City of Detroit - Rockwell Automation · The Detroit Water and Sewerage Department ... Process Controls equipment from Emerson/Ovation & Rockwell/AB > 95% ... Emerson Ovation DCS

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

City of Detroit PlantPAx Process Library and WWW Accelerator Toolkit Save $ for Integrator and City of Detroit

Hassan Ajami PCI General Manager Date – 11/5-6/2012

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

PCI is a System Integration firm established in 2000 to serve the Metro Detroit region.

Offices in Detroit, Cleveland, Louisville and Shreveport.

Industry focus is on Water/Wastewater and Automotive

Involvement in projects encompasses both design and construction phases.

Clients include both public and private utilities, major automotive companies, and petro-chemical companies.

Process Control & Instrumentation


The Detroit Water and Sewerage Department (DWSD), one of the largest water and sewer utilities in the United States, has a rich history as a public utility dating back to 1836.

Serves 35% of Michigan’s Population including Detroit and 76 other communities.

Fresh Water System - 5 water treatment plants pump an average of 596 million gallons of clean drinking water each day. Maximum capacity 1.2BGD

Wastewater System - Treats an average of 707 million gallons of flow per day. Maximum capacity 1.65BGD


Process Networks and SCADA Systems Division – WWTP & CSO Equipment

Operational Support: 21 freshwater and 10 wastewater pump stations 5 Water and 1 Wastewater treatment plant 5 Combined Sewer Overflow basins

Process Controls equipment from Emerson/Ovation & Rockwell/AB > 95%

21,000 Hard I/O Points > 200,000 Total Points 282 PLC/Controllers 92 PC Workstations


Common industry situation

Multitude of HMI solutions: Ovation, Wonderware, Ifix, RSView32

Large variety of systems integration implementations Disparate process control implementations Usually only hardware platform specified PLC Code developed using only written narratives No standard control software strategies No standard graphics, other than color standard Implementation varies by Contractor/SI/Programmer

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Goals - Accelerator Tool kits

Reduce the engineering time required to create standard, repeatable process applications

You can focus your energies on the custom aspects of your applications. Increase control system quality and reliability.

The reuse of well tested code conforming to industry standards reduces the likelihood of code bugs.

Drive logical and visual consistency The Process Library aids in producing standard Graphics formats that increase the consistency of your HMI thus reducing the need for Operator Training.

Superior diagnostics Built in process diagnostics will make applications easier for operators and maintenance to troubleshoot and debug without requiring PAC programming tools

Scalability – You can build ever larger systems using the same reusable modules.


Modular Programming Concept Use industry standard format -ANSI/ISA-S88

Create reusable application code based on “Best in Class” designs

Faster and easier development of application software. Examples of proven software programming techniques and recommended programming styles are provided for programmers to use in their own code.

Faster and easier testing of application software. Standards make testing of modular software objects easier, as there is less chance that new software developments will impact existing software objects that are already proven.

More reliable application software. The standards described ensures that changes to one software object will have little or no impact on another.

Improved maintenance and operation of application software The standardized look and feel of the automation controller programming and the human machine interface (HMI) for graphic objects makes it easier for operators and software personnel to recognize application functionality across applications and suppliers.

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 8

Contents of an Accelerator

• An Accelerator provides a package of tools, which significantly simplifies the Design, Manufacturing, Start-Up and Support of Rockwell Automation control systems.

• An Accelerator CD provides the – selection tools and – basic panel layout, – wiring diagrams, – Logix program, – HMI screens and – Quick Start manual

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 9

The Process Library High-efficiency suite of Control Modules

Mode Selection

Standard Alarm

AI w/ Scaling & Alarms

DI w/ Alarms

Single-Speed Motor

Permissives with Bypass

Protectives with First-Out, Bypass

Run Time and Start Accumulator

Re-start Inhibit for Large Motor

Date/Time Blocks • Solenoid-Operated 2-state Valve

• Motor-Operated 2-state Valve

• PIDE-based PID with Standard Modes and Deviation Alarms

• Analog Output

• Variable-Speed Drive (e.g., PF70-style)

• 2-Speed Motor

• Reversing Motor (e.g., FVR)

• Pulse-Input flow meter dosing with pre-act and in-flight adjustment

• Analog-Input flow meter dosing as above

• Weigh-Scale dosing (Loss-In-Weight and Gain-In-Weight supported)

• Controller CPU Utilization

• Hand-Operated Valve Monitor

• Hand-Operated Motor Monitor

• Cascade and Ratio supported PID

• Advanced AI with High Rate of Change Alarm, Square Root Extraction, and Deviation Alarms


Benefits of Using Accelerator Toolkit Standardized scalable integrated architecture

Single hardware and software platform Standardized controller logic and HMI graphics

Single Scalable HMI Platform based on FactoryTalk FactoryTalk SOA - Services Oriented Architecture

Standards Based – Use of common reusable code and engineering templates

Creates standards for HMI graphic symbols and operation

Significantly enhanced systems diagnostics Leverages diagnostics built into AOP and HMI Templates

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Case Study City of Detroit- DWSD

PC-761 Control System Upgrade at 2 CSO basins Replacement of obsolete Bailey DCS system

Issues Obsolete Workstation Spare Parts Availability Old Tape Backup Lack of Local Support Complicated ABB PLC Interface between Bailey & Rotork valve

system

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Hubbell/Southfield CSO

Hubbell-Southfield CSO RTB The Hubbell-Southfield CSO RTB is one of DWSD’s most active, longest operating CSO facilities and the largest on the Rouge River. Since August 1999, it has been effectively capturing and treating combined sewage through screening, settling and disinfection to meet discharge permit requirements that protect public health. Sized to fit into the available land and site constraints, the basin has a 22 million gallon storage capacity. Located next to the Tournament Players Championship Golf Course (TPC) in Dearborn, this RTB serves as an example of how these facilities can be good neighbors and blend in with the surrounding environment. The facility features an innovative design component that enables three different operational modes within the RTB and prevents resuspension of solids during large storms with high flow rates.


Puritan/Fenkell CSO

Puritan-Fenkell CSO RTB Located in Eliza Howell Park, the Puritan-Fenkell CSO RTB is the third Rouge River CSO RTB. This facility successfully demonstrated that a facility sized to provide 20 minutes of detention time for settling and disinfection of the 1-year, 1-hour storm event peak flow is sufficient to meet protection of public health standards. The 2.8-million-gallon facility became operational in August 1999 and eliminated two untreated CSO outfalls.


Existing Bailey Infi 90/OIS40


Control System Options

1. Bailey Upgrade

2. HMI 3rd Party Upgrade with Bailey hardware

3. Rip & Replace 1. Emerson Ovation DCS 2. Rockwell/Allen Bradley 3. WonderWare/Allen Bradley 4. Intellution/Allen Bradley


Considerations

Cost (Initial & Life Cycle)

Functionality - DCS vs PLC

Maintainability

System Downtime

Support & Support Options

How many platforms to support: Parts Training


PC-761 Contract

Scope: Hubbell Southfield CSO Total Points 643 Puritan Fenkell CSO Total Points 374

PlantPAx solution including: Redundant ControLogix L73 PAC with Enhanced Redundancy Redundant Ethernet Network- Stratix 8000 Redundant FTViewSE Windows 7 Workstations Process Library V1.5 W/WW Accelerator Toolkit Rotork Master Stations Added Prosoft Modbus Comms Interface to DWSD Ovation System


Water/Wastewater Accelerator Toolkit Implementation

Utilized 12 Symbols and Faceplates Pump, ValveMO, ValveSO, ValveHO, Conveyor, Mixer, Agitator,

P_Ain, P_Din, P_AinAdv, P_AinDual, P_Aout Required some modification of graphics to meet DWSD HMI

standards Utilized Chemical Feed and Lead/Lag pump application

Editing the Toolkit Standard

Red vs Green for Run Face Plate Control Modes-symbols Rockwell Enhanced Toolkit – Added Color Change Tool


Old Bailey Overview Screen Hubbell Southfield


Followed DWSD Operator Graphic Standards


New Rockwell Overview Screen Hubbell Southfield


Flushing System Screens

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Chemical Feed Control Screen

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Lead / Lag Pump Control Screen

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System Status Screen

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Construction Issues

Failed field wiring in existing conduit duct bank Added Head Works Building PLC/Panelview Control Panel with fiber

optic connectivity.

Instrumentation and final elements failures Not in original project scope

Delayed project construction


Results-Total construction costs significantly below estimate

Reduced Deployment Time • Resulted in a 50 percent reduction in design time, contract oversight, and post-contract

documentation and support. • Provided process control with advanced networking and diagnostic capabilities • Increased access to process data for better preventive and predictive maintenance

Reduced Engineering Hours and Costs • Saved estimated $120,000 in configuration and systems integration time • Saved $90,000 in factory-acceptance testing and Startup/commissioning

Drove standardization for DWSD wide graphics FTViewSE/ME platform

Advanced HMI without the associated development cost

Software configuration that is fully documented and tested


New Operators Control Room


New PLC Panel in Control Bldg.


New PLC Head Works Control Panel


Water Wastewater Accelerator Toolkit on the AB.com IA Tools Website

W/WW Accelerator Toolkit CD-IASIMP-SP012B


City of Detroit DWSD Success Story

Further documentation on: Hubbell Southfield CSO Puritan Fenkell CSO

Publication Number WATVP-AP014A-EN-P April 2012

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Copyright © 2012 Rockwell Automation, Inc. All rights reserved. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Questions

Hassan Ajami Process Control & Instrumentation Ilc [email protected] Detroit, Michigan Ph 313-874-5877

PlantPAx Process Library

Documents

City of Detroit - Rockwell Automation · The Detroit Water and Sewerage Department ... Process Controls equipment from Emerson/Ovation & Rockwell/AB > 95% ... Emerson Ovation DCS