Download - Cs09 Detroit Water Sewage District Psug 2012
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 1/33
Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.
City of DetroitPlantPAx Process Library and WWW Accelerator Toolkit Save $ for Integrator and City of Detroit
Hassan AjamiPCI General Manager
Date – 11/5-6/2012
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 2/33
Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
PCI is a System Integration firm established in 2000 to serve the MetroDetroit region.
Offices in Detroit, Cleveland, Louisville and Shreveport.
Industry focus is on Water/Wastewater and Automotive
Involvement in projects encompasses both design and constructionphases.
Clients include both public and private utilities, major automotivecompanies, and petro-chemical companies.
Process Control &Instrumentation
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 3/33
Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
The Detroit Water and Sewerage Department (DWSD), one of the largestwater and sewer utilities in the United States, has a rich history as a publicutility dating back to 1836.
Serves 35% of Michigan’s Population including Detroit and 76 other communities.Fresh Water System - 5 water treatment plants pump an average of 596 million gallons of clean drinking water each day. Maximum capacity1.2BGD
Wastewater System - Treats an average of 707 million gallons of flowper day. Maximum capacity 1.65BGD
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 4/33
Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Process Networks and SCADA SystemsDivision – WWTP & CSO Equipment
Operational Support:21 freshwater and 10 wastewater pump stations5 Water and 1 Wastewater treatment plant5 Combined Sewer Overflow basins
Process Controls equipment from Emerson/Ovation & Rockwell/AB > 95%21,000 Hard I/O Points > 200,000 Total Points282 PLC/Controllers
92 PC Workstations
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 5/33
Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Common industry situation
Multitude of HMI solutions:Ovation, Wonderware, Ifix, RSView32
Large variety of systems integration implementationsDisparate process control implementationsUsually only hardware platform specifiedPLC Code developed using only written narrativesNo standard control software strategies
No standard graphics, other than color standardImplementation varies by Contractor/SI/Programmer
5
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 6/33
Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Goals - Accelerator Tool kits
Reduce the engineering time requiredto create standard, repeatable process applicationsYou can focus your energies on the custom aspects of your applications.
Increase control system quality and reliability .The reuse of well tested code conforming to industry standards reduces the likelihood of
code bugs.Drive logical and visual consistency
The Process Library aids in producing standard Graphics formats that increase theconsistency of your HMI thus reducing the need for Operator Training.
Superior diagnostics
Built in process diagnostics will make applications easier for operators and maintenance totroubleshoot and debug without requiring PAC programming tools
Scalability – You can build ever larger systems using the same reusable modules.
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 7/33
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 8/33
Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 8
Contents of an Accelerator
• An Accelerator provides a package of tools, which significantly simplifies theDesign, Manufacturing, Start-Up andSupport of Rockwell Automationcontrol systems.
• An Accelerator CD provides the – selection tools and – basic panel layout, – wiring diagrams, – Logix program,
– HMI screens and – Quick Start manual
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 9/33
Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 9
The Process LibraryHigh-efficiency suite of Control Modules
Mode Selection
Standard AlarmAI w/ Scaling & Alarms
DI w/ Alarms
Single-Speed Motor
Permissives with Bypass
Protectives with First-Out,Bypass
Run Time and StartAccumulator
Re-start Inhibit for LargeMotor
Date/Time Blocks • Solenoid-Operated 2-stateValve
• Motor-Operated 2-stateValve
• PIDE-based PID withStandard Modes andDeviation Alarms
• Analog Output
• Variable-Speed Drive(e.g., PF70-style)
• 2-Speed Motor
• Reversing Motor (e.g., FVR)• Pulse-Input flow meter dosing
with pre-act and in-flightadjustment
• Analog-Input flow meterdosing as above
• Weigh-Scale dosing (Loss-In-
Weight and Gain-In-Weightsupported)
• Controller CPU Utilization
• Hand-Operated ValveMonitor
• Hand-Operated MotorMonitor
• Cascade and Ratiosupported PID
• Advanced AI with HighRate of Change Alarm,Square Root Extraction,and Deviation Alarms
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 10/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Benefits of Using Accelerator Toolkit
Standardized scalable integrated architectureSingle hardware and software platformStandardized controller logic and HMI graphics
Single Scalable HMI Platformbased on FactoryTalk
FactoryTalk SOA - Services Oriented ArchitectureStandards Based – Use of common reusable code and engineering
templates
Creates standards for HMI graphic symbols and operation
Significantly enhanced systems diagnosticsLeverages diagnostics built into AOP and HMI Templates
10
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 11/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Case Study City of Detroit- DWSD
PC-761 Control System Upgrade at 2 CSO basinsReplacement of obsolete Bailey DCS system
Issues
Obsolete WorkstationSpare Parts AvailabilityOld Tape BackupLack of Local SupportComplicated ABB PLC Interface between Bailey & Rotork valvesystem
11
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 12/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Hubbell/Southfield CSO
Hubbell-Southfi eld CSO RTBThe Hubbell-Southfield CSO RTB is one of DWSD’s most active, longest operating CSO facilities and the largest on theRouge River. Since August 1999, it has been effectively capturing and treating combined sewage through screening,settling and disinfection to meet discharge permit requirements that protect public health. Sized to fit into the available
land and site constraints, the basin has a 22 million gallon storage capacity. Located next to the Tournament PlayersChampionship Golf Course (TPC) in Dearborn, this RTB serves as an example of how these facilities can be goodneighbors and blend in with the surrounding environment. The facility features an innovative design component thatenables three different operational modes within the RTB and prevents resuspension of solids during large storms withhigh flow rates.
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 13/33
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 14/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Existing Bailey Infi 90/OIS40
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 15/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Control System Options
1. Bailey Upgrade
2. HMI 3rd Party Upgrade with Bailey hardware
3. Rip & Replace1. Emerson Ovation DCS2. Rockwell/Allen Bradley3. WonderWare/Allen Bradley4. Intellution/Allen Bradley
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 16/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Considerations
Cost (Initial & Life Cycle)
Functionality - DCS vs PLC
MaintainabilitySystem Downtime
Support & Support Options
How many platforms to support:PartsTraining
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 17/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
PC-761 Contract
Scope:Hubbell Southfield CSO Total Points 643Puritan Fenkell CSO Total Points 374
PlantPAx solution including:Redundant ControLogix L73 PAC with Enhanced RedundancyRedundant Ethernet Network- Stratix 8000Redundant FTViewSE Windows 7 WorkstationsProcess Library V1.5
W/WW Accelerator ToolkitRotork Master Stations Added Prosoft Modbus CommsInterface to DWSD Ovation System
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 18/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Water/WastewaterAccelerator Toolkit Implementation
Utilized 12 Symbols and FaceplatesPump, ValveMO, ValveSO, ValveHO, Conveyor, Mixer, Agitator,P_Ain, P_Din, P_AinAdv, P_AinDual, P_AoutRequired some modification of graphics to meet DWSD HMI
standardsUtilized Chemical Feed and Lead/Lag pump application
Editing the Toolkit StandardRed vs Green for RunFace Plate Control Modes-symbolsRockwell Enhanced Toolkit – Added Color Change Tool
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 19/33
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 20/33
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 21/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
New Rockwell Overview ScreenHubbell Southfield
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 22/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Flushing System Screens
22
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 23/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Chemical Feed Control Screen
23
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 24/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Lead / Lag Pump Control Screen
24
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 25/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
System Status Screen
25
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 26/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Construction Issues
Failed field wiring in existing conduit duct bank Added Head Works Building PLC/Panelview Control Panel with fiber optic connectivity.
Instrumentation and final elements failuresNot in original project scopeDelayed project construction
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 27/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Results-Total construction costssignificantly below estimate
Reduced Deployment Time• Resulted in a 50 percent reduction in design time, contract oversight, and post-contract
documentation and support.• Provided process control with advanced networking and diagnostic capabilities• Increased access to process data for better preventive and predictive maintenance
Reduced Engineering Hours and Costs• Saved estimated $120,000 in configuration and systems integration time• Saved $90,000 in factory-acceptance testing and Startup/commissioning
Drove standardization for DWSD wide graphics FTViewSE/ME platform
Advanced HMI without the associated development cost
Software configuration that is fully documented and tested
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 28/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
New Operators Control Room
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 29/33Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
New PLC Panel in Control Bldg.
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 30/33
Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
New PLC Head Works Control Panel
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 31/33
Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
Water Wastewater Accelerator Toolkiton the AB.com IA Tools Website
W/WW Accelerator Toolkit CD-IASIMP-SP012B
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 32/33
Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.
City of Detroit DWSDSuccess Story
Further documentation on:Hubbell Southfield CSOPuritan Fenkell CSO
Publication Number WATVP-AP014A-EN-P
April 2012
32
7/28/2019 Cs09 Detroit Water Sewage District Psug 2012
http://slidepdf.com/reader/full/cs09-detroit-water-sewage-district-psug-2012 33/33
QuestionsHassan AjamiProcess Control & Instrumentation [email protected], MichiganPh 313-874-5877
PlantPAx Process Library