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Item 10 PPP 09-04-19 Operations Committee - SP-196 Info Item
Process Control Systems Upgrades Study Project No. SP-196 Information Item e0A Mike Dorman, Engineering Manager Operations Committee ~- September 4, 2019 RU �A ANN- K"T" A en da 9 Update on where we are since we started Project SP- 196 , Process Control Systems Upgrades Study Supervisory Control and Data Acquisition (SCADA) Internet HMI Server 1 HMI Server 2 Historical Data Server Record Events _� Firewall '�I�®�® �®�� I®®�®�� and Historical ■ . Data for • Firewall Reporting and Office ��� Troubleshooting Network .��� Industrial Control Systems (ICS) Network Controller Remote Input/Output (1/0) Control and Monitor Processes Local Human (Wastewater, Electrical and Machine Interface - _ Central Generation) •..s.. (HMI) — — — — — — — — — — — — — I or 71 A - f �- - - - - ® _ — — i Motor Starter Ultrasonic Level 1 Graphical User i Interface to Monitor, =r Pump High Level Control and Configure No. 1 i Float Switch the Control System Pressure Flow High SCADA used for Process, Electrical, !Pressure Wet Well Central Generation, and Pump Stations Switch 1 Controller Remote Input/Output (1/0) W6Z" LEVEL Feet Ultrasonic MOTOR Level STARTER Start _ Level Pump No. 1 Stop _ Level JONI CIF man Machin Int rf ARE 55 • ROCKY POINT ROCKY POINT PUMP A • WETWELL SUMP L-H • .. D M%LEL ' CS PUMP 1: CS PUMP 2: S CS PUMP 3: INCH I-CS PUMP 4: L 1 2 3 4 OP ON 0 0 0 =% =% =% =% ®RPM MRPM MRPM RPh,1 JMMGD FORCE IF MW PSI MAIN 1 S OP FORCE MR MGD MAIN 2 44 S L STATION • f' f' STATUS DRYWELL FLOODED: GENERATOR: ELECT ROOM INTRUSION: DRYWELL INTRUSION: GENERATOR INTRUSION: EXT PANEL INTRUSION: IL WANING CYCLE: Zj MENU GRAPHIC I CONFIGUREI TRENDS I SUMMARY RUNTIME HELP 1r..W man Machine Interface ROCKY POINT PUMP STATION V 1 VEL CONTROL VFD PUMP 1 300 LEVEL SETPOINT - 300 - - 100 - 250 .. .. .. .. .._. - 225 - - 75 - 200 150 - 150 - - 50 - 100 75 - - 25 - 50 Q I 0 - - 0 - 6D 50 4D 30 2D 1D 0 IIIIIIIIIII IIIIIIIIIII 0 50 100 0 50 100 PID OUTPUT & PUMP SPEED LEVEL: 89.2 INCH SETPNT: 0._3 % 100 SETPNT: 90.0 INCH OUTPUT: 0.9 % 90 OUTPUT: 70.9% SPEED: 71.3% 80 70 �-� MWam 60 50 CLEANING STATUS: OFF STATUS: 40 .. .... E: Al iY V CS: V� 30 .. IILOCK: DUTY: I 20 --- onoff am 10 --- ww= Q 6D 5D 4D 3D 20 10 D Human Machine Interface OPERATING & ALARM SETPOINTS PUMP DUTY SEQUENCE SELECTION i"v CURRENT LEAD START/ STOP LEVELS: VALUE LEAD LAG1 LAG2 STDBY SEQ LEAD START (0-190): INCH 1 2 3 4 1 LEAD STOP (0-190): INCH 2 3 4 1 2 3 4 1 2 3 LAG START / STOP SPEED: 4 1 2 3 4 LAG1 START (65-90): LAG1 STOP (65-90): % LAG2 START (65-90): % EQUIPMENT SELECTION LAG2 STOP (65-90): % IN SERV OUT SERV F6RCEMAIN PRESSURE ALARM: VFD PUMP 1: VFD PUMP 2: HI HI ALARM (0-50): PSI VFD PUMP 3: HI ALARM (0-50): PSI VFD PUMP 4: �/ LO ALARM (0-50): PSI LO LO ALARM (0-50): PSI SONIC 1 LEVEL SENSOR: WETWELL LEVEL ALARM: SONIC 2 LEVEL SENSOR: HI HI ALARM (0-190): INCH SUPPLY FAN: HI ALARM (0-190): INCH EXHAUST LO ALARM (0-190): INCH LO LO ALARM (0-190): INCH ' ' LEL ALARM: ACTIVE HI HI ALARM (0-100): % SONIC 1 LEVEL: IN HI ALARM (0-100): % NIC 2 LEVEL:MN IN Q 0 a > I MENU I GRAPHIC I CONFIGURE TRENDS I SUMMARY I I RUNTIME I HELP Plant 1 Control -Hlu ; SCADA system allows 24-hour operation from 1 location at each plant Why Replace Machine Int ace? - • HMI System CRISP SEJe y _ L fiL (Process , electrical and AEP.BSPI£ pump stations) M • 100 HMI Workstations AER65NG a Q sw • -850 Graphics Screens Fs_ rsL a_ ew • 33 ServersrJ © o 31@33uR ruif+E F 1M�E� ru Ml�!; K/L I.�P • 25 years old ` ' a ais =wnc nur • Uses VAX workstation and VAX emulation software • OCSD owns the software code • Added features over the years to meet our needs • CRISP programmers reaching retirement age • H M I System — Wonderware (Central Generators) Why Replace the Programmable . L: ---A 7,w ' Logic • • ; 7 • PLC — Modicon Quantum • 150 Networked PLC's • 25+ Standalone PLC's • —44,000 p input/output oints • 20 Years Old • Processors no longer manufactured • Input/output modules no longer manufactured in the near future • Maintainability Plan - • Spares in warehouse for replacement and near term future projects (purchased 38 spare processors) • Using next generation Modicon PLC (M580) for new projects (J-117B) ) = 19 • Scope • f Work 61 ram; • Determine Requirements • Available SCADA technology • System requirements • Smart devices and instruments • Integration with business and maintenance systems • Predictive maintenance • Advanced control feature • Historian • Select a Vendor • 20-Year agreement (software and hardware) • HMI replacement SCADA System Replacement • Replace existing HMI software through Project No . J- 120 (price included in proposal ) • Develop new graphic standards • Develop new controller programming standards • Replace controllers as part of future CIP projects over the next 20 years (costs for hardware and programming included in CIP budget) Our SCADA system replacement project will be easier than other systems: • Excellent documentation of our system, programs and standards • Not doing a gut and replacement of the controllers • ecision Programmable Logic Controllers (PLC) versus Distributed Control System ( DCS) A DCS System HMI Software HMI Vendor X Controller PLC Vendor X Training HMI and PLC Vendor X Control Panel Panel Fabricator X Programming In-House / Systems Integrator In-House / X DCS's traditionally more expensive. OCSD elected to compete DCS with HMI/PLC since DCS's are becoming more competitive. DCS offers a more integrated system. We could have just extended the sole source, but we felt it was important to openly bid for the next 20 years RF /RF P Process ���� oil QUALIFYING PHASE SELECTION PHASE Oct Dec RFQ RFP —No- Ranking Response Scoring Classroom Absolute Trials Requirements to - ProposalTOP Work with Our - Non- QUALIFIED Existing System Disclosure PROPOSERS Ranking Agreement Vendor (NDA) Interviews - Price • ' Progresstiations Pricin Finalized the SOQ Phase - 20 year software licensing (6 Vendors Submitted - HMI replacement (Project J-120) 3 Vendors Qualified) - Total cost to replace all controllers = 196 Scope of Work SOQ Proposers • DCS • ABB • Emerson • Honeywell • HMI • AVEVA — Wonderware • Rockwell Automation • Trihedral — VTScada Future Board Action il6h6, A _M � . Future Board Action 1 . Approve a 20-year unit-price agreement Master Service Agreement 1 . Software licensing costs 2. Equipment costs 3. Programming hourly rates (DCS only) 4. Control panel costs (DCS only) 2 . Award Project J- 120 uest �1610 ,L- ons ?.