| Digitalisation


past, whereas, in reality, 82% of asset failures happen at random intervals7


. The goal of APM 4.0, then, is to


leverage real-time data available to drastically reduce unplanned equipment failures. Let’s illustrate the point using the analogy of a physical


exam. If a physician only asks a patient how you are feeling as opposed to taking their temperature, doing blood work, etc, then they will only get half the picture. It stands to reason that more quantitative information equates to much better decision-making. In an industrial context, maintaining assets efficiently (i.e. only when needed) has been shown to decrease maintenance costs by 20–30%, and machine downtime by 20–50%8 Digital twins – digital replicas of a physical assets


.


– are also evolving, enabling industries to test and refine multiple critical processes and scenarios without impacting real-world operations. ABB uses a hybrid modelling approach. We begin with a physics-based solution that may utilise traditional methods such as thermodynamics and hydraulics9


. Second, we deploy


data driven models using embedded AI and ML to detect equipment anomalies not being monitored by physics based models alone. Then, in combining rules based, physics based, and data driven models, we create a ‘hybrid’ model that creates a digital twin based on information extracted from the measured equipment or instruments. The ABB team then employs thermodynamics to estimate some of the parameters required, and applies diagnostic models to run “What-If” scenarios that can assist in addressing faults or bottlenecks.


APM in the water and dam industry As we have seen, AI technologies including machine


learning, predictive analytics and digital twins are being successfully integrated into APM tools, analysing vast datasets from sensors and control systems to predict asset failures, optimise maintenance schedules and improve decision-making. For water and dam operators, the benefits include


improved reliability and longevity of critical assets like turbines, pumps, and control systems; the ability to more accurately predict asset degradation, reducing unplanned downtime and costly repairs; increased operational efficiency via data-driven decision-making for more proactive maintenance and optimized resource allocation; and reduced environmental impact through optimized water resource management and energy consumption. Key features of ABB’s APM solution are predictive


maintenance (potential of reducing maintenance costs by more than 15%)10


; real-time monitoring,


resource optimisation (potential to increase overall productivity by 8%+), extended asset lifespan (25%+) and environmental and regulatory compliance. Let’s look at how this works in a real-world project. In Italy, ABB is delivering predictive maintenance solutions that will enable a major operator’s hydroelectric plants – across 33 sites, comprised of around 100 units – to move from hours-based maintenance to predictive and condition-based maintenance11


.


The contract includes digital software solutions and services that will provide analysis of more than 190,000 signals and the deployment of around 800 digital asset models. The overarching aim of the project to improve plant operational performance, reduce unplanned failures and enable more efficient planned maintenance practices through predictive maintenance. The integration of the ABB system is expected to yield savings in both fleet maintenance costs and increase plant productivity. The ABB Ability™ Collaborative Operations Center for power generation and water will help bring wider benefits of digitalization and engagement, supporting informed decision-making, real-time solutions and cost savings. The centre provides similar digital solutions and advanced applications for more than 700 power plants, water facilities and electric vehicle charging stations globally.


Future-proof operations using APM In conclusion, then, the integration of digital innovations


such as AL, ML, digital twins and big data into more traditional APM represents a step change in how industrial assets along the value chain are managed. This gives water utility managers, dam operators, infrastructure engineers and asset managers unprecedented visibility across their operations, enabling them to make the transition to predictive maintenance, reducing downtime while optimizing production, safety and sustainability. New-generation APM systems are designed


to meet increasing demand for enhanced APM systems to handle the complexities of modern water infrastructure, such as aging assets, stringent regulatory requirements and environmental concerns. Deployed strategically, in partnership with a trusted technology provider, these smart solutions have the potential to transform how critical assets are monitored and maintained, future-proofing operation and ensuring that the water keeps flowing.


References


[1] https://new.abb.com/industrial- software/asset-performance- management


[2,9] ‘Optimize energy consumption using APM 4.0’ – Anindya Chatterjee, ABB


[3,4,5] ‘ABB brings Advanced Analytics and Enhanced Asset Performance into Reach’ – ABB white paper


[6,7,8] ABB Ability Genix APM External Presentation - Stacey Jones


[10] https://new.abb.com/ industrial-software/asset- performance-management


www.waterpowermagazine.com | November 2024 | 23


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