scada upgrades to otay water treatment...
TRANSCRIPT
Standards
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Conferences & Exhibits
SCADA Upgrades to
Otay Water Treatment Plant
2012 ISA Water & Wastewater and Automatic Controls SymposiumAugust 7-9, 2012 – Orlando, Florida, USA
Speaker: Dr. Noune Garounts
2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA 2
Presenter
• Electrical and Control Engineer for MWH Global Company. More than thirteen years of electrical engineering experience working in Generating stations and electrical substation from 500kV to 4kV, electrical power transmission & distribution, substation & industrial automation projects. Completed several water/wastewater projects that include design, engineering, and contraction support.
• MWH Global is an organization providing strategic planning, design, construction and engineering program management services for projects around the world.
2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA 3
Presentation Outline
• About the Project
• Responsibilities
• Existing Otay WTP
• Existing SCADA Control Room
• Otay WTP Upgrades
• Instrumentation and Control Design
• Network Diagram Upgrade
• Work in Progress
• SCADA Control Room in Operation
• Control System Transition
• Construction Challenges
• Lessons Learned
• Feedback From the Operators
• Conclusion
2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
About the Project
• Client – City of San Diego
• Lower Otay Water Treatment Plant
• Started from 2000 to Ongoing
• MWH: Project Managment, Engineering services, and Service During Construction
• EMA: Instrumentation System Architecture Design and SCADA Integration
• Constructor Western Summitt: Construction Services
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2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
Responsibilities
• Design the Otay Water Treatment Plant Upgrades
• Sub-consultant coordination, including completion of design work within budgetary and schedule parameters.
• Planning, final design, bid support and engineering services during construction. This $25 million project, necessitated to meet and exceed stricter Federal and State drinking water regulations, will provide a state of the art facility with increased performance, capacity, quality and reliability. It will sustain a clean drinking water supply for the ever growing San Diego population.
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2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA 6
Existing Otay WTP
• The Otay water treatment plant (WTP) was originally built in 1979 and the plant was last upgraded and expanded in 1986.
• 31 MGD Conventional
• 2 Flocculation/
Sedimentation Basins
• 16 Self-Backwashing
Filters (6 gpm/sf)
• 2 - 6.9 MG Clearwells
• Free chlorine added at end of sedimentation basin
• Ammonia added at end of filters
2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
Otay WTP Upgrades
The current process improvements were designed and implemented during the Otay WTP Upgrades Phase 1 and Phase 2 project. The plant was designed for a future upgrade to 40 million gallons per day (MGD), with ultimate capacity up to 60 MGD.
• Phase I
• 3rd Flocculation/Sedimentation Basin
• Filter Upgrades
• Pumped Backwash
• New Underdrains and Media
• Filter to Waste
• Inlet Meter
• SCADA System Upgrades
• Phase II
• Chlorine Dioxide Generator and Contactor
• PAC Feed System
• Chemical Feed System
• SCADA System Upgrades
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2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
Otay Water Treatment Plant Phases
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Chlorine Vapor Scrubber
Clearwell Storage
Phase I
Phase II
2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
Instrumentation and Control Design
• Developed P&IDs
• Coordinated with Process, Mechanical, Electrical, and SCADA Integrators (EMA)
• Coordinated with Operators at Otay Water Treatment Plant current conditions of the SCADA.
• Specifying Hardware and Software for SCADA
• Design new SCADA Room with Architects
• Technology selection
• All PLCs were replaced with newest version of standardized PLCs
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2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
Network Diagram Upgrade
• New redundant PLC and remote I/O panels
• Fiber Optic communication system backbone
• Communication equipment upgrades.
• Replacing relays for backwash control for the new filter operations and existing plant facilities.
• New package system PLCs: PAC and chlorine dioxide generator feed systems.
• Signals to the existing antiquated plant Main Control Board were integrated into the new PLC system and incorporated into the new plant SCADA system.
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2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
Control System Transition
• From Chart recorders, lights and switches to server and HMI
• PCS will enable operators to access components of the new system from all HMI workstations
• Improving plant operation by providing multiple access points to the new system
• Provide a fully functional historical database that better prepares the City to meet regulatory requirements, and provide adequate backup and redundancy for the connection point between the existing and new control system
• Filter operation during construction, manual backwash.
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2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
Construction Challenges
• Maintaining Operation throughout Construction
• Major Rehabilitation to Existing Filters
• SCADA System Upgrades/Transition
• Extensive Electrical Relocations
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2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
Lessons Learned
• Needed to coordinate number of the conduits/conductors for I/O
• Existing plant facilities – main control board coordination
• Computer system –locations of servers, workstations, monitors, UPS, fiber optics, etc. and provide power source and CAT6 cabling
• Keep low voltage instrumentation equipment out of high voltage MCCs and panels
• Plan shutdowns required for electrical work, loss of safety alarms
• Provide monitoring for UPS on critical
•
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2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
Feedback From the Operators
• Otay WTP operator comments during construction on filter performance improvements with new pumped backwash system.
• ”It would appear from these data that the new pumped backwash system is providing a significant improvement in filtered water quality. This is definitely a HUGE step in the right direction.”
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• Main Control Room improvement was great change for the operators.
• The operation of the Plant is more efficient and effective.
2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
Conclusion
• Transition plan was implemented successfully
• One server-grade machine has been purchased and installed.
• This machine replaced the existing control room HMI workstation as the connection-point between the existing and new control systems.
• Connected to the Modbus Ethernet ring as well as the TI system, this station was configured for both the Modicon and TI controls.
• This station configured as an interim control system server hosting all HMI workstations, as well as an SQL-based Historian provided robust historian functionality.
• Connected all HMI workstations onto the Ethernet control backbone and synchronize operational displays.
• All PLCs and Workstations were installed, configured, and operated as it was planned.
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2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA
Phase I and II Upgrades Project Completion
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