scada system upgrade of a major water system · emps scada area 2 chemical room switch cmplx cmplx...

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Rockwell Automation

Process Solutions User Group (PSUG)

November 14-15, 2011

Chicago, IL – McCormick Place West

SCADA System

Upgrade of a Major

Water System

John Walker, Regional Water Supply

Mark Robertson, Insyght Systems Inc.

Abstract

• A complete SCADA retrofit of two large Water Plants,

plus over 70 remote facilities supplying drinking water to

the City of London and 20 surrounding municipalities-

approximately 400,000 people

• The area includes over 4,500 square km from Grand

Bend, on Lake Huron to Port Stanley, on Lake Erie.

Abstract

• The new SCADA system includes controller and

distributed I/O, operator interfaces, historical data

collection, automated reporting, and document

management systems

• Project requirements will be compared to actual

implementation, with lessons learned.

Presentation Outline

• Who are we? (John and Mark)

• Project Drivers

• Project Goals and Targeted Benefits

• Implementation Strategy

• Final Construction Solution

• Significant Improvements Gained

• Lessons Learned

Presenters

• John Walker

– Operations Manager

– Regional Water Supply

– SCADA Project Manager

• On project from beginning to

• Mark Robertson

– President

– Insyght Systems Inc.

– Sr. Project Manager

• On project from beginning to

Lake Huron Primary Water Supply

Elgin Area Primary Water Supply

Project Drivers

• Existing SCADA servers, software, and PLC’s were at

the end of their asset life

• No longer able to get spare parts

• Unreliable wide area communication

• Increased demands by regulators for better operation

Project Goals and Targeted Benefits

• Up to date, reliable SCADA system

• Significantly better documentation of the SCADA system

• Implementation using SCADA standards

• Optimized water treatment plant automation strategies

• Much greater access to historical SCADA information

Implementation Strategy

• SCADA Construction

Contract– $9 million contract

– Includes 8 municipalities

– Replacement of controllers and SCADA servers for 5 regional centrals

– 2 large, 1 small water plant

– 2 wastewater plants

– 60 remote water and wastewater stations across 1,500 square miles (30x50 miles)

• SCADA WAN Contract– One tender

– Third party WAN Provider

– Over 100 WAN links

– Five Contracts by SCADA Network

– Performance Based contract

Lake Huron Water Treatment Plant

Lake Huron Primary Water Supply SCADA System

• Water Plant– Redundant SCADA Servers

– 13 Operator View Clients

– FactoryTalk Data Collection and Reporting Server

– SDMS Server

– Redundant ControlLogix

– 20 Remote FLEX I/O systems using ControlNet Coax and Fiber

– DeviceNet to power monitors

– Wireless SCADA Client network everywhere

• Remote Sites– CompactLogix at 10 valve chambers, reservoirs, and water booster stations

Control Ethernet

Corporate Ethernet

(User Supplied)Domain Controller•W2K3 Server O/S

•DNS Server

•DHCP Server

•Pent 4 2+GHz, 512M Ram

Firewall

Elgin Area

OperationsWAN

Control Ethernet

SCADA Server #1• (1) FT Directory Server• (1) HMI Server • (1) Data Server

RSLinx Enterprise• W2K3 SP1 Server O/S• Dual Xeon 2+GHz, 2G

SCADA Server #2• (1) HMI Server • (1) Data Server

RSLinx Enterprise• W2K3 SP1 Server O/S• Dual Xeon 2+GHz, 2G

Area 1

RedundantPair

2 Clients

Access Points

SCADA Workstation

•FTView SE Client

•WinXP Pro

•Pent. 2+GHz, 256M Ram

SCADA Historian Server• SQL 2000• FT Transaction Manager• FT VantagePoint Server• W2K3 SP1 Server O/S• Dual Xeon 2+GHz, 2G

Ram, RAID 5

CNet 2

Flex Flex Flex

Switch5 Clients

Control Room

Lab Room

Portables

CLXCLX

Redundant

Control

Ethernet

CLXCLX

Redundant

Fiber Optic Ethernet

Switch

CNet 3

SCADA Server• (1) HMI Server• (1) HMI Client• (1) Data Server

RSLinx Enterprise• W2K3 SP1 Server O/S• Dual Xeon 2+GHz, 1G Ram

CNet 1

Flex Flex Flex Flex

Modbus

Flex Flex Flex

CNet 1

3rd Party 3rd Party

Low Lift Pump Station

HMI System Parameters

Control System

•600 Digital I/O Points

•250 Analog I/O Points

Main HMI Server

• Unlimited Display Count including Pop Up

• 5000 Tags Total

• 1000 Historical Tags

• 1 single project with 2 areas

Low Lift Pump Station

• FTView SE Client to use Main HMI Server

with ability to switch to Standalone as

backup to loss connection to Main

Historical Data Backup Requirements

•SQL is to backup to a second SQL

package off site through the Operations

WAN on a daily basis

Typical Plant Architecture

Distance 1 km

Switch

1MB Wireless EtherNet

2-3 sec poll rate

Switch

1MB Ethernet

SCADA Terminal Server& EDMS Server • Windows Terminal

Server• (8) CAL Licenses• FT AssetCentre• RSLinx Classic Lite• Unlicensed RSLogix 500

and 5000• (8) HMI Clients• W2K3 SP1 Server O/S• Dual Xeon 2+GHz, 2G

Ram, RAID 5

SCADA Workstation / Eng Stn

•FTView SE Studio

•RSLogix 500/5000

•FT AssetCentre Client

•WinXP Pro

•Pent. 2+GHz, 512M Ram

EMPS SCADA

Area 2

Chemical Room

Switch

CMPLX CMPLX CMPLX

Elgin Area Primary Water Supply SCADA System

• Water Plant– Redundant SCADA Servers

– FactoryTalk Data Collection and Reporting Server

– SDMS Server

– Redundant ControlLogix

– 12 Remote FLEX I/O systems using ControlNet Coax and Fiber

– Modbus to Particle Counters

– Wireless SCADA Client network everywhere

• Remote Sites– Low Lift

• ControlLogix

• Back up SCADA Server

– Elgin Middlesex Pump Station

• ControlLogix

• Back up SCADA Server

– CompactLogix at 3 valve chambers and surge tank

Municipality of Central Elgin SCADA System

• SCADA Central– Redundant SCADA Servers

– FactoryTalk Historian Server

– SDMS Server

– Automated Paging System

– Remote Internet Access through corporate network to SCADA screens

• 20 Remote Facilities – MicroLogix1100 at 10 wastewater pumping stations

– MicroLogix1100 at 12 water valve chambers and towers

– Upgraded SLC500 at small water plant

– Upgraded SLC500 at small wastewater plant

City of St. Thomas SCADA System

– SDMS Server

– Upgraded SLC500 at small water plant

– Upgraded SLC500 at small wastewater plant

APAM SCADA System

– SDMS Server

Typical SCADA System Design

Contract Operator and Regional Water Supply VPNs (Ethernet)

Front End Communication

Controllers (FECs)

Real Time Control (RTC) (Ethernet)

(Real time control and data collection)

Remote I/O Networks

(real time control and data collection)

Servers

(desktop applications, email)

5Instrument Network (Ethernet)

(uninterruptible power supplies,energy management data, etc.)

4Instrument Network (Fieldbus)

(smart instruments, etc.)

Wireless SCADA (Ethernet)

(SCADA HMI data via wireless routers)6

Plant Operations/Security/Internet Access for WaterTrax (Ethernet)

P(desktop applications, email)

Neutral Zone (Ethernet)

N(desktop applications, email)

SCADA (Ethernet)

(SCADA HMI data)1

Workstations

Historical Data

Web Server Firewall(s) Internet Link

Firewall

Local SCADA

Historical Data

SCADA Test Bench

S(external users)

Significant Improvements- SCADA Technology

• Hot standby SCADA Servers that actually work!

• Hot standby dual ControlLogix provide full redundancy

for plant control

• Very reliable plant SCADA system

• Reliable wide area network links using Ethernet

• Backup local data storage at remote sites for regulatory

reporting

• SCADA Document Management Systems (SDMS)

System Diagnostics

Significant Improvements- Operations

• Vastly improved chemical dosing control

• Improved filtration and backwash control features

• Better plant flow control

• Real time CT calculations for compliance reporting

• Much better alarm management

• Remote paging of alarms

• Remote access to SCADA system from anywhere, via

Internet

Operational Improvements in Filtration

Operational Flexibility Improvements

Significant Improvements- Data Management

• Automated off site historical data backups

• SQL database provides much improved data queries

and reporting

• Local data storage at remote sites prevents data loss-

which greatly helps with compliance reporting

• Access to historical data from RWS headquarters as

well as at the plants

Instant Water Quality Information

Information on Operator Workstations

Reports on Management Web Server

Lessons Learned- WAN

• Detailed scope of work

– Ensure uptime requirements are met without conditions

• Service provider should be experience in

municipal/industrial applications – not just residential!

• Contract should have an ‘out clause’ or have a 1 + 4

year frame.

• Beware of Latency!

Lessons Learned- Technology

• Don’t make assumptions

– Alarm/event viewer

• Operations input during design and implementation

process is critical and was missing because of Contract

Operations relationship

• Ensure scope of work is highly detailed

– Time stamp issues – all process logs should be started at the same time!

– Time interval issues – e.g. 5 minutes on the minute!

– Engineering units – ensure they are the same and all present!

Lessons Learned- Contract Management

• Be aware that scope changes = schedule increase

• Money = time to complete

• Need better leverage to keep Contractors on schedule

• Leading edge vs. bleeding edge

Questions

John Walker, Regional Water Supply

Mark Robertson, Insyght Systems Inc.

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