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LESSONS LEARNED FROM A $5 MILLION SCADA UPGRADE
Columbus Water Distribution System
Phil Schmidt, PEJohn Gilmore
Overview of Distribution System
• Service to approximately 1.2 Million Population
• 135 MGD Average
• 3,500+ Miles of Water Lines Maintained by Division of Water
• 13 Primary Pressure Districts
• Franklin County and parts of Fairfield, Licking, Delaware, Union, Pickaway
Operations Control Center
Operates and Maintains:• 35 Elevated Storage Tanks• 3 Ground Tanks• 28 Booster Stations • 24 SCADA Controlled Valves• Operate High Service Pumps at 3 water
treatment plants
• 4 crews – Operators, Techs, Mechanics, Electricians
• Management/Support• 40 staff
Need for Upgrades
• Obsolescence of Equipment – Replacement parts and technical support issues
• 18 years old – host system• Pre-9/11 – Security concerns were different
• Risk– Longer term disruption to SCADA system would have likelihood of rolling losses
to thousands of customers’ water service
Overview of Upgrades
• Radio Network Improvements
• Construct remote backup control center
• Renovation of existing main control center
• Upgrade all RTUs in the system
• Improved Security
Radio Network – Existing
Control Center
Booster Station A
Tank 1 Booster Station F
Repeater
PRV 4
Booster Station E
RepeaterBooster
Station D
PRV 3
Repeater
Booster Station C
PRV 2
Repeater
Booster Station B
PRV 1
Existing Network - 900 MHz Entire system dependent on Control Center
Tank 2
Tank 3
Tank 4
Tank 5
MCC
Repeater
Repeater
BCC
Repeater
Repeater
Booster Station D
PRV 4
Tank 4
Booster Station C
Tank 3
PRV 3
Booster Station B
Tank 2
PRV 2
Booster Station A
Tank 1
PRV 1
Radio Network – Redundant Wireless Ring
900 MHz network remains in placeMCC, BCC and Master Repeaters are connected with a 5.8 GHz loop.If any site on the loop goes down, the data can still travel on the ring.
RTU Upgrades• Schneider (Telvent) Sage 2400 boards
• Upgrade from Sage 2200 boards
• Purchased 85 through contract and they were installed at all remote locations by our control center staff
• Improved Security
Backup Control Center (BCC)
• Constructed in a secure remote location
• 2 operator stations• Diesel standby generator• HVAC system• Dimmable LED lighting
• 30 day BCC operational demonstration before starting demolition/remodeling of MCC
Backup Control Center (BCC)
Main Control Center (MCC)• Operator Console
– Adjustable Height– 2 Operator Stations and 1 Engineering Station
• Video Wall Display – Four 55-inch monitors
• Incident Command Room – Conference Table and Wall-Mounted Monitors
• Lockable Wardrobe Style Lockers and File Cabinets for Each Operator
• Kitchenette
• New HVAC system
• Dimmable LED Lighting
Main Control Center – Construction
Main Control Center – Construction
Main Control Center – Construction
Main Control Center – Construction
Main Control Center – Construction
President’s Day Surprise – Water Damage
Newly installed plumbing fixture failed sometime over holiday weekend
Water sprayed into control room until discovered Tuesday morning after holiday
Items Destroyed:• Carpet• Kitchenette Casework • Sink Faucet• Wood Lockers
President’s Day Surprise – Water Damage
President’s Day Surprise – Water Damage
President’s Day Surprise – Water Damage
Challenges During Construction
Tower Variance
Graphics
• Graphics were converted to new format
• Conversion process compatibility issues
• Should have recreated them instead of convert
Electrical Issues
• Generator
• UPS
• Restrictions from existing variance
Self-Healing Radio Ring
Completed Control Room
Completed Control Room
Completed Control Room
Completed Control Room
Completed Control Room
Old New
Completed Control Room
Project Details• Construction Cost is $5.2 Million
$4.6 Million + $600K Contingency
• Prime Contractor – Schneider Electric BuildingsSubcontractors:
Schneider Electric (Telvent)Corna KokosingJ&K CommunicationsMid City Electric
• Design Professional – CDM Smith• Construction Administration - DLZ
Going Forward
Recreate Graphics
More Frequent Upgrade Cycle
More Nodes On Wireless Ring
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