Master Planning 101 - Carollo Engineers in general, is the interface between the plant control system and the operators. It is the primary tool with which operators and managers try

SCADA

SCADA, in general, is the interface between the plant control system and the operators. It is the primary tool with which operators and managers try to coordinate and control the processes of their facilities. While SCADA was first introduced for large scale power distribution systems over 50 years ago, the first wave of water and wastewater SCADA systems were not implemented until the early 90s. As these original systems age, municipalities are finding themselves with components and software that is outdated, unsupported, and cumbersome to maintain. Enter the SCADA Master Plan!

The term ‘SCADA Master Plan’ is a misnomer, as much more than just the SCADA system is being master planned. These projects typically refer to a re-evaluation and sometimes overhaul of the entire process control system including:

• Programmable Logic Controller (PLC) Hardware • PLC Software • PLC Cabinets • SCADA Software • SCADA Servers • Ethernet Switches • Control Philosophies • Reporting • Alarming and Alarm Management • Energy Management

Master Planning 101

Project Elements

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Client Name/Project Name

City of Yuma, AZ - East Mesa WTP • • • • City of Casa Grande, AZ - WRF Phase 3 Expansion SCADA • • • • St. George, UT - Quail Creek WTP Instrumentation • •

Salt Lake City Public Utilities, UT - WRF Process Control Upgrade • •

South Valley WRF, UT - Projects 4C and 4D SCADA • •

Metropolitan Water District of Salt Lake & Sandy, UT - Point of the Mountain WTP SCADA • • • Weber Basin WCD, UT - Weber South WTP SCADA • •

Weber Basin WCD, UT - Davis North WTP SCADA • •

Magna Water Improvement District, UT - Barton Wellfield WTP • • • Central Utah WCD, UT - Ashley Valley WTP Process Control System Upgrade • • •

Provo River Water Users Association, UT - SCADA System • • • Contra Costa Water District, CA - SCADA WTP System • • • • Contra Costa Water District, CA - Randall-Bold WTP DCS Upgrade • • •

Contra Costa Water District, CA - Bollman WTP DCS Design-Build Project • • •

Contra Costa Water District, CA - Randall-Bold MPP Pump Station PLC/HMI Programming Project • • •

Cities of Mesa and Phoenix, AZ - Val Vista WTP Upgrade DCS • • •

City of Roseville, CA - Barton Road WTP Communications Upgrade • •

Sacramento Regional County Sanitation District, CA - WWTP Boiler System Control •

City of Santa Maria, CA - Water Telemetry/SCADA System DCS • • • City of Santa Rosa, CA - Laguna Wastewater Plant DCS Upgrade • •

South Tahoe Public Utility District, CA - Effluent Pumping SCADA Upgrade Project • • • • City of Watsonville, CA - Recycle Water Facility • • •

Central Marin Sanitation Agency, CA - Wet Weather Improvement Project • • •

City of Arlington, TX – John F. Kubala WTP Expansion SCADA Programming •

City of Reedley, CA – WWTP Expansion SCADA Programming • •

Collier County, FL – NCRWTP Control & Information System Replacement • •

City of Roseville, CA – Pleasant Grove WWTP UV Conversion • •

City of Roseville, CA – Dry Creek WWTP UV Conversion • •

City of Merced, CA – 10-mgd Expansion SCADA System • •

City of Fresno, CA – WWTP Expansion DCS • •

Carollo Approach

Carollo has performed more than 50 SCADA Master Plans throughout the country and has developed a proven approach to conducting and implementing these challenging projects. The table below showcases Carollo’s experience in conducting SCADA Master Plans throughout the country.

Carollo’s approach is workshop intensive and focuses on the participation and buy-in of the client and the critical stakeholders, from operations staff to management. The workplan shown below is an example of the critical steps required for a typical SCADA master plan.

E&IC Design StandardsWorkshop

Scoping Workshop Kick-off Meeting Tech Memo No. 2Review Workshop

Tech Memo No. 3Review Workshop

Tech Memo No. 4Review Workshop

Develop Detailed ScopeDevelop Project

Management PlanInvestigation and Analysis of Existing Infrastructure

Investigation of Currentand Emerging Technologies

Develop Alternatives and Cost Estimates

Compile Tech MemosInto PAS ReportsE,I&C Design Standards

E&IC Design StandardsDocuments

Tech Memo No. 1Scoping Summary

ProjectManagement Plan

Tech Memo No. 2Existing Hardware & Software

Tech Memo No. 3Current & Emerging Technologies

Tech Memo No. 4Recommendations

Draft PAS Report

Final PAS Report

TASK

S/W

ORK

EFFO

RTS

DELI

VERA

BLES

MEE

TING

/WOR

KSHO

PS

75th Street Wastewater Treatment PlantPROCESS AUTOMATION SYSTEM • STRATEGIC PLAN

TASK 0 TASKS 1-4 TASK 5 TASK 7 TASK 6 TASK 10

• Evaluate Existing Documentation

• Site Tour and Control Cabinet Audit

• Corrosion Assessment Forms• Verify Architecture and Risk

Diagrams• Determine Upgrade Paths

and Packages

• Identify Needs and Desires• Review Viable Technologies• Describe Pros and Cons• Identify Costs• Coordination with

Manufacturers

• Develop Criteria for Future PAS Upgrades

• Prioritization of Alternatives to Balance Criticality, Risk, and ROI

• Develop Realiable Cost Estimates Through Close Coordination with Vendors

• Look at Implementation into CIP and Provide Justification

• Compile Surveys• Develop Hardware Components

Standards• Develop Software Components

Standards• Power Standards• Screen Standards• Control Panels Standards• Tagging Requirements• Control Philosophies• Networking Standards

• Compile Tech , Memos• Develop Executive Summary

• Scope, Schedule, And Budget• Project Team and Contact

Information• Management Procedures

(Communication, Reporting)• Quality Management

Procedures• Project Risk Management

& Response Plan• Decision Log

START/END DATES

9/17/12 • 10/3/12 9/18/12 • 10/10/12 10/11/12 • 11/30/12 10/12/12 • 1/11/13 1/7/13 • 2/22/13 2/25/13 • 3/29/13 4/1/13 • 5/3/13

Process Automation System (PAS) User Survey

Name:Department:Position:

Introduction:

1 not at all2 not really3 no opinion4 somewhat5 yes

1 2 3 4 5 NA123456

789101112

1314

15

16

17

18192021

QUESTIONSGeneral

Do you have access to all the reports you need?Are reports easy to generate?

Is the PAS system reliable?Historical Data and Trending

Do you currently interact with the PAS real‐time data?

Process Automation

Do you feel that there are plant processes that require improved automation?

Do you feel that there are plant processes that should be automated that are not currently automated?

Do you feel that the WWTP process is adequately automated?

Operation and MaintenanceIs O&M data easily accessible?Is O&M data organized in a way that makes it easy to find what you need?Do you use the Online Operations Manual (OLM)?Is the OLM easy to access?

This survey has been prepared for management and staff to examine the utilization, strengths, and shortcomings of the Boulder WWTP Process Automation System (PAS). The PAS system includes the SCADA and PLCs that gathers and transmits, in real‐time, data that is used by operations and maintenance staff to control the WWTP. The PAS allows real‐time data to be summarized and stored for later retrieval. The data can be used for analysis, planning, internal reports, and reports to outside agencies. The results of this survey will be used to help identify and prioritize potential upgrades to the existing PAS system.

Do you currently use summarized or historical PAS data?Do you currently interact with the reporting function of the PAS?Do you currently interact with the alarming of the PAS?Does the PAS system operate in timely fashion?

SCALE

The questions relate to your present and possible future utlization of the PAS. For each question below, mark the box to the right that best fits your answer. Use the scale above to match your selection.

Do you have access to all the historical data you need?

Is the retrieved historical data in a format that can be readily used?Can you retrieve trending data easily?

Reporting

Do you have access to all the real time trending data you need?Can you retrieve historical data easily?

Is the trending data in a format that can be readily used?

Key aspects of nearly every SCADA Master Plan include:

• Staff Interviews – Determine the current perception of the automation system

• Control Cabinet and Software Audits – Determine the current state of the automation system infrastructure The workplan shown below is an example of the critical steps required for a typical master plan.

PCM Panel Location: DAFT BLDG Inspection Date: 1/7/13PCM Panel Tag: ACC‐DAF AREA CONTROL CENTER Install Date: JAN. 2008Process(es) Served: DAFT Condition*: 1Panel Dimensions: 3'X9'X6' Inspection By: MKR

Picture ‐ Panel External Picture ‐ Panel Internal

General Comments: Good Condition ‐ no visible issues *Condition

1 ‐ Very Good

2 ‐ Minor Defects3 ‐ Needs Significant Maintenance4 ‐ Requires Rehabilitation

Controller Model: GE RX3i Pac Systems 5 ‐ Requires Replacement (>50%)

RACK 0 RACK 2Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 Slot 9 Slot 10 Slot 11 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5

WER

SUPP

LY

320

001

CE CE CE CE CE CENET

MASTER

CENET

MASTER

001

WER

SUPP

LY

4PWR3

30

4ALG

442

4ALG

442

CE 4MDL930

Controller Layout ‐ Include IO type, card model #, and spare capacity where possibleSlot 6 Slot 7 Slot 8 Slot 9 Slot 10 Slot 11 Slot 1 Slot 2 Slot 3 Slot 4 Slot 5 Slot 6 Slot 7 Slot 8 Slot 9 Slot 10 Slot 11

RACK 2 RACK 1Component Models:UPS: APC ‐ Smart UPS (UPS‐DAF) SPD: CUTLER HAMMER AEGIS

DC Power Supply: PHX. CONT. QUINT POWER Relays:(4) 24VDC 5A Quint‐PS‐100‐24DAC/24DC/S

Terminal Blocks: HMI/OIT: Optiplex 745/ Simatic 15" Flat Panel

Relays: idec NEMA: 12

Switches: Hirschmann Mice‐MS20, MM3‐2FXM4/2TV1 HVAC:HMI/OIT: Backpanel:Other: APC Redundant Switch (STS‐DAF‐1) Enclosure: Other: Accopian Power Monitor (PS‐DAF‐1) Circuit Breaker: SIEMENS SSY41Other: Other: T‐STAT A‐TEMNO (HOFFMAN)

SPACE

SPACE

SPACE

EXP. POWER

SUPP

LY

IC69

4PWR3

30

IC69

4ALG

442

IC69

4MDL230

IC69

4MDL230

IC69

4MDL930

IC69

4MDL930

SPACE

SPACE

SPACE

POWE

CPU 3

ETM 0

SPACE

SPACE

SPACE

SPACE

SPACE

DEV

IC

SPACE

IC69

4MDL230

DEV

IC

LRE 0

POWE

IC69

4

IC69

4

IC69

4

SPACE

IC69

4

IC69

4MDL230

IC69

4MDL230

IC69

4MDL230

• Develop and Prioritize Alternatives – Balance criticality, risk, and return on investment

• I&C Design Standards – Develop a living document defining the automation system for staff and consultants

• Cut-Over Plan – Develop a step-by-step plan for cut over to the new automation system including a process coordinated schedule, planned outages, testing, and start-up procedures.

Cabinet Tag Component ModelOverall Panel

Condition (1‐5)* Component Life CycleRemaining Service Life

(Years)Meets City

Standard (Y/N)RX3i CPU IC695CPU310 Active Approx 10 years YRX3i Power Supply IC694PSA140 Active Approx 10 years YRX3i Ethernet Module IC695ETM001 Active Approx 10 years YRX3i DeviceNet Master IC694DNM200 Active Approx 10 years YRX3i Expansion Module IC695LRE001 Active Approx 10 years YRX3i Expansion Power Supply IC694PWR330

ActiveApprox 10 years Y

RX3i Mixed Analog Module IC694ALG442


RX3i DI Module IC694MDL230 Active Approx 10 years YRX3i Relay Module IC694MDL930 Active Approx 10 years YUPS APC smart UPS Mature Approx 5 years N

DC Power SupplyPhoenix Contact Quint‐PS‐100‐24VDC/(2) 5A, (2) 10A

MatureApprox 5 years N

Ethernet Switch

Hirschmann Mice‐MS20, MM3‐2FXM4/2TV1,MM2‐2TX1


OIT Siemens Simatic Flat Panel 1P 6AV7861‐2TB00‐1AA0


Thin Client Dell Optiplex 745 Active Approx 10 years Y

SPDCutler Hammer Aegis AGSHWCH12ON20XC


Fiber Patch Panel Corning Lan Scape Active Approx 10 years YCircuit Breaker Siemens SSY41 Active Approx 10 years YRX3i Back Plane IC695CHS012BA Active Approx 10 years Y

Redundant SwitchAPC Redundant Switch (STS‐DAF‐1)


Thermostat A‐TEMNO (HOFFMAN) Active Approx 10 years Y

Power MonitorAccopian Power Monitor (PS‐DAF‐1)


*Overall Panel Condition: 1. Very Good 2. Minor Defects 3. Needs Significant Maintenance 4. Requires Rehabilitation 5. Requires Replacement

ACC‐DAF AREA CONTROL CENTER

1

Carollo Systems, LLC is a SCADA systems programming and integration firm, created to provide outstanding control systems and services for water and wastewater utilities. Through a flexible and innovative contracting approach, Carollo Systems provides a proven alternative to traditional low-bid contracting, delivering comprehensive SCADA system solutions to maximize both facility performance and the value of our clients’ investment in control technology.

As a subsidiary of the largest consulting firm in the United States dedicated solely to water and wastewater engineering, Carollo Systems draws on our national expertise with water and wastewater processes, as well as Carollo’s 75-year history of client focused service. This brochure will further explain the services we provide and how our clients have benefitted from our tailored solutions and services, delivered by experts who understand their utility’s needs.

The Future of SCADA

SCADA and process automation is fast changing and continuously adjusting to the current technological advancements. There are several exciting developments in process automation including:

• Tablets – Allows the operator to get away from the control room and into the facility for critical operations

• Artificial Intelligence – Allow predictive control by allowing the automation system to analyze the plethora of control system variables and learn the most efficient method for control

• Energy Management System (EMS) – Monitor the facilities energy consumption and carbon footprint down to each process.

• Game Theory – Allow operators to compete to optimize process control by providing the interface for competition and incentives for performance

For more information concerning SCADA master planning please contact:

Monte Richard

[email protected]

303.980.8260 (Ph) • Littleton, CO

Why Carollo

Carollo in teaming with Carollo Systems has the unique ability to perform both the SCADA master planning as well as implementation. This arrangement provides sig-nificant advantages to the Client by insuring coordination of the integrator into the design process, saving significant cost during design and implementation. Our experi-ence has led to the development and refinement of several tools that have a proven track record for optimizing the decision making process through the planning process. These tools can be utilized and customized for individual SCADA master plans improv-ing efficiency of the master planning process. Carollo is uniquely positioned to provide SCADA master planning to its clients because of their inherent knowledge of the facili-ties process and operation. Many SCADA master plans are conducted by an integrator who does not necessarily understand I&C design or the facility unique and interrelated processes. Carollo offers its clients the unique advantage of providing a multi-faceted, coordinated team that can provide a holistic approach to SCADA master planning by providing:

• Process optimization by leading process engineers in the water and wastewater industry

• Instrumentation and control design by leading I&C engineers specifically dedicated to the water and wastewater industry

• Programming and implementation by leading integrators dedicated to the water and wastewater industry