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Illinois Section AWWA Presents:Planning For Critical Data Systems –SCADA and Technology Master Planning April 26, 2012
Presented by:
William (Bill) Biehl
Cell: 913.601.0104
bill.biehl@we-inc.com
Presentation Outline
• Presentation Goals
• Master Plan Goals and Objectives
• SCADA Master Planning Drivers
• Master Plan Key Issues
• SCADA Master Planning Methodology
• Summary
2
2
Presentation Goals
�Review the purpose of Master Planning
�Review the Drivers of Technology Master Planning
�Discuss the major components of a SCADA Master
Planning
�Discuss An Approach for SCADA Master Planning
�Understand the benefits of preparing a SCADA Master
Plan
3
Presentation Outline
• Presentation Goals
• Master Plan Goals and Objectives
• SCADA Master Planning Drivers
• Master Plan Key Issues
• SCADA Master Planning Methodology
• Summary
4
3
Utility Master Planning
• Most Utilities develop Master Plans of one sort or
another
• Water Resources Plan
• Treatment Facilities Master Plan
• Collection Systems Master Plan
• BioSolids Master Plan
• Recycle Water Master Plan
• Master Planning looks at the “big picture”
• Developing long-term objectives and solutions
• Planning time frame can be from 5 years to 20 years.
5
Technology Master Planning
Master Planning for
Technology Systems
• Information Technology
Master Plan
• Information Technology
Strategic Plan
• SCADA Master Plan
• Integrated Technology
Plan
6
4
Why Conduct a Technology Master Plan?
Technology Master Planning aligns Technology and
Governance with the business requirements of the Utility.
Business
Strategy
Technology
Strategy
Business
Performance
Technology
Performance
7
Technology Master Planning
8
5
Utility Technology Systems
9
Simplified Overall System
10
6
SCADA vs. PCS
• SCADA System - monitors many remote sites, utilizes
radio or telephone communications systems; typically
uses Industrial Processors: PLC & RTUs
• PCS - monitors in-plant processes utilizing local area
network technology; typically uses “intelligent” PLCs,
RTUs, or DCUs
• Distinctions have blurred as technology evolves. The
term SCADA is now widely used for both in-plant
control systems and remote site monitoring
applications.
11
Components of SCADA / PCS Systems
• Instrumentation / Final Control Elements
• PLC / DCU / RTU
• Communications Systems
• Networks
• Host / Servers
• Client / Workstations
• Historical Data Collection
• Reporting
12
7
Simplified Overall System
13
• Proactive plan to:
• Define the current state
• Establish strategic vision for
automation maturity
• Prioritize requirements and
determine project
interdependencies
• Plan for the required scope,
budget, time, and resources
What is a Technology Master Plan?
14
8
Presentation Outline
• Presentation Goals
• Master Plan Goals and Objectives
• SCADA Master Planning Drivers
• Master Plan Key Issues
• SCADA Master Planning Methodology
• Summary
15
SCADA Master Planning Drivers
Most water agencies would be hard-pressed to maintain service levels if their SCADA system suffered a catastrophic (or even partial) failure.
• Operating Knowledge Retained in Control Strategies
• Improved Operating Efficiency
• Regulatory Compliance
• Operating Data for Planning
• Protection of People, Environment and Equipment
SCADA is Mission Critical!
16
9
Role of SCADA in Utility Operations
Critical Need Role of SCADA/Control
Meet Regulatory
Compliance
• Monitor and report regulatory compliance
• Control process within regulatory constraints
Protect Public Health
and Safety
• Early detection and warning of process upsets
• Prevent processes and equipment from
reaching dangerous levels of operation
Maintain Service
Levels
• Operational flexibility and tight control
• Staffing levels and experience
Operate Efficiently • Unattended operations
• Process optimization
Capture and Retain
Knowledge
• Historian maintains operational history
• Operational experience captured in control
strategies and narratives
Plan Capital
Improvements
• Equipment condition and performance data
• Data to calibrate the hydraulic model
17
Planning Approach Should Ensure a Total Solution
18
10
Process
• Difficulty in defining, prioritizing and justifying SCADA projects
• Lack of change management, revision control and back-up procedures
• SCADA Standards do not exist or not enforced
• New regulatory regulations or business requirements
• High costs for maintenance and support
• Inaccurate or missing documentation
• Significant expansion
• Difficulty in sharing SCADA data with other business applications
Common Drivers for SCADA Master Planning
19
People
• Pending retirement of experienced operating or maintenance staff
• Attracting new staff and assimilating cultural changes
• Need for additional training
• Staffing reductions
Technology
• System reliability issues
• Missing or inaccurate historical data
• Obsolete equipment; spare parts hard to get
• Software vendor no longer supports product
• System doesn’t support regulatory and operational reporting
• Accessing meaningful historical data requires a SCADA specialist
• Frequent nuisance alarms
• Minor system/component upgrades cause failures in other components
• Inadequate bandwidth/throughput
• Need for expanded remote access
• Concerns about cyber security
Common Drivers for SCADA Master Planning
20
What are your
challenges?
11
Aligns Technology with Business Need
A proactive plan aligns SCADA technology and
governance with the business requirements of the Utility.
Business
Strategy
Technology
Strategy
Business
Performance
Technology
Performance
21
Bringing Order to Chaos
A logically sequenced, SCADA program meets business
needs within the resource constraints of the Utility.
22
12
Build Stakeholder Consensus
23
Presentation Outline
• Presentation Goals
• Master Plan Goals and Objectives
• SCADA Master Planning Drivers
• Master Plan Key Issues
• SCADA Master Planning Methodology
• Summary
24
13
What is the Utility’s Vision for SCADA?
25
Automation Maturity Model ™
Technology Areas to Support the Vision
• Overall System Design
• Supervisory and Field Control
• Instrumentation
• Local Area Networks
• Remote Site Communications
• Alarm Management
• Data Management Reporting
• SCADA Security
• SCADA Governance
26
14
Presentation Outline
• Presentation Goals
• Master Plan Goals and Objectives
• SCADA Master Planning Drivers
• Master Plan Key Issues
• SCADA Master Planning Methodology
• Summary
27
Methodology
28
15
SCADA Planning Methodology
Project Initiation1
Current State2
Requirements3
System Assessment4
Alternative Analysis5 SCADA Master Plan6
29
Key Activities Deliverables
• Kickoff Meeting • Project Charter
• Establish Core Planning Team • Project Plan
• Establish Executive Steering Committee • Project Website
• Review Project Plan & Schedule • Document Templates
• Review Project Deliverables
SCADA Planning Methodology
Project Initiation1
Current State2
Requirements3
System Assessment4
Alternative Analysis5 SCADA Master Plan6
30
16
Project Initiation – Collaborative Approach
31
Project Initiation - Project Core Team
� Core Team:
� Small Group (5 to 6)
� Represents interest of Utility staff
� Integral to Utility/Consultant project team
� Attends all Meetings
� Internal Advocates for Utility
� Executive Steering Committee:
� Utility Management (Vice Presidents / Directors / Assistant Directors)
� Provide Oversight and Direction to Master Planning Process
� Ensure Overall Goals of Plan are aligned with Strategic Business Plan
of Organization
� Committee Briefed at Key milestones
� Actively involved in Development of Strategic Vision
32
17
Project Initiation – Develop Project Charter
33
�Purpose: An overarching document guiding the overall
project.
�Focus on both the goals for the Interceptor SCADA
system and the Preliminary Design Project.
• GROUP ACTIVITY – (10-15 Minutes)
• Review and Discuss A Sample Project Charter
Key Activities Deliverables
• Review Existing Documentation • Current State Tech Memo
• Field Survey of Representative Sites • “As-Is” SCADA Block Diagram
• Staff Interviews • Facility/Process Summary Table
• Current State TM Review Workshop • Prevalent Standards and Exceptions
• Technology and Governance
SCADA Planning Methodology
Project Initiation1
Current State2
Requirements3
System Assessment4
Alternative Analysis5 SCADA Master Plan6
34
18
Current State – Staff Interviews
35
� Important for Operator and Maintenance Buy-In to the
program
� It is valuable to get the input of these key individuals in
a more personal environment outside influence from
Manager and Peers.
• GROUP ACTIVITY – (10-15 Minutes)
• Review A Sample Staff Interview / Group Workshop Questionnaire
SCADA Planning Methodology
Project Initiation1
Current State2
Requirements3
System Assessment4
Alternative Analysis5 SCADA Master Plan6
Key Activities Deliverables
• Stakeholder Workshops • SCADA Requirements Tech Memo
• Visioning Workshop •Executive Summary
• Requirements Validation Workshop • Utility Vision for SCADA
• Business Requirements
• Technical Requirements
• Governance Requirements
36
19
Requirements:Steering Committee - Strategic SCADA Vision
37
Any Town Steering Committee SCADA Strategic Vision:
The SCADA systems will provide a reliable means of monitoring and control
for the safe production of quality water and gas services for our customers.
SCADA systems will also utilize technology for the enhancement of job
satisfaction, improvement of utility operational efficiency and optimization
initiatives, reduction in system operating and maintenance costs, and the
reduction or mitigation of potential risks to the utility and public.
The ongoing SCADA enhancement process will include responsible
investment in planned capital SCADA projects that account and utilize existing
SCADA system capital and operational practices where appropriate.
System Control SCADA SystemWhere Do We Want to Be?
38
Any TownAny Town
20
Key Activities Deliverables
• Assessment Review Workshop • System Assessment Tech Memo
• Presentation to Steering Committee • Executive Summary
• Existing System Overview
• Best Practices Benchmark
• Initial Recommendations
SCADA Planning Methodology
Project Initiation1
Current State2
Requirements3
System Assessment4
Alternative Analysis5 SCADA Master Plan6
39
Technology Areas to Support the Vision
• Overall System Design
• Supervisory and Field Control
• Instrumentation
• Local Area Networks
• Remote Site Communications
• Alarm Management
• Data Management Reporting
• SCADA Security
• SCADA Governance
40
21
Technology Areas to Support the Vision
• Overall System Design
• Supervisory and Field Control
• Instrumentation
• Local Area Networks
• Remote Site Communications
• Alarm Management
• Data Management Reporting
• SCADA Security
• SCADA Governance
41
Best Practice: ODMS
• Independent Data Warehouse for Plant and SCADA
Information
• Independent of Plant / SCADA Operation Historian
• SQL compliant Database
• Data Rollup capabilities
• Data Validation
• Ad-hoc reporting / analysis capability
• Reports and KPIs available on web-based system
Examples of Best Practices For Assessment
42
Best Practice: Historical Systems
• Dedicated Operational Historian for each Plant
• Server class hardware with RAID 5 or better
• Independent data collection (buffer data on failure of
Historical server)
• SQL compliant and/or OPC-DA Database
• Variable data collection rates
• Data Rollup capabilities
• Data Validation
• Ad-hoc reporting / analysis capability
Best Practice:
• Standardized, Fully Supported HW and SW Platforms
• Integrated SCADA System to monitor entire system
• Redundant, Meshed Communication Paths between
Control Facilities and to Critical Remote Facilities
• Redundancy at SCADA Server Level, with distributed
Front End Processing
• SCADA Network Separation from Business Network
• Thin-client HMIs available for wide use of SCADA
Information
• RTU Process Control with remote setpoints
Best Practice:
• Up to Date Record Drawings
• Accurate SCADA and Network Block Diagrams
• Up to Date SCADA System O&M Manuals
• Documentation Standards enforced
• SCADA O&M Manuals, including Documented Control
Strategies are complete
• Electronic storage, centralized server or web-based
repository
• Change Management Procedures in place
22
• System architecture that achieves
availability and performance
objectives
• Industry leading products improve
support, product availability,
ease of integration
• Mainstream technologies reduce
cost and avoid obsolescence
• Modular, open architecture
enables the replacement of
components with minimal impact
• Standardization enhances
maintainability & cost of delivery
Overall System Design
Solidifies Automatic
Control
43
Overall System Design
44
23
SCADA System BenchmarksOverall SCADA System Architecture
Least Desirable Most Desirable
AutoDialer
Alarm Only
HMI with
“Dumb”
RTUs, no
control
capability
HMI with
Proprietary
RTUs and
Protocols.
Local-
Automatic
Controls
Multiple
Monitoring
Systems
with
overlapping
capabilities.
Local
Automatic
Control Only
Integrated HMI
(Single System)
supporting
multiple RTUS
and Protocols.
Remote
Supervisory
Control
Proprietary
HMI with
Proprietary
RTUs and
Protocols
Limited
Local
Control
Any TownAny Town
45
• Data Capture• Quality Data – timely and
accurate
• Buffering at RTU/PLC
• Data Accessibility• User-friendly Tools
• Scheduled and Ad-hoc Reporting
• Dashboards/KPIs
• Data Management• Secure, Back-up, and
Recovery
• Enterprise Integration• CMMS, CIS, GIS, LIMS
Data Management & Reporting
46
Any Town, USA – Dewatering Statistics
24
Data Management & Reporting
47
Data Management & Reporting
48
Any Town, USA – Dewatering Statistics
25
49
Least Desirable Most Desirable
No Historical
Databases
Multiple Plant
Historian Databases
(Separate databases)
Limited Data
Exchange
between
Applications
Dedicated
ODMS, based on
Open Database
(Oracle, etc.).
Web tools for
data analysis
and reporting.
Any TownAny Town
SCADA System BenchmarksOperational Data Management System
Data Mining, Visualization and Analysis
Enterprise Integration
CMMS GIS LIMS FIS WQSHydraulic
Model
Unified Operations Data Model
Consequence
Value
Criticality
Operations Data Management & Reporting
PLCs:
Raw Water, Filtration, Disinfection
Reads and
Rounds – manual data entry
Instrumentation Power
Monitoring
$
ODMS Governance and Management
50
26
SCADA Governance
� SCADA Support
� Staffing
� Training
� External Resources
� Software and Hardware Design and
Development Methodology
� SCADA Standards
� Change Management
� Preventative Maintenance
� Planned Growth versus Organic
Migration
� Security
� Disaster Recovery / Business
Continuity
51
Requirement – Assessed against SCADA System Industry Best Practices
• Overall System Architecture
• Communications Architecture (In-Plant)
• Wide Area Networking
• Communications Architecture (Remotes)
• HMI Hardware Configuration
• In-Plant Control Philosophy
• In-Plant Control Architecture
• Re-Pump Station Control Philosophy
• Re-Pump Station Control Architecture
• RTU Architecture – Other Remote Sites
• RTU and PLC Programming
• Field Instrumentation
• Physical Security (SCADA Components)
• Alarm Subsystem
• SCADA Historical System
• Operational Data Management
• Data Integration
• System Optimization
• System Documentation
• SCADA System Standards
• SCADA Cyber Security
• Disaster Recovery / Business
Continuity
• Service and System Maintenance
52
27
SCADA Planning Methodology
Project Initiation1
Current State2
Requirements3
System Assessment4
Alternative Analysis5 SCADA Master Plan6
Key Activities Deliverables
• Prioritize Requirements • Alternatives Tech Memo
• Alternatives Review Workshops • Executive Summary
• Vendor Presentations • High Priority Requirements
•Alternatives Validation Workshop • Alternatives Analysis
• Functional Requirements
• Evaluation Process
• Recommended Alternatives
53
Alternative Analysis: Alignment of Projects to Project Charter
54
�Review List of Projects Resulting from Analysis
�Align the projects with the Project Charter & Vision
�Rank the Project from Most Important to Least
Important
�Determine Which Projects Can Executed in Multiple
Manners and Make Quantitative Decision on Direction
of the Projects
28
Any Town, USA
SCADA Master Plan Development Project
Project Charter
� Standardization
� End-Of-Life Equipment Upgrade
� Security Management
� Technology Improvements
� Integration of SCADA Assets
� Continuity of Operations
� Enhancing Reliability
� Operations:
� Coordination
Develop a Master Plan which will start with an audit of existing SCADA
system and operations, and work through the development of the Master
Plan to address the following key items:
55
Any Town, USA
SCADA Master Plan Development Project
Project Charter
• Build consensus among stakeholders for system requirements
• Be completed in a timely manner to support Utility budgetary
planning efforts.
• Align SCADA technology and governance with the business
requirements of the Utility.
• Outline Short-term and Long-Term Projects with scope
statements, budget estimates, and CIP scheduling
The SCADA Master Plan will:
56
29
Final plan is a fully defined SCADA program
57
Outcome:
Prepare a 5 year program to move
the Utility from current state to the
desired state following best practices
and supporting the Utility’s Business
Requirements
Any Town, USA
SCADA Master Plan Development Project
Project Charter – Core Team Project Priorities Rating
� Standardization
� (2) End-Of-Life Equipment Upgrade
� (3) Security Management
� Technology Improvements
� Integration of SCADA Assets
� Continuity of Operations
� (4) Enhancing Reliability
� (1) Operations
� Coordination
Develop a Master Plan which will start with an audit of existing SCADA
system and operations, and work through the development of the Master
Plan to address the following key items:
58
30
Core Team Rating of Project Priorities
Ranked Priority – (1) Operations (Section 5.2)
Project Charter Key Item: Operations
Operations: Assessment of staffing, operation, support, and third parties contracts related to meeting the District’s business requirements.
System Assessment Initiatives - Project Title
Priority Tasks:
� Find and Hire a SCADA Engineer to drive the project
� Assess the need for a new position “SCADA Technician”
59
Core Team Rating of Project Priorities
Ranked Priority – (2) End-of-Life Equipment Upgrade (Section 5.3)
Project Charter Key Item: End-Of-Life Equipment Upgrade
End-Of-Life Equipment Upgrade - review which elements of the current SCADA systems have reached their expected end-of-life and replacements are no longer available.
System Assessment Initiatives - Project Title
Priority Tasks:
� Christmas WTP SCADA system upgrade required to ensure continuous operations and availability of
spare parts that are not readily available for the existing system.
� Christmas WTP well field communications need to be enhanced to insure remote operation of
equipment is available and reliable.
� Easter Plant communication cables to equipment s monitoring panels should be upgraded from Coax
cable to fiber optic cable to support reliability and enhanced capability.
� Easter Plant upgrade the SCADA system to take advantage of optimization of CIP improvements
project, and insure the system is reliable and available. Some system components are at the end-of-
useful life and require upgrade and replacement.
60
31
Core Team Rating of Project Priorities
Ranked Priority – (3) Security Management (Section 5.4)
Project Charter Key Item: Security Management
Security Management – improve existing SCADA systems’ security and comply with regulatory requirements. This will address aspects of SCADA security such as: system physical/logical isolation, firewalls, anti-virus software, passwords, patch updates, management processes, etc.
System Assessment Initiatives - Project Title
Priority Tasks:
� Implementation SCADA System computer virus protection, operating system patching, and general IT
management assistance that will require improvements to the SCADA Network Segmentation on a
Facility by Facility Basis. Each facility will require implementation of:
� Coordinated IP address scheme
� A test and programming SCADA server at each facility
� Implementation of security zones for safe data transfer into and out of the SCADA networks
61
Core Team Rating of Project Priorities
Ranked Priority – (4) Enhancing Reliability (Section 5.5)
Project Charter Key Item: Enhancing Reliability
Enhancing Reliability – review system architecture for redundancy and reliability. Items under this would include communications, primary/standby I/O servers, development nodes, etc.
System Assessment Initiatives - Project Title
Priority Tasks:
� Allow backup control center for Remote Monitoring and Control during Emergency
� Improve Historical Data Collection equipment, policies and methods to support operational
requirements.
� Improve System Redundancy at SCADA systems (servers & historians)
� Provide tools to improve start-up of Gas Production Plants
� Easter Plant Network Monitoring Software with Failure Notification & Network IP Addressing
improvements
� Improvements for Pumping Stations to enhance operations through automation and
environment monitoring (building temperature and fire detection monitoring)
62
32
Core Team Rating of Project Priorities
Short Term Projects (Section 5.1)
Short Term Projects
Short Term Projects – The Short-term initiatives consist of those projects which should be undertaken in the next six months to one year. These issues are typically relatively straightforward to correct and normally require a limited budget
System Assessment Initiatives - Project Title
Priority Tasks:
� Initial SCADA System Standards required for Christmas WTP Upgrade to avoid additional organic
growth of SCADA system without definition by MUD
� Definition of how Utility will implement Historical Operational Data for report and alignment with
business systems. This project defines what type of database and DB tools are required.
63
SCADA Planning Methodology
Project Initiation1
Current State2
Requirements3
System Assessment4
Alternative Analysis5 SCADA Master Plan6
Key Activities Deliverables
• Review of Recommended Projects • SCADA Master Plan
• Master Plan Review Workshops • Executive Summary
• Presentation to Steering Committee • Current State Summary
• Requirements Summary
• Recommended Alternatives
• Program Plan
• Scope Definition
• Cost Estimate
• Schedule & Dependencies
64
33
Examples – Any Town, USA
65
Examples – Any Town, USA
66
34
Examples – Any Town, USA
67
Presentation Outline
• Presentation Goals
• Master Plan Goals and Objectives
• SCADA Master Planning Drivers
• Master Plan Key Issues
• SCADA Master Planning Methodology
• Summary
68
35
Summary – SCADA Master Planning
�Due to the criticality of SCADA to Utility operations, every
Utility should have a formal SCADA Master Plan
�Master Plans should be reviewed and updated on an
annual basis.
�Major updates or revisions should be performed
approximately every five years.
69
Summary – SCADA Master Planning
70
� Stakeholder Input – Plant staff provide input
� Core Team to facilitate and Provide ongoing input to planning
� Executive Steering Committee provided vision and commitment to planning
� Results Should Align with Project Requirements & Project Charter:
� Program addressing highest priority projects to mitigate Utility risks� Each planned project includes a statement on Project Goal, Project Need,
and Project Tasks and Deliverables.
� Projects scheduled to balance annual capital improvement costs over
the plan duration.
� Create Standards / Governance to facilitate efficient maintenance and
operation across systems
36
Lifecycle Management of SCADA
People and
Practices required
to manage and
maintain the
SCADA system in
an “evergreen” state
over its entire
lifecycle
71
Illinois Section AWWA Presents:Planning For Critical Data Systems –SCADA and Technology Master Planning April 26, 2012
Presented by:
William (Bill) Biehl
Cell: 913.601.0104
bill.biehl@we-inc.com
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