SCADA Upgrades to Otay Water Treatment Plant

Transcription

1 SCADA Upgrades to Otay Water Treatment Plant Standards Certification Education & Training Publishing Conferences & Exhibits Speaker: Dr. Noune Garounts 2012 ISA Water & Wastewater and Automatic Controls Symposium August 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. 2

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 3

4 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 4

5 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. 5

6 Existing Otay WTP The Otay water treatment plant (WTP) was originally built in 1979 and the plant was last upgraded and expanded in MGD Conventional 2 Flocculation/ Sedimentation Basins 16 Self-Backwashing Filters (6 gpm/sf) MG Clearwells Free chlorine added at end of sedimentation basin Ammonia added at end of filters 6

7 Existing SCADA Control Room 7

8 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 3 rd 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 8

9 Otay Water Treatment Plant Phases Chlorine Vapor Scrubber Clearwell Storage Phase I Phase II 9

10 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 10

11 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. 11

12 Work in Progress 12

13 Work in Progress 13

14 SCADA Control Room in Operation 14

15 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. 15

16 Construction Challenges Maintaining Operation throughout Construction Major Rehabilitation to Existing Filters SCADA System Upgrades/Transition Extensive Electrical Relocations 16

17 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 17

18 Feedback From the Operators Main Control Room improvement was great change for the operators. The operation of the Plant is more efficient and effective. 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. 18

19 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. 19

20 Phase I and II Upgrades Project Completion 20

21 Questions 21