WBG030410171936AUS

Project Life Cycle Support (SCADA)

Texas Association of Clean Water Agencies

Garland , TXMarch 26, 2010

Yehuda Morag CH2M HILL, Austin TX

Agenda

• Introduction to SCADA• Utility Managers / Decision

Makers• Project Life Cycle Support• Benefits to the Utility• City of Garland - LCS• Other Examples – LCS• Summary

Goals of this Session

• Identify SCADA / Facility Automation and Information Management LCS issues faced by most Utilities

• Show how Planning for SCADA /Facility Automation Life Cycle Support can benefit the Utility

• Introduce Utility Managers with resources and ideas for efficient SCADA Life Cycle Support.

Introduction to SCADA

Water Eng.WasteWater

FinancialsService Sectors

Optimize Systems:- BusinessProcesses

- SCADA- GIS- CMMS- CIS

Financial Resources:- StrategicPlanning

- Rates/Charges

- CIP

Plan for theFuture:- StrategicBusiness Planning

Manage Business Info:- EnterpriseSystems Integration

- Web Apps

AssetSolutions:- AssetMgmt.

- Infrastructure Security

Env.Mgmnt.

Services

O&M

Watershed Mgmt:Integrated Resource Planning- Storm Water Utility Dev.

Utility Management

Introduction to SCADA

UMS

Inst.

Control

SCADA

SCADA

Supervisory ControlAndDataAcquisition

Introduction to SCADA

UMS

Inst.

Control

SCADA

- IO Cabinets- Programmable Logic Controllers- Distributed Control Units

- Pumps- Valves- Field instruments

- Flow meters- Level Transmitters - Etc.

Introduction to SCADA

UMS

Inst.

Control

SCADA

- Information Management Systems- Historical Databases- Reporting Systems- Web Portals- Dashboards

- Human Machine Interface- Graphical User Interface

Range of SCADA Platforms

Terminal

Workstation

Portables

DesktopPC

SingleServer

ServerCluster

From the very largest to the smallest

Pocket PCSmart PhonePagers

Utility Managers and SCADA

Utility Managers and SCADA

Effective Utility Management

• May 2007: 6 major water and wastewater associations and EPA signed an agreement to support Effective Utility Management

• Result: Primer for Water and Wastewater Utilities:• Ten Attributes of Effectively Managed Water

Sector Utilities

• AWWA

• WEF

• AWCWA

• NAWC

• APWA

• AMWA

Ten Attributes of Effectively Managed Water / Wastewater Sector Utilities

Source: “Effective Utility Management, A Primer for Water and Wastewater Utilities, June 2008

How a SCADA System Fits In

Up to date information

on the quality of

W/WWInformation

to make uniformed decisions

Fine tuning processes

Maximizing energy and chemical usage

Real-time Monitoring

for fast responses

Tie into CMMS

Planningand

long-term Monitoring

How a SCADA System Fits In

AnalyticalEquipment

Results

AssetManagement

Analysis

Reports andFinancial

Statements

UsageInformation

Capital AssetManagement

CMMSComputerizedMaintenance

Management System

ERPEnterpriseResourcePlanning

SCADASupervisoryControl and

Data Acquisition

GISGeographicalInformation

System

Customer ServicesLIMS

Laboratory InformationManagement System

Effective Utility Management

• Pressure to do more with less resources• Aging Facility Automation systems• Increasingly stringent regulatory requirements• Rising labor and components costs• Rapidly changing workforce

• Legacy SCADA systems reaching the end of their shelf life

• Most Utilities try to turn from one urgent priority to another

Utility SCADA Bottom Line

• Need accurate field information in order to plan

• Need methods to access information regarding asset inventory and energy consumption

• Need to be able trust and depend on the field information

Utility Managers and SCADA

RAMS – Reliability, Accessibility, Maintainability, Security (asset, SCADA and network)Connectivity to UMS (Auto. Reporting, CMMS)Systems standardization (Efficient O&M)Process optimization (for cost saving - labor, power and chemicals use) Systems upgrade to comply with growth needs Remote access (via secure connection)

Project Life Cycle Phases

Source: DOJ, 2003

Project Life Cycle Phases

Initiation Concept Develop. Planning Pre-

Design

Design Constr. Integ. and Test

Commiss.

Operations and Maintenance Disposition

Project Life Cycle Phases

Phase Key Deliverables Key Participants

Concept/Planning

Needs assessment, Feasibility studies

UM, Eng. Finance, O&M

Require.Analysis

Master Plan, technical and

financial studies

UM, Eng. Finance, O&M, Consultant

Project Life Cycle Phases

Phase Key Deliverables Key Participants

Pre-Design Concept design, Studies, Cost, Systems selection

Eng, O&M, UM, Consultant Eng.

Design DWG’s, Spec’s, Cost, Schedule

Eng, O&M, UM,Consultant Eng.

Project Life Cycle Phases

Phase Key Deliverables Key Participants

Construction Hardware, Software, Networks, in-house testing

AES (Application Engineering SI), Cont., O&M

Integration Systems install, final testing, Commisstraining

AES (Application Engineering SI), Cont., O&M

Project Life Cycle Phases

Phase Key Deliverables Key Participants

On GoingO&M

Systems operation & maint,upgrades

O&M, Eng. Contract support,

Disposition Retain procedures, Data, Maintain

systems running

UM, Eng., O&M, IT, Contract support

Benefits to Utility

• Increased Operational Efficiency• Lower Operating Costs• Document Regulatory

Compliance• Systems Upgrades and

replacements are planned and financially based on CIP and not O&M expenditure

• Framework for educated decision making process

Questions for the Utility

Are you getting value out from your automation and SCADA investments?

Are your facilities operating at peak efficiency? Are you able to automatically generate

Regulatory and internal reports & trends based on laboratory, control/SCADA system, & operator data?

Do you trust your data collection methods and communication systems?

Do you have a plan for automating the monitoring & control of your operations?

Do you have a SCADA Master Plan in place?

Garland Duck Creek WWTC

Garland Duck Creek WWTC

The Duck Creek Wastewater Treatment Center (WWTC) began operation as a trickling filter/solids contact (TF/SC) plant in 1986, with a permitted capacity of 30 mgd.

The plant was evaluated in 2001-2002 and a need was identified to expand the capacity to provide for future growth and planned diversion of flow from the Rowlett Creek WWTC.

Garland Duck Creek WWTC

The project to expand the plant from a nominal treatment capacity of 20 mgd to a capacity of 40 mgd was initiated in 2002.

The expansion, completed in 2006, provides a new stand-alone activated sludge system that has the capacity to treat 50-percent of the 40 mgd design flow, with the TF/SC system treating the remaining 50-percent.

Garland SCADA System Diagram

Garland – P&ID Detail

Garland Duck Creek WWTC

Since the client was familiar with Control Microsystems controllers, nine new Control Microsystems SCADA Pack 32 controllers were added, seven new SCADA Pack controllers were added, and the existing SCADA Pack controllers were relocated to the filters.

Garland Duck Creek WWTC

Redundant Wonderware servers were added along with three operator workstations. A Historian with reporting capability was added. The system was originally designed to monitor plant operations only. However, we were able to provide remote control as well.

Garland Duck Creek WWTC

Data from packaged control systems was also brought into the HMI to allow remote monitoring for systems such as the diesel engine generators and the aeration blowers.

Garland Duck Creek WWTC

Misc. instruments were added throughout the plant:• 12 Hach LDO probes in the new aeration basins• Flowmeters on sludge piping throughout the facility• Pressure and level devices throughout the plant.

Garland SCADA Maint. support

Next Step:Assisting the Client with Maintenance support to include: Phone Support On site Support Systems’ Yearly Maintenance Support

Example: City of Rio Rancho, NM

Objectives: • Assess the existing

SCADA and Telemetry systems

• Identify SCADA and Communication System needs

• Formulate a practical and cost-effective implementation

Recommendations: • Formulate SCADA system standards: develop

standards for the SCADA system and the PLCs• Relocate central operations to a newer site• Develop Network Master Plan: to improve SCADA

system security & to establish comm. standards

CoRR, NM SCADA Master Plan

• SCADA Master Plan included:• Assess the existing conditions• Define the client’s requirements• Study and compare the applicable

technologies and options • Interview / work with Vendors• Perform pilot tests

• Perform Cost Analysis of various options

• Produce a phased, sequenced road map to deliver final SCADA system

Assess Define

CostStudy

Road Map / Master Plan

CoRR, NM SCADA Master Plan

• Study included:• Communications between treatment plants

and all conveyance points (lift stations etc)• Radio path studies between sites• Methods for data reporting for compliance• Methods for saving and accessing data

across the entire Utility• Methodology for verifying and collecting

field and manually entered data• Accuracy of primary field instruments• Communication protocols between

processors and remote sites• Tie in with CMMS, LIMS and other systems

Summary

Project Life Cycle involves Planning:

“If you don’t know where you are going, every road will lead you nowhere.” Henry Kissinger

Visions of the Future

Summary

Summary

Project Life Cycle Primary Subjects:

Government – Here To Help?

Summary

Project Life Cycle Primary Subjects:

Electrical Costs!

Summary

Project Life Cycle Primary Subjects:

Chemical Costs!

Summary

Project Life Cycle Primary Subjects:

Proprietary System VS, Open System

Summary

Project Life Cycle Primary Subjects:

Upgrade of Obsolete Equipment

Summary

Project Life Cycle Primary Subjects:

Upgrade Your Software and Hardware??

Summary

Project Life Cycle Primary Subjects:

In-House or Out-Source SCADA Support?

Summary

Project Life Cycle Primary Subjects: Data Management

Data Is A Drug!

Data Storage & Recovery

Summary

Your Control Room can look like this or…