Master Metering using your SCADA System

Jim Mimlitz

SCADAmetrics

Master Metering

Using Your SCADA System

A Briefing to the AWWA Midwest Water & Wastewater Technology Conference

05 June 2014 Grayslake, Illinois

© 1995-2014 COPYRIGHTSCADAMETRICS ALL RIGHTS RESERVED.

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Why Integrate Master Meter Data

Into The SCADA System?

• Track Distribution System Flows In Realtime.

• Bulk Customer Billing & Automatic Reports.

• Detect and Zone Transmission Line Leaks.

• Increase Employee Safety.

• Improve Data Accuracy.

• Leverage Already-Existing SCADA System Infrastructure.

The Bottom Line: Reduce Operational Costs

ISAWWATraining

© 1995-2014

COPYRIGHT SCADAMETRICS.

ALL RIGHTS RESERVED.

SCADAmetrics

Track Distribution System

Flows In Realtime…

SCADA Systems Excel At:

• Collecting Large Amounts of Sensor Data Within Short Time Intervals• Graphical Presentation of Data• Alarming Unusual Conditions (Audible Alerts, Text Messages, etc.)• Graphical Presentation of Historical Trending Charts

ISAWWATraining

© 1995-2014



SCADAmetrics

GPM

GAL

477724330

GALLONS

950.2

GPM

Bulk Customer Billing &

Automatic Reports…

Connect SCADA Database to:

• Billing Software System• Excel Spreadsheets

ISAWWATraining

© 1995-2014



SCADAmetrics

Bulk Water

Customer

(RE Water Corporation)

Purchase Point

From Supplier

(City of Albion, IL)

Standpipe

Storage

Pump Station #1 Flow

– RE Water (Bulk Customer) System Flow

– Standpipe Storage Flow

= Approximate Residential And Business Usage

Pump Station #1

Water Company

SCADA Server

Residential And Business

Customers

ISAWWATraining

© 1995-2014



SCADAmetrics

Detect and Zone

Transmission Line Leaks…

Pump Station #2

Flow (gpm)

Overnight Usage Trends

Provide A Useful Measure

Of Potential Water Leaks

ISAWWATraining

© 1995-2014



SCADAmetrics

Increase Employee Safety…

• Meter Vaults – Safety Hazard.• OSHA Confined Space Compliance.

ISAWWATraining

© 1995-2014



SCADAmetrics

Improve Data Accuracy…

SCADA/Meter Instrumentation Saved The Utility $14K On This Month’s Bill.

4 Below-GradeMaster Meters Eyeball-Read By Human Meter Reader. (Errors)

4 Master Meters Machine-Read By SCADA System.(Error-Free)

ISAWWATraining

© 1995-2014



SCADAmetrics

Leverage Already-Existing

SCADA Infrastructure…

• Computer Hardware

• Computer Software

• Communication Infrastructure(Radio, Fiber-Optic, Etc.)

• Remote Sites(eg Water Towers, Pumping Stations)

How To Integrate Master Meters

Into A SCADA System?

• Case Study I –Licensed FM Radio Telemetry

• Case Study II –Cellular Ethernet Telemetry

• Case Study III –Extraterrestrial Satellite Radio Telemetry

ISAWWATraining

© 1995-2014



SCADAmetrics

• Collect Data From 34 Master Meters(Various Brands) Using SCADA System.

• 4 Readings Per Day.

• Revenue-Grade AccuracyOf Meter Readings.

• Accelerated Leak Detection.

• Minimize Recurring Costs:Low Energy Footprint (Solar Solution)Eliminate Manual Read PayrollReduce Fuel and Vehicle Wear/TearReduce Data Entry and Reporting Time

• Increase Employee Safety.

• 3 Year Investment Payback.0 105

miles

Case Study I –

Licensed FM Radio Telemetry

ABS Water Cooperative (Clayton, IL)

ISAWWATraining

© 1995-2014



SCADAmetrics

Project Goals:

• Several Meter Brands MixedThroughout System

• Customer Desired To UtilizeExisting Meters

Sensus

Badger

34 Master Meters…

ISAWWATraining

© 1995-2014



SCADAmetrics

• Utilize Absolute Encoder TechnologyNo Pulse Signaling (Pulse-Counting Errors)No 4-20mA Signaling (Integration Errors)

• Required Register Retrofits:Sensus – ICE RegistersBadger – ADE Registers

Revenue-Grade Accuracy…

ISAWWATraining

© 1995-2014



SCADAmetrics

Sensus ICERegister

Badger ADERegister

Minimize Recurring Costs…

ISAWWATraining

© 1995-2014



SCADAmetrics

Solar-Power Eliminated Need For Electric Utility Service:• No Up-Front Utility Hookup Charges• No Monthly (Minimum) Usage Charges

Lexan Window“Visual Read” Backup

Telemetry Hardware Diagram…

ISAWWATraining

© 1995-2014



SCADAmetrics

Solar Panel (50W) andBattery Charge Controller

EM-100 EtherMeterSCADA/Meter Gateway

DL-3400FM Telemetry Radio

Fusing

12V Battery

Radio Communications UsingRS-232 and Modbus/RTUIndustrial Protocol

Water Towers Were NaturalRepeaters For Meters InLow-Lying Areas.

• Software Library Created ThatLinked the SCADA Database To Excel Spreadsheets.

• Automatic and Fast ReportGeneration.

• Data Analytics QuantifiesUsage Anomalies/Leaks.

• Data Transcription ErrorsEliminated.

Reduced Data Entry and

Reporting Time… ISAWWATraining

© 1995-2014



SCADAmetrics

• Collect Meter Data From 20 Custody Transfer Meters (Various Brands) UsingCellular Ethernet Technology and the Existing SCADA System.

• Main Purpose = Billing. Revenue-Grade Accuracy Required.

• Readings Every 15 Minutes.

• Minimize Recurring Costs:Low Energy Footprint (Use Solar Wherever Power Not Available)Eliminate Ineffective Legacy System and Associated Monthly Contract

• Interface With Bulk Customer Telemetry Equipment.

Case Study II –

Cellular-Ethernet Telemetry

Utility:Missouri American Water Company (Saint Louis, MO)

Project Goals:

ISAWWATraining

© 1995-2014



SCADAmetrics

Water

Company

HQ

Cellular

Carrier

Master Meters

Retrofitted with

Encoder-Type Registers

IMPROVED

MASTER

METERING

SYSTEM

Local

Cellular Tower

Infrastructure

Private

Cellular

Network

Industrial

Ethernet

Protocols

Cellular Ethernet System…

ISAWWATraining

© 1995-2014



SCADAmetrics

• Private Cellular Network For SCADA Security.

• Data Communications Using KepServerEx.

• Nice Extra: Modbus/UDP Industrial Protocol (not Modbus/TCP).

• UDP Protocol Achieved Order-of-Magnitude Decrease In Billable Cellular Kilobytes.

ISAWWATraining

© 1995-2014



SCADAmetrics

Cellular Master Meter Site…

Cellular Telemetry

Hardware Diagram… ISAWWATraining

© 1995-2014



SCADAmetrics

Cellular Antenna


AC/DC Power Supply (24V)

Raven-ECellular Gateway (Modem)

ADAM-40244-20mA Output Module(Signaling To Bulk CustomerTelemetry)

ISAWWATraining

© 1995-2014



SCADAmetrics

Case Study III – Extraterrestrial

Satellite Radio Telemetry…

• Collect Meter Data From Custody Transfer Meters (Various Brands) UsingExtraterrestrial Satellite Modem Technology.(Cellular Not Available, FM Radio Insufficient Range).

• Main Purpose = Billing. Revenue-Grade Accuracy Required.

• Readings Every 6 Hours.

• Minimize Recurring Costs:Low Energy Footprint (Utility Power Not Available).

Utility:Northwest Area Water Supply District (Bismark, ND)

Project Goals:

ISAWWATraining

© 1995-2014



SCADAmetrics

ISAWWATraining

© 1995-2014



SCADAmetrics

Case Study III – Extraterrestrial

Satellite Radio Telemetry…

ISAWWATraining

© 1995-2014



SCADAmetrics

Satellite Telemetry

Hardware Diagram…

JouBeh 9602WSatellite Transceiver

Satellite Antenna


ISAWWATraining

© 1995-2014



SCADAmetrics

Satellite Telemetry Typical Site…

Hardware Diagram…

Solar Panel.

Telemetry Enclosure.

Below-Grade Master Meter:

Badger w/ ADE Register(Absolute Digital Encoder).

ISAWWATraining

© 1995-2014



SCADAmetrics

Satellite – SCADA Integration

Nice Extras(Self-Diagnostics):

Satellite Signal Strength

Battery Voltage

ISAWWATraining

© 1995-2014



SCADAmetrics

Satellite – Automatic

Report Generation…

SCADA Useful For…

• Tracking Distribution System Flows In Realtime.

• Alarming.

• Historical Trending.

• Data Visualization.

• Assisting With Bulk Customer Billing

• Generating Reports Automatically.

• Detecting and Zoning Transmission Line Leaks.

• Increasing Employee Safety.

• Improving Data Accuracy (Eliminating Human Reading and Transcription Errors).

Key Technology Components…

• Absolute Encoder-Based Meter Registers.

• Leverage Existing SCADA Infrastructure.

• Utilize Most Suitable Communication Method (eg. FM Radio, Cellular, Satellite).

• May Utilize Solar Power When Needed.

ISAWWATraining

© 1995-2014



SCADAmetrics

Summary & Key Points –

Jim Mimlitz

SCADAmetrics

Saint Louis, Missouri

scadametrics.com

ISAWWATraining

© 1995-2014



SCADAmetrics

Engineering

Master Metering using your SCADA System