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Home My WebLink AboutItem No 117/6/2021 1 Process Control Systems Upgrades Study Project No. SP‐196 Presented by: Mike Dorman Engineering Manager Operations Committee July 7, 2021 Master Service Agreement Supervisory Control and Data Acquisition (SCADA) Human Machine Interface (HMI) Controller Industrial Control Systems (ICS) Network Motor Starter Pump No. 1 Pressure Ultrasonic Level Wet Well Remote Input/Output (I/O) Flow High Pressure Switch High Level Float Switch Monitor and Control Process, Electrical, Central Generation and Pump Stations Record Events and Historical Data for Reporting and Troubleshooting Graphical User Interface to Monitor, Control and Configure the Control System HistorianHMI Servers 2 1 2 7/6/2021 2 Start Level Stop Level 12345678910 LEVEL Pump No. 1 ONOFF MOTOR STARTER Feet Pump Level Control Controller Remote Input/Output (I/O) Ultrasonic Level 3 Human Machine Interface 4 3 4 7/6/2021 3 Human Machine Interface 5 Human Machine Interface 6 5 6 7/6/2021 4 7 Plant 1 Control Center SCADA system allows 24-hour operation from 1 location at each plant Why Replace the Human Machine Interface (HMI)? •HMI System –CRISP (Process, electrical and pump stations) •>27 years old •No longer commercially supported •3rd party CRISP programmers are reaching retirement age •HMI System – Wonderware (Central Generation and Load Shedding) •Replace to have one system 8 7 8 7/6/2021 5 Why Select New Programmable Logic Controllers (PLC)? •PLCs – Modicon Quantum •>23 Years Old •No longer manufactured 9 SCADA System Replacement Plan •HMI: Replace now under Project No. J‐120 •PLC/Controllers: Replace as part of future CIP projects over the next +25 years 10 9 10 7/6/2021 6 Competitive Procurement HMI/PLC System DCS System HMI Software HMI Vendor DCS Vendor Controller PLC Vendor DCS Vendor Training HMI and PLC Vendor DCS Vendor Control Panel Panel Fabricator Panel Fabricator/DCS Vendor Programming In‐House / Systems Integrator In‐House / DCS Vendor / System Integrator Competed Human Machine Interface (HMI) and Programmable Logic Controllers (PLC) versus Distributed Control System (DCS) 11 Fact Finding Fact Finding PLANNING AND CONSULTANT SELECTION Study and Procurement Jan 2017 –Feb 2018 SCADA Requirements SCADA Requirements ‐Workshops ‐Determined features ‐Procurement process ‐Workshops ‐Determined features ‐Procurement process OC SAN AND CONSULTANT Procurement Documents Procurement Documents Vendor Outreach and Testing Vendor Outreach and Testing ‐Tested vendor HMI with sample PLC logic ‐Tested vendor HMI with sample PLC logic Consultant RFP and Selection of Stantec Consultant RFP and Selection of Stantec Issued RFQIssued RFQ ‐Request for Qualifications (RFQ) ‐Request for Proposals (RFP) ‐Master Services Agreement (MSA) ‐HMI Scope ‐Request for Qualifications (RFQ) ‐Request for Proposals (RFP) ‐Master Services Agreement (MSA) ‐HMI Scope Feb 2018 –Feb 2019 12 11 12 7/6/2021 7 RFQ RFQ Absolute Requirements to Work with Our Existing System Absolute Requirements to Work with Our Existing System QUALIFYING PHASE RFQ/RFP Procurement Process Pass/FailPass/Fail 3 Firms Passed the RFQ Phase3 Firms Passed the RFQ Phase Feb 2019 – August 2019 DCS ABB Emerson Honeywell HMI AVEVA ‐Wonderware Rockwell Automation Trihedral –VTScada Firms Pricing ‐25‐year software licensing ‐HMI replacement (Project J‐120) ‐Total cost to replace all controllers Pricing ‐25‐year software licensing ‐HMI replacement (Project J‐120) ‐Total cost to replace all controllers Jan 2020 – June 2020 July 2020 – Aug 2020 Oct 2020 (Emerson) March 2021 April 2021 – June 2021 TOP QUALIFIED PROPOSERS RankingRanking Classroom Trials Classroom Trials Vendor Interviews Vendor Interviews Ranking / Selection/ Negotiations Ranking / Selection/ Negotiations RFP Response RFP Response Scoring ‐Proposal ‐Non‐ Disclosure Agreement (NDA) ‐Price Scoring ‐Proposal ‐Non‐ Disclosure Agreement (NDA) ‐Price SELECTION PHASE Reference Checks Reference Checks DCS ABB Emerson HMI AVEVA ‐Wonderware Proposers Feb 2021 (ABB) (ABB) (ABB) 13 Master Services Agreement 15‐year agreement (hardware and software) plus 10 years of renewals (1‐to 5‐year increments) •Hardware, software, training, and labor based on unit prices •Work executed through task orders •Guarantees lowest pricing based on verified costs 14 13 14 7/6/2021 8 Three Task Order Types Type 1 – Product and Services Task Order •Supply hardware and software products to OC San •Provide hourly services to support OC San Type 2 –Project‐based Task Order •Implement OC San project scope of work for hardware, software and engineering/programming services Type 3 –Project‐based Task Order assigned to Other Contractors •Provide field‐side hardware and/or field services to CIP Contractors 15 Task Orders •Task Order No. 1: Replace existing HMI software through Project No. J‐120 (price included in proposal) •Future Task Orders •Perform HMI and/or controller programming on future projects •Add system features •Enhanced alarming •Predictive maintenance •Integrate Standard Operating Procedures •Simulation system for training 16 15 16 7/6/2021 9 RFP Scoring Proposer Non‐ Disclosure Agreement Response (Pass/Fail) Price Proposals (Max.40 Points) Project Delivery Response (Max. 10 Points) Technology Response (Max. 50 Points) Total Score (Max. 100 Points) ABB Pass 40 7 32 79 AVEVA Pass 25 6 34 65 17 RFP Evaluated Pricing 18 ABB AVEVA J‐120 HMI Replacement J‐120 Labor and Training $5.6M $42.9M J‐120 Licensing and Components $2.8M $3.2M J‐120 Total $8.4M $46.1M Complete PLC Hardware Replacement $30.2M $11.2M Licensing (25 years)$9.3M $20.9M Graphics Upgrade $0.5M $0.7M Additional Commercial Items $0.0M $0.1M Total Evaluated Price $48.4M $79.0M 17 18 7/6/2021 10 SP‐196 Recommended Action Recommend to the Board of Directors to: A. Award a Master Services Agreement with ABB Inc. for the design, installation, implementation, and maintenance of a process control system; and B. Authorize staff to specify ABB Inc. as the sole source provider for equipment, materials, software and services for control systems on current and future projects; and C. Ratify the addition of ABB Inc. to the list of pre-approved Original Equipment Manufacturers for procurements under $100,000 for equipment, materials, software and services for control systems. 19 Questions ? 20 19 20