enhanced training methods for operations staffnysawwa.org/docs/pdfs/session_6_4.pdf · 1 20 october...

© ARCADIS20 October 20151 © ARCADIS20 October 20151

Enhanced Training Methods

for Operations Staff

Ways to make training stick

September 24, 2015

September 24, 2015

© ARCADIS20 October 20152

Authors

• Suman Bopaiah, ENV SP

‒ ARCADIS, Commissioning/Training Coordinator (CMJV)

• Edward G Kowalski, PE, PMP

‒ ARCADIS, Control Systems Commissioning Leader (CMJV)

• Jim Hanratty, PE

‒ NYCDEP BWS, Eastview Regional Manager


What We’ll Be Covering

• Enhanced staff training provided during the

commissioning phase at the Catskill/Delaware

Ultraviolet Facility (CDUV)

• Benefits of augmenting traditional training with

immersive training

• Lessons learned and current use of enhanced

training tools at CDUV


Project Background: Water Flow & UV Facility

Rendering

Hillview

Reservoir

UV

Catskill Aqueduct

City Tunnels

Kensico

Reservoir

Delaware Aqueduct

Shafts 19

Future Pressurized

Catskill Aqueduct

North Forebay

UV Building

Shaft 19Generator

Building


Project Background

• Location: Town of Mt. Pleasant, NY

• Largest UV water disinfection facility in the world

• Largest unfiltered surface water system in the U.S.

• Serves ~9 million customers

• Can disinfect (UV) up to 2.4 BGD of water

• Project Cost ~$1.6B


Project Background: Key Facility

Components

• Forebays / Influent Gates

• 56 UV Units (cap. 60 MGD each)

• 4 Quadrants

• 16 Energy Dissipating Valves

• 5 Generators

• 6 Venturis144”

Venturi

Diameter


March 30,

2011

Enclose UV

Building

March 17,

2012

Electrical

Substation

August 3,

2012

1st UV

Quadrant

October 29,

2012

Plant Fully

Operational

February 2013

BWS

Turnover/Acceptance

August 31,

2012

2nd UV

Quadrant

November 8,

2012

Commissioning

Period Ends

2014

BWS Full

Facility

Operations

CMJV Operation + BWS Staff Support, Engagement & Training

Facility Commissioning:

Milestones (~ 2 years Training)


Facility Commissioning: Team

Collaboration (CDUV Staff)

• SEW, Welsbach, LJ Coppola and Sub-Contractors

• Hazen & Sawyer / CDM Smith

• ARCADIS / CH2MHill

• DEP(BEDC/BWS)

NYCEP

Construction Management Joint Venture

ContractorsDesign

Joint Venture

25 Operations & Supervisory Staff

15 Maintenance, Instrumentation, SEE, &

Computer Specialists

6 Administration Staff & Others


Vendor Training (Contractor)

Systems Training

(DJV)

Systems O&M Manual Training

(DJV)

Health & Safety and Other

(DEP)

Traditional Training

Facility Commissioning:



Recognizing Enhanced Training

Opportunities

• Meeting testing and meet water demand

Flow Demand

• Complex coordination upstream and downstream

• Transition from manual to complex auto control strategies

Flow Control/Automation

• UV Units in and out-of-service

• DOH reporting needs

Disinfection

• Troubleshooting at “live” facility

• System response: e.g. takes 40 minutes to open north forebaygates

Construction & Testing

• First UV system for the DEP

• Hiring and rapid on-boarding

Staff

• Power savings, UV dose, instrument calibrations

System Optimization


Operations EngagementConstruction Tracking

Engagement

Communication

Coordination

Vendor Training (Contractor)Systems Training

(DJV)


(DJV)


(DEP)


Computer-Based Simulation

En

ha

nc

ed

Tra

inin

g

Enhanced Training Approach:

Augmenting Traditional Methods


Operations Engagement:

Control Room

• On-the-job training (OJT) during 24/7 Control

Room Operations:

‒ Trained small groups by witnessing CMJV staff

operate initially (CMJV – 2; BWS – 3)

‒ Performed walk-through of facility

‒ Provided training on Control Room duties -

recognizing PMCS data and alarms

Operations


Operations Engagement:

Control Room

• On-the-job training (OJT) during

24/7 Control Room Operations:

‒ Process monitoring forms

‒ Routine/Round Forms

‒ Targeted training (UV basics,

alarm management, etc.)

Operations


Construction Tracking Engagement

• Increase familiarity of system components and

ensure uninterrupted water supply:

‒ WARF/Process

‒ Incident

Notifications

Construction Tracking

Work Activity Registration Form


Communication Coordination

• Institute Communication Plan to ensure effective

information transfer between shifts

‒ Flow Control Oversight

‒ Daily Planning Meetings

‒ Email Notifications

‒ White-board updates

‒ Daily conference calls

Communi-cation



• Monitoring

‒ PMCS & Equipment

• Issues Notification

‒ Startup & Commissioning

• Beginning & End of Shift

Reporting

‒ Flow Testing Status

Communi-cation

Equipment Monitoring Form

Flow Testing Status Form



Beginning and End of Shift Reports

Communi-cation



• DOH Reporting

‒ Collected input from commissioning team members to

configure Historian

‒ Reformatted the report, adjusted the HMI to simplify

manual data

‒ Collaborated with staff and provided training

throughout DOH refinement process

Communi-cation


Simulation Environment

• Simulation Environment:

‒ Full complement hardware/software

Limitation: no complete UV Vendor Unit

Panel/ or Entire Model/Quadrant

‒ Offline Control Logic Revision Testing

Modification to Control Strategies tested in

the simulator (either on site or at the

integrator facility)

‒ Implementation Planning

Methodical approach with buy-in from team

on schedule of execution of more complex

strategies

Computer-Based

Simulations

Simulator: Transition to Automation


• Simulation set up in

software/hardware

• Operator training teams

‒ Risk, failure scenarios

‒ High level strategies

‒ Vendor panel sequences

Computer-Based

Simulations

Simulator: Set up & Training


• Changes run through multiple times/

varying scenarios

• “Actual” reflected in control room, real

training environment

Operation Team Exercise : Simulate failure UV chemical cleaning

Computer-Based

Simulations

Simulator: Updates


Simulator: Updates

• Tiered Approach to Staged transition to

Automatic Operation:

‒ Level 1: Semi-Automatic

NYCEP “co-pilot” / CMJV & Contractor “pilots”

Local Auto control (UV) coupled with Remote

Manual (EDV)

• 6-8 months

• Gain familiarity with simulator/embedded logic

‒ Level 2 – Automatic: Full auto flow control

‒ Level 3 – Optimization: System-wide flow

optimization, energy optimization

Computer-Based

Simulations


• Increases staff engagement

• Increases knowledge of equipment/ system

operations

• Elevates confidence levels

• Fosters ownership of system

• Prepares staff for high levels of automation

and new technology

23

• Meets contract requirements

• One-size-fits-all approach

• Non-immersive

• Short-term impactsVendor Training (Contractor)

Systems Training

(DJV)


(DJV)


(DEP)


Operations Engagement

Construction Tracking Engagement


Computer-Based Simulations

En

ha

nc

ed

Tra

inin

g

Traditional vs Enhanced Training


Current Operations

>1.1

BGDNormal flow

Dose

Reduction

3%Critical Alarms

Manual/Auto

Full Auto next year

SimulatorTraining Tool

EOM,

SOP

Updates


Lessons Learned & Results of

Enhanced Training

• Needs to be customized to fit utility and staffing needs

• Routine Round Sheets adopted and currently in use

Operations Engagement

• Budget for additional training as early as possible

• WARF currently used by utility staff

Construction Tracking engagement

• Led to healthy collaboration

• Beginning & end of shift report currently in use


• Simulator has limitations. Costly.

• Train staff in a virtual environment (identical to control room)Computer-Based

Simulator


Staff Feedback

“Morning WARF

meeting was great”

“Hands-on

training is critical”

“Pilot and co-pilot

exercises helped

during commissioning”

“End of Shift reports

quickly summarized

Ops for next crew”


Future

• Cross-training of Operations & Maintenance staff

• Electronic Operation Manual (EOM) updates will

document system improvements and SOPs

• Dose Reduction and Energy Optimization

• Continual Improvement


Questions?

enhanced training methods for operations staffnysawwa.org/docs/pdfs/session_6_4.pdf · 1 20 october...

Documents