that won’t break the bank · 2016-11-15 · helix’s scada modernization • 1986 vax , rtus and...
TRANSCRIPT
AWWA Conference Spring 2016
Three SCADA Technologies
That Won’t Break the Bank
Helix Water District
• 1885 Cuyamaca Water Company
• East County of San Diego
• 106 MGD WTP / Ozone
• 50 Site distribution system
• System storage of 68.5 MG
• 50 square miles
• 268,000 population
• 722 miles of pipeline
• Supply three other districts
• 3 Connections
• Up to 36 MGD
Helix’s SCADA Modernization• 1986 VAX , RTUs and phonelines
• 1996 – 1998 Wonderware TP / Dist
• 1998 to 2002 plant expansion
• 2002 – 2004 MCC PLC bricks project
• 2006 – 2007 Master Plan New Data Historian
• 2009 New SCADA Cluster
• 2010 Ignition SCADA and use of OPC-UA
• 2013 – 2014 Radio pilot project
• 2014 – 2015 Radio project phase one
• 2015 – 2016 Radio project phase two 3
Water Utilities Need Better Solutions
• The utility’s informational needs
• Stringent regulation
• Better summary reports
• Better historical storage
• Economic pressures
• Drought and conservation
• Fixed cost and rates
• Better business model on purchase
• One that doesn't age like legacy systems4
SCADA Technology is Expensive
• Designed, built and maintained by outside staff
• Some districts are moving to in house solutions
• Reducing the cost of ownership
– Commercial off-the-shelf (COTS)
– Moore's law
– Open source
• Younger staff understands technology
• Less than 20 cent on the dollar solutions exist
– Solution moves the risks to in house staff
– Phased approach (learn and pay as you go)
5
Conversation with a SCADA Designer
• Wonderware, AB PLC and Dell servers
– Vary any one and they ask “what are you doing?”
– Stable designs but they use very old technology
– Designer’s, not the utilities best interest
– May not be the most open, powerful or cost effective
• Understanding the long term cost of supporting a
system like this
• A paradigm shift may be a good thing
6
Conversation with a SCADA Integrator
• Real world SCADA outside support person
• SCADA integrators need to make a profit
• Won’t recommend $99 PLC
• My programing fee = the PLC cost
7
SCADA software $60K
IWR Radio $1,200
SLC504-L541 $3,920
1746 four Ch AI $1,340
1746 Gateway $5,091
RS500 Pro $4,190
InSQL $$,$$$
About 1/10th the Cost
SCADA software $6K
Radio $89 to $139
DL250 CPU $286
AI $83 to $207
MB Gateway $189
Free to $395
SQL Historian free
Money saved allows us to fix other issues
Helix Legacy Helix Now
http://www.1sourcedist.com
http://www.automationdirect.com 8
Three Parts of a SCADA System
• Central hardware and software
– Including data historian
• Communication network
– TP Ethernet cable and fiber
– Dist. wireless or radio
• Programmable Logic Controller
HWD PLC Infrastructure
• District PLC and radio 1998 – 1999
– Fifty Direct Logic 250 PLCs
• Plant upgrade 1998 – 2002
– Eleven Direct Logic 340 and 450 PLCs
– Now considered legacy PLCs
10
Current Low Cost PLC Options
• Not from the big four
– AB, Schneider Electric, GE, or Siemens
– Not value based automaton providers
– Multinational companies
• Lower cost at the PLC level
– Redesigned CPUs
– Micro PLCs
– Stackable PLC
– PLC and HMI in one unit
Legacy Direct Logic 450 PLC
12
Low Cost Do More Replacement
13
3
PLC Replacement Side by Side
14
15
Next Generation of IP Radios
• Designed for WISP market
• Easily interfaces to SCADA
• Higher power radio and high gain antennas
• Bandwidth supports video on demand
• Powerful, secure and very low cost
• Web page administration
• Power over Ethernet
• Several good vendors
• Radio cost $89 to $300
• Real throughput 30 to 100 Mbps
• Can view and edit ladder remotely
• 802.11 G/N/AC
• Antenna diversity
HWD Ethernet Radio Network
16
Radio Configuration and Antenna
Alignment
Requires direct line of sight
Rifle Scope on T-Square = $200
Use of red balloon = $10
18
Antenna Alignment Tool
19
RF Armor Antenna Shield
20
• Reduces unwanted
RF interference
• Increases throughput
HWD OSPF Mesh Network
2121
SCADA Technology Time and Money
• 1986 BBI VAX based $1.2M
• Full turn key system
• 1997 Wonderware $335K
• BBI tag-server issues (16/32 bit)
• Full system done in house
• 2007 IA SCADA total cost since ‘07 $47.2K
• Used AB and Modbus UA tag-server
• Open systems reduce investment losses
• Full system done in house
• Reused PLCs and radios (phased plan)22
Our New SCADA System
• Centrally administrated
• Web based (uses an Apache web server)
• Licensed by the server and not tags or clients
• High availability built in
• Cross platform
• Totally open database options
• Zero client software to install or license
• Open communications UA with DA support
• Lower lifecycle cost compared to other options23
NEW SCADA TECHNOLOGY
24
Lakeside Water District
• Lowest water rates in San Diego county
• Very small district
• Resourceful
• Narrow radio re-banding causing issues
• Legacy Wonderware software
• Downtime in the system
• Radio proof of concept
– Three site plan
25
Lakeside Water District
• Not line of site (used tank as a repeater)
• Lakeside staffing
– Distribution superintended
– Six Utility workers
• one with some electrical experience
Path Doesn’t Have Line of Site
27
28
Lakeside Water District
• Work started Oct 2015 (two radio sites)
• Proven the radio links work
• SCADA communicating over the links
• Logging tank levels
• MySQL used as the data historian
• Converting HWD pump station screen
• Adding HOA contact blocks to the PS
• 11 sites with radios, 4 more in progress
29
Questions?
Three SCADA Technologies
That Won’t Break the Bank
30