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Beamex customer case story

DC Water, United States

How DC Water made an 80% time saving by automating their calibration processes

Beamex / Case stories / DC Water, United States | Beamex MC6 and CMX case story

Summary

Through automated calibration, DC Water has been able to meet the increasing requirements associated with control system upgrades and evolving compliance. Implementing a paperless solution enabled the automation of manual work processes and these streamlined workflows enables them to accomplish more work with the same or less resources with a total return on their investment within the first year.

All in all, the plant has experienced dramatic time savings and implemented a more reliable calibration strategy while realizing a 100% return on investment in the first year.

Robert Hopkins DC Water, Process Control System Specialist, DC Water, US

Using the Beamex MC6 field calibrator and communicator for pressure calibrations has decreased the time it takes to conduct the calibration procedure itself in the field by over 80%.

Bill Adams, Process Control Systems Specialist, DC Water, US

75%

Time saved on pressure calibrations

80%

Time saved on conducting calibration test procedures

100%

ROI in the first year

DC Water Plant

About the DC Water Blue Plains

DC Water’s Blue Plains Advanced Wastewater Treatment Plant opened in 1937. Currently it treats wastewater from the District of Columbia, Maryland and Virginia and is considered the largest treatment plant of its kind in the world. On an average day, close to 300 million gallons of raw sewage flows into the Blue Plains Advanced Wastewater Treatment Plant to be treated.

After treatment, the cleaned water flows into the Potomac River which leads to the Chesapeake Bay. To protect our waterways, DC Water is under strict requirements to dramatically reduce the amount of nitrogen and phosphorous in the cleaned water we discharge into the Potomac. In fact, these permit limits are some of the most stringent in the country.

DC Water calibration

A better way with Beamex and process standardization

With the control system expansion and upgrades, there was a need for calibrating more instrumentation, competently calibrating smart transmitters with higher accuracy, and most importantly, better data for performance reporting was required by the Engineering Group.

The Maintenance Group needed to make substantial improvements to the calibration program to accomplish these objectives while keeping resources at current levels. A key component for success was automation. They invested in the Beamex integrated calibration solution comprised of Beamex CMX calibration software and Beamex MC6 advanced field calibrator and communicator, and pumps.

Documenting calibrations

A foundation to the solution was defining and documenting the calibration procedures for all calibratable assets into a database inside of the Beamex CMX software. These centralized and well-defined procedures could now drive methods that ensured measurement data is captured, measurement errors are calculated and compared to defined tolerances, and data is organized for easy access and reporting.

Building information assets provided the Engineering Group the information they needed for analysis, and the transparency and visibility greatly increased confidence levels for both upper management and third party stakeholders.

Achievements at DC Water

Better planning

Planning calibration work is now streamlined using CMX, yielding substantial time savings. The Maintenance Group uses fully electronic and paperless workflows by utilizing the MC6. Procedures are programmed into the MC6, measurement errors are calculated and presented in real time, and all measurement data is captured electronically.

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Intrinsically safe calibrator and communicator - Beamex MC6-Ex

Quality improvements

In addition to time savings, there has also been substantial improvements to the quality of calibration. With the more streamlined workflow and automated documentation, they could now justify a more thorough strategy consisting of additional test points, as well as up and back down the span.

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Beamex CMX calibration software analytics dashboard

Documented results

With the CMX software, they have automated calibration. They can automatically generate calibration certificates and attach these certificates inside of their maintenance management system, Maximo. This provides transparency and visibility to management. The electronic documentation also minimized the opportunity for human error.

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