidential Property of Schneider Electric |
Solutions
Pump efficiency
To perform better maintenance, it is vital you know
what condition your pump is in, and what support
it may need.
Page 14Confidential Property of Schneider Electric |
Challenges
Traceability
A smart pumping system along with IIoT
enables traceability through:
a.Variable speed drives with active QR codes
can be used not only for diagnostics but also
to help operators more easily access
information for support
b.By remaining in contact with pumps,
manufacturers not only know the exact
location of the pumps but are also able
to provide timely support and spare parts
Page 15Confidential Property of Schneider Electric |
Solutions
Traceability
• Introduce energy measuring devices
into system architectures
• Use controllers with intelligent
applications for better protection and
reduced commissioning time, while
following guidelines for standards as
set by local and global organizations
• Replace fixed speed pumps with
variable speed pumps
• For smart visibility of pumping
systems use remote monitoring for
maintenance and energy efficiency
Page 16Confidential Property of Schneider Electric |
Start small, start smart
Page 17Confidential Property of Schneider Electric |
To find out more, visit us at
Hall 11, booth C
Share your thoughts and comments
on Twitter @SchneiderElec #HM16SE
Page 18Confidential Property of Schneider Electric |
How IIoT and Intelligent Pumping can contribute to solving the Global Water Crisis

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How IIoT and Intelligent Pumping can contribute to solving the Global Water Crisis

  • 1. Confidential Property of Schneider Electric IIoT in Pumping How IIoT and intelligent pumping can contribute to solving the global water crisis Hussain Ahmed Program Manager, Schneider Electric
  • 2. Page 2Confidential Property of Schneider Electric | 1 The global water crisis 2 Challenges 3 Solutions 4 Energy efficiency 5 System efficiency 6 Pump efficiency 7 Start small, start smart AgendaAGENDA
  • 3. Global water shortages, growth in urban population, environmental regulations, and process inefficiencies are all contributing to a crisis in the Water & Wastewater industry. It is estimated that the amount of energy wasted as a result of traditional methods of water processing and delivery can be cut by up to 25%. Page 3Confidential Property of Schneider Electric | The global water crisis Introduction
  • 4. Page 4Confidential Property of Schneider Electric | Challenges Driving factors for the pump industry 24.8% 13.7% 15.8% 6.7% 12.2% 22.5% 4.3% Pumps Fans Compressed Air Refrigeration Material Handling Material Processing Other Industrial motor energy use1. Energy efficiency 2. System efficiency 3. Pump efficiency 4. Traceability Object model increases system efficiency
  • 5. IIoT incorporates machine learning and big data technology, harnessing sensor data, machine-to-machine (M2M) communication and automation technologies that have existed in industrial settings for years. The driving philosophy behind IIoT is that smart machines are better than humans at accurately, and consistently capturing and communicating data. The concept of “smart pumping”, also referred to as an “intelligent pumping system”, combines greater efficiencies with sensors and software to drive the ability to regulate and control flow or pressure. This approach results in energy savings, increased equipment lifetime, and maintenance cost reductions. Page 5Confidential Property of Schneider Electric | Solutions Smart pumping Industrial Internet of Things Two major pillars
  • 6. Page 6Confidential Property of Schneider Electric | Electricity costs account for 40% of the total cost of ownership (TCO) of a pump. By following energy management best practices, a manufacturer can decrease the electrical consumption of its pumping system by at least 30%, yielding a 20% reduction in TCO and a return on investment within 24 months for the pump operators. Challenges Energy efficiency 50.5% 10.0% 27.0% 12.5% Pumps Fans Compressed Air Other Potential energy savings
  • 7. A smart pumping system along with IIoT enables energy efficient systems through: a.Monitoring of pumps, which helps operators to detect higher energy usage b.Libraries and algorithms to ensure that pumps are running in energy efficient manner c. Pumps driven by variable speed drives which can save up to 30% energy compared to fixed speed pumps Page 7Confidential Property of Schneider Electric | Solutions Energy efficiency Energy per liter Deviation + 0.57 Wh 2.89 Wh Weekly Report Energy per liter AVERAGE 2.89 Wh Dec, 21st, 2010 – 18:05:02
  • 8. An “inefficient “ system can result in: a.Frequent breakdowns b.Increased operational and maintenance costs c. EPA issues A pumping system is considered “efficient” if it is: a.Available b.Reliable c. Compliant Page 8Confidential Property of Schneider Electric | System efficiency Reduced revenue and profits Excessive maintenance costs Increased fuel costs Reduced margins Decreased ROA Unnecessary maintenance costs EPA issues Environmental credit purchase Maintenance cycles too short Unneeded OEM rebuilds Forced outages and derates Catastrophic failure Heat rate increases Environmental equipment issues Pump performance • Reliability • Availability • Compliance • Efficiency Challenges
  • 9. A smart pumping system along with IIoT enables an efficient system by: a.Establishing preventive maintenance plans for systematic inspection to detect potential failures b.Enabling condition-based maintenance by monitoring pumping system data for an accurate status and risk assessment c. Deploying corrective maintenance measures as needed in response to an unanticipated problem or emergency Page 9Confidential Property of Schneider Electric | Solutions System efficiency By monitoring operational parameters, an operator can ensure smooth operations and adjust maintenance schedules as needed. Wireless sensors Intelligence programmed in controllers Pump info from drive Gateways Remote monitoring platforms HMI edge box With data storage /IIoT
  • 10. Page 10Confidential Property of Schneider Electric | Solutions System efficiency
  • 11. Data from boosters in multiple locations (1, 2, n…) Keep talking to your boosters
  • 12. Source: EuroPump Are you sure the pump is running at an optimal point? It is estimated that 75% of pump systems are oversized, many by more than 20%. Page 12Confidential Property of Schneider Electric | Challenges Pump efficiency “House of efficiency” Covered range of requirements on ŋpump: 75 – 110% QBEP
  • 13. A smart pumping system along with IIoT enables pump efficiency by: a.Monitoring operating curves in real time b.Ensuring, with intelligent algorithms, that pumps operate at their most optimized point – which is defined as Q(bep) by EuroPumps c. Enabling pump system manufacturers and operators to ensure that the pumps used are the appropriate size Page 13Confidential Property of Schneider Electric | Solutions Pump efficiency
  • 14. To perform better maintenance, it is vital you know what condition your pump is in, and what support it may need. Page 14Confidential Property of Schneider Electric | Challenges Traceability
  • 15. A smart pumping system along with IIoT enables traceability through: a.Variable speed drives with active QR codes can be used not only for diagnostics but also to help operators more easily access information for support b.By remaining in contact with pumps, manufacturers not only know the exact location of the pumps but are also able to provide timely support and spare parts Page 15Confidential Property of Schneider Electric | Solutions Traceability
  • 16. • Introduce energy measuring devices into system architectures • Use controllers with intelligent applications for better protection and reduced commissioning time, while following guidelines for standards as set by local and global organizations • Replace fixed speed pumps with variable speed pumps • For smart visibility of pumping systems use remote monitoring for maintenance and energy efficiency Page 16Confidential Property of Schneider Electric | Start small, start smart
  • 17. Page 17Confidential Property of Schneider Electric | To find out more, visit us at Hall 11, booth C Share your thoughts and comments on Twitter @SchneiderElec #HM16SE
  • 18. Page 18Confidential Property of Schneider Electric |