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Effluent/Overland Flow (OS50) – PLC50

Maintenance Building (OS60) – PLC60

Chemical CL2/SO2 (OS80) – PLC80

The PLC-5s were programmed using ladder logic format.

DeviceNet is used to communicate between the existing PLC and motor starters. Allen-Bradley Fiber Optic DataHighway+ is used to communicate between the existing PLCs. Fiber optic cable is used to transmit data between PLC cabinets.

PLC21/22 has been modified to operate in a “cold standby” mode. The second processor has been loaded with the same PLC program but is stored, unplugged, outside the PLC rack. If the PLC faults, the PLC technician can replace the faulted processor with the backup processor.

PLC60 communicates via an Omni antenna to PLC40, Wetlands Recirculation RTU, Wetlands Effluent RTU and Channel A RTU.

The following describes the Fiber Optic Cable communication between the PLCs:

PLC FIBER OPTIC CARD - CABLE ROUTING

PLC Channel Method To/From (PLC)

Location

20 A

Tx 80 Ch A- Rx Rx 50 Ch A - Tx

B Tx 50 Ch B- Rx Rx 80 Ch B - Tx

50 A

Tx 20 Ch A- Rx Rx 60 Ch A - Tx

B Tx 60 Ch B- Rx Rx 20 Ch B - Tx

60 A

Tx 50 Ch A- Rx Rx 80 Ch A - Tx

B Tx 80 Ch B- Rx Rx 50 Ch B - Tx

80 A

Tx 60 Ch A- Rx Rx 20 Ch A - Tx

B Tx 20 Ch B- Rx Rx 60 Ch B - Tx

Fiber Optic Patch Panels are located in the Operations Building - Electrical (Communications) Room. The room, historically labeled “Electrical,” primarily houses SCADA hardware and the patch panel. The main electrical service to the building is via an MCC located elsewhere.

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SCADA SYSTEM ARCHITECTURE

The existing SCADA system was developed using GE (Intellution) iFIX SCADA software with SCADAlarm autodialer software. The autodialer software has been replaced with SCADAPhone by the City. PC Operator Interface Stations (OIS) are installed at the following locations:

Plant Operator Central 1 Computer Station (OS-1) – Reporting Software

Operations Building Basement (OS-20)

Maintenance Building (OS-60-M) – Maintenance Office

Electrical Office (OS-60-E) – Development

Ops Trailer – (OS-T) – Reporting Software

Laptop – Remote Access

All of the OIS are connected on the SCADA Network.

SECURITY

It is imperative that the Plant SCADA network be firewalled or a DMZ be installed from off-site SCADA connections. Failure to install security measures to protect the SCADA network from off-site sources leaves it vulnerable to hostile attacks.

City staff report that no additional video monitoring will be required at the plant.

INTEGRATION OF NEW AND EXISTING FACILITIES

It has been determined that existing PLC hardware is approaching the end of its useful life. Increased maintenance and reduced spare parts availability will present increasing difficulties and costs as the system continues to age. Furthermore, integrating the necessary extensive new control systems into the existing system with its outdated and aging hardware would result in high costs and high risk of failure and serious plant operation disruptions.

In accordance with standard industry practice, it is recommended that the City standardize on a single control system architecture. However, the need to replace existing PLCs presents an opportunity to select a platform different than the existing platform. The existing Allen-Bradley platform has performed well, is well respected and is widely used in wastewater (and many other industrial) applications. A second manufacturer, Modicon, is similarly viewed and considered to be an equivalent alternative to the Allen-Bradley based system.

Regarding the SCADA software and servers, the existing system functions adequately but would require extensive modification to incorporate the new facilities. The number of “input/output” points being processed by the SCADA software program will likely triple or quadruple when the new facilities are added. During construction of the new facilities, the existing treatment plant shall remain fully functional and automated to ensure continuous permit compliance without exceeding the available level of staffing. To that end, it is recommended that new facilities be controlled by a

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separate new SCADA system during construction, and that the existing facilities be transferred to the new system at an appropriate time selected to minimize the potential for disruption of existing operations. The new SCADA system shall be developed in software commonly used in publically owned treatment works, and that has a broad base of reliable, experienced programming support in the local (northern California) area. The City will identify two acceptable options for SCADA software.

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PROJECT CRITERIA

MINIMUM REQUIREMENTS

All PACs will be supplied by a single manufacturer; either the Allen-Bradley ControlLogix or Modicon Quantum platform is allowed.

One of two SCADA software packages (yet to be determined) will be used to develop the new SCADA system.

PERFORMANCE CRITERIA

The new SCADA system shall be developed by the design-build team to run in parallel to the existing SCADA system plant.

The Plant should be fully automated with minimal action required by the Operator.

DESIGN CRITERIA

Communication between the new processors shall be by Fiber Optic Ethernet. This shall be brought back to the Operations Building and tied into the existing PLC Ethernet network.

All equipment shall be UL listed – UL listed equipment will ensure a baseline quality in manufacturing.

No non-NEMA equipment will be permitted to be installed on this project – NEMA rated equipment is understood to have stricter specifications than IEC (European) rated equipment. This is also the City’s standard.

MCC cubicles will be provided with Run Light (Green) and Fail Light (Amber) – The City has decided that these are the only pilot devices they want on the MCC cubicle.

Programming of PACs provided by the DB team will be under the DB contract utilizing Ladder Diagram format.

The instrument tag numbering system will also be used similar to the 1997 design. The City Staff is familiar with the system and the tagnames with numbers are used throughout the SCADA system. The letter prefix will follow standard ISA instrument identification lettering (e.g. LIT – Level Indicating Transmitter). The instrument number will be 5 digit and consist of a three digit number assigned to the process area and the last two digits representing a predefined group. The last two digits vary, but will remain consistent in that process area (e.g. Digester 1 area 10s circulation pumps, 20s mixers, 30s transfer pumps, 40s heat exchangers, etc).

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DEMONSTRATION REQUIREMENTS

DB team is responsible for programming the new PACs that will replace the existing PLC-5s while keeping the plant operational and in compliance with all permit requirements. DB team shall describe their transition plan for this task.

REFERENCE PROJECT

The following sections describe the Reference Project.

PAC/PLC SYSTEM

The new process control system (Programmable Automation Controller/ Programmable Logic Controller – PAC/PLC) utilizes the Allen-Bradley ControlLogix platform.

PAC/PLC processors are reliable units with a low rate of failure. Hot standby processors are not necessary and City staff has removed its existing hot standby system. A spare PAC processor is provided to the City, with copies of the PAC program in the event of a processor failure.

Processors are installed at major process areas. Processors that are provided as part of packaged systems (Filters, Belt Press, etc) utilize the same Ethernet processors and I/O cards provided as part of the Reference Project. This minimizes the need for the City to have several different types of I/O cards as spare.

The existing PLC-5 system is also replaced to match the Allen-Bradley ControlLogix platforms provided. The new PACs retain the same functionality as the existing PLC-5 system, including programming and monitoring the existing MCC motor electronic overload status alarms and amperages. An extended warranty is provided for the SCADA system and PAC programming.

The PACs access all of the available registers in the new motor starters. The information displayed or logged is coordinated with the City. All power monitor information from each MCC is available via SCADA.

SCADA SYSTEM ARCHITECTURE

The alarms on the autodialer for operator action that do not need callout are coordinated with the City.

New OIS are provided in the Control Panels where new PAC/PLCs are provided.

Data transfer between PACs is independent of the SCADA system.

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INSTRUMENTATION

The existing instruments are acceptable, and will not be replaced. In the interest of the Reference Project, the same type of instrument is supplied across the entire improvements project. Components supplied by the contractor are the same for each specific type of instrument (i.e., Siemens MagFlow for all magnetic flowmeters, and another manufacturer would be acceptable for ultrasonic flowmeters).

HART programming is provided for all new instruments whenever possible.

New instruments, installed in the field, have a descriptive nameplate in addition to instrument tagname next to instrument. (e.g. Aeration Basin 1, Zone 4, Dissolve Oxygen AIT-31481). This facilitates Operator familiarity with the official instrument name and location.

Disconnect switches are installed next to all motorized equipment to meet Code, where line of site to the MCC is not possible. Position Status feedback of the disconnect status is not necessary.

All equipment started by the PLCs is provided with remote SCADA Control. SCADA Manual will allow the Operator to start / stop the equipment regardless of equipment call requirements or start sequence. SCADA Auto is the normal operation for PLC control.

Control Panels provided by a packaged equipment supplier have indicating lights that follow the City’s standard. Indicating lights and switches are mounted on the exterior of the control panels to allow the Operator to view status from a distance.

Instruments with displays or other digital display units are mounted inside a NEMA 4X enclosure to protect it from the damaging effects of the sun.

Process and Instrumentation Diagram (P&ID) drawings are prepared similar to the 1997 design. The drawing numbering are by area and are proceeded by an “I” (e.g., Drawing I-XXXY). XXX – is the process area and Y is the individual sheet.

All instrumentation numbers maintain the following numbering scheme:

XXXNNA

XXX – Process area (e.g. 100 – Influent, 301 – Primary Sedimentation Tank 1, etc)

NN – Predefined Group 00 – Common Alarms

01~09 – Individual Items

10 ~40s – Pumps, valves, and other motorized equipment

50s – Level Devices

60s – Pressure Devices

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70s – Flow Devices

80s – Analytical Devices

90s – Safety and Security Devices

A – Suffix for an instruments located in the same physical location with similar functions (e.g. A – Open, B-Closed)

The SCADA network protected by a state-of-the are firewall.