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Brady Bell, Donohue
MWEA Process Seminar
November 12, 2015
SCADA SYSTEMS -
CHOOSING YOUR PATH FORWARD
MWEA 2015 Page 2| November 12, 2015
Acknowledgements
Rockwell Automation
WIN-911
Google Photos
Schneider-Electric
GE
Iconics
MWEA 2015 Page 3| November 12, 2015
Presentation Outline
Why Talk SCADA
SCADA Defined
Steps to Choosing Your Path Forward
Inventory Existing System
Network Architecture
Define Goals
Research & Develop Alternates
Prepare Planning Level Cost Opinion
Develop Approach for Replacement/Upgrades
Why Talk SCADA?
MWEA 2015 Page 5| November 12, 2015
Key to TP Removal
Why Talk SCADA?
Aging Control Systems
Compatibility
Reliability
Expensive to Maintain
• Hardware
• Software
• Specialized Staff Allen-Bradley PLC5/80 1785-L80E Controller List Price: $50,500
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Key to TP Removal
Why Talk SCADA?
Efficiency
Electrical & Chemical Usage
Labor
Quality
Troubleshooting
Planning for the future
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Level
SCADA Defined
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Key to TP Removal
What is SCADA?
Supervisory Control And Data Acquisition Typically – Lower Level Controls Completely Automated
Supervisory Control
• Operations Making Higher Level Decisions, Adjust Set Points, etc.
• Using Process Measurement to Adjust Set Point Automatically
Data Acquisition
• Collect Data Automatically
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Key to TP Removal
Supervisory Control Examples
To Control a Parameter it Must be Measured
To Control a Parameter There Must be a Controllable Device (VFD, Valve, Gate Position, etc)
Math and Algorithm Capabilities in PLCs are Unlimited
Add, Sub, Mult, Divide, Square Root, All Trig Functions, Log, Ln and Compute
Controllers range from simple to complex (On/Off, Level, Flow, DO, etc)
Subtract Cruise
Controller Throttle/
Engine
Speedometer
Set Point = 70 MPH
Measured Speed= 65 MPH
Error = -5 MPH More Gas
Controllable Device
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Key to TP Removal Supervisory Control Example Typical Activated Sludge Process
V1
NH3
AIT
Ammonia
AIT
DO
AIT
DO
V2 DO is controlled to set point by the Valve V1 Ammonia can be controlled by changing DO setpoint in a feed forward manner or if Temperature is low by changing set point of the wasting rate to a lower value via Valve V2 (SRT)
FIT
Air Flow
FIT
RAS Flow
FIT
Influent Flow
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Key to TP Removal
Typical SCADA Architecture
Steps to Choosing Your Path Forward
Step 1: Inventory Existing
System
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Key to TP Removal
Inventory Existing System
Hardware
PLCs
Computers & Servers
Network Components
Control Wiring
Instrumentation
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Key to TP Removal
Inventory Existing System
Previous Project Drawings and Shop Drawings
Process & Instrumentation Diagrams (P&IDs)
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Key to TP Removal
Inventory Existing System
Software
SCADA
• Software Revision
• License Information
Historical & Reporting
Alarm
Step 2: Network Architecture
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Key to TP Removal
Network Architecture
How the individual components of the system communicate with each other
Network Diagram
All major components in the system
Physical Media
Fiber, Coax, Cat6, etc
Protocol
Rules Define How Information is Exchanged
Ethernet, DF1, Modbus, DH, etc.
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Key to TP Removal
Example Network Diagram
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Key to TP Removal
Network Architecture
Understand the Network
Distance Limitations
Bandwidth Limitations
Limited Number of Devices
Compatible Devices and Gateways
Step 3: Define Goals
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Key to TP Removal
Define Goals
Current and Future Operational Goals
24/7 Operation vs. Unmanned Shifts
Define Level of Control
Remote Alarming
Remote Access
Cross Training
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Key to TP Removal
Define Goals
Define Critical Areas
Redundancy Requirements
Alarming
Power Recovery
Standardized Control
Security
Research & Develop Alternates
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Key to TP Removal
Research & Develop Alternates
Assess Condition of Existing Control System
Reuse vs. Replace
Upgrade “In-Kind” with Existing System
Potential Cost Benefit for Purchases
Potential Migration Plan Available
Ensure Functionality Meets Goals
Some Features & Benefits May Not “Migrate”
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Key to TP Removal
Research & Develop Alternates
Evaluate Industry Standard Alternates
Don’t be the Guinea Pig
Some Options (Not All Inclusive)
FactoryTalk View by Rockwell Automation
iFix by GE
Wonderware by Schneider Electric
Iconics
Prepare Planning Level Cost Opinion
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Key to TP Removal
Cost Opinion
Create a Bill of Materials & Get Quotes
PLC Hardware
SCADA, Historian, Reporting Software
• Don’t Forget Support
Instruments, etc
Alternates Allow for Competitive Pricing
Estimate Labor Costs for Installation
Estimate Programming Costs
Account for Inflation
Approach for Replacement/Upgrades
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Key to TP Removal
Approach for Replacement/Upgrades
Determine If/How Much Down Time is Acceptable
Sequence To Avoid Rework
Typically Top to Bottom Approach
Utilize Removed Hardware Where Possible
Phase the Replacement/Upgrade to Fit the Budget
Phase With Other Capital Projects Where Possible
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Key to TP Removal
Your Path Forward
Should Provide
Clear Understanding of Current System
Overall Concepts and Goals For Operation
Alternates and Selections
Estimated Cost
Plan for Implementation
Brady Bell, Donohue
MWEA Process Seminar
November 12, 2015
SCADA SYSTEMS -
CHOOSING YOUR PATH FORWARD
