Windsor Water Treatment Plant SCADA and Power Upgrades
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1 Windsor Water Treatment Plant SCADA and Power Upgrades John Stuart COO Windsor Utilities Commission Copyright 2011 Rockwell Automation, Inc. All rights reserved.
2 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 2 Agenda 1. Windsor Utilities Commission Overview 2. SCADA Pre Project Overview 4. Selection Process for SCADA Vendor 5. Deliverables and Lessons Learned
3 Windsor Utilities Commission (WUC) Owned by the City of Windsor Supplies potable water to City of Windsor and Towns of Tecumseh and LaSalle Located on the Detroit River, between Lake St. Clair and Lake Erie Lies to the south of Detroit, Michigan 3
4 Windsor Utilities Commission WUC Fast Facts Total daily treatment capacity: 349 ML (91 MGD) Average daily demand: 160 ML (42 MGD) Maximum daily demand: 280 ML (73 MGD) Peak hour demand: 380 ML (99 MGD) Reservoir storage capacity: 118 ML (31 MG) 71,763 accounts (66,804 residential, 4,959 ICI) Length of watermain: 1,100 km (688 mi) Service population of 270,000 Service area of 280 sq. km. (109 sq. mi.) Number of treatment plants: 2 Number of pumping stations: 3 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 4
5 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 5 Windsor Utilities Commission 2010 Volume Split 2010 Account Split 21% 7% 38% 41% 93% Windsor Residential Volume Windsor ICI Volume Wholesale Volume Active Residential Accounts Active ICI Accounts
6 Windsor Utilities Commission Service Area Copyright 2011 Rockwell Automation, Inc. All rights reserved. 6
7 Windsor Utilities Commission Copyright 2011 Rockwell Automation, Inc. All rights reserved. 7
8 Windsor Utilities Commission A.H. Weeks Water Treatment Plant This state-of-the-art Water Treatment Facility was commissioned in In 2001, the plant was upgraded to use Ozone as the primary disinfectant. The plant has a maximum capacity of 349 million litres of water per day. It requires 29 employees to operate the plant 24 hours/day, 365 days a year A.J. Brian Pumping Station Located across from the A.H. Weeks Treatment Plant, this pumping station was built in Low lift pumps draw water from the river to the A.H Weeks Treatment Plant and in turn, high lift pumps move the treated water to the distribution system. J.F. Cook Reservoir Pumping Station This facility was built in 1973 on Howard Ave. in the south end of the city. It was designed to provide supplemental storage and additional pressure to serve the South Windsor and LaSalle distribution systems. The reservoir stores up to 45 million litres of water. Copyright 2011 Rockwell Automation, Inc. All rights reserved. 8
9 Environmental Scan Increased regulatory pressure Rate pressures Infrastructure funding gap Aging workforce Copyright 2011 Rockwell Automation, Inc. All rights reserved. 9
10 WUC SCADA Circa 2006 Disparate processors and systems distributed across operational space Dated servers Dated hardware No redundancy HMI had been glued together to accommodate various process upgrades occurring after 1994 Operational trending functionality was limited Compliance reporting function was insufficient Copyright 2011 Rockwell Automation, Inc. All rights reserved. 10
11 Project Overview $4M budget 2 year timeframe for implementation No service interruptions during implementation Reduce operational costs Full 2n redundancy Improved reporting Standardization of graphic screens and process logic Control room improvements Utilization of internal resources Phased installation and commissioning Copyright 2011 Rockwell Automation, Inc. All rights reserved. 11
12 SCADA Needs Analysis Performed an industry scan to assess vendors that would meet our needs: Common platform for programming tools and controllers Scalability Redundancy, no single source of failure for hardware and software Remote monitoring Security SAP partner Reporting functionality Audit trail Support Power products expertise Copyright 2011 Rockwell Automation, Inc. All rights reserved. 12
13 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 13 Vendor Selection Rockwell Automation as sole vendor of choice
14 Project Highlights Copyright 2011 Rockwell Automation, Inc. All rights reserved. 14
15 SCADA Infrastructure Copyright 2011 Rockwell Automation, Inc. All rights reserved. 15
16 Network Architecture Copyright 2011 Rockwell Automation, Inc. All rights reserved. 16
17 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 17 Typical Control Layer on ControlNet AJ Brian Pumping Station RSNetworxs
18 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 18 Redundant Control System Reduction in number of sub systems Ethernet communications backbone ControlNet for I/O Separate UPS power feed
19 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 19 Redundant Server Rooms Construction of two new server rooms Secured access to rooms Supports remote access and remote management Independent UPS and HVAC
20 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 20 Revised Control Room Dual monitors for each station Large overview monitors Secure log on for each operator
21 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 21 Wireless Tablets Remote plant access Security Maintenance
22 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 22 Wi-Fi Gear Panels CISCO routers & switches CISCO Wi-Fi
23 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 23 Medium and Low Voltage Equipment AB CENTERLINE low voltage MCC AB IntelliCENTER software AB PowerFlex AC drives
24 Medium and Low Voltage Equipment Copyright 2011 Rockwell Automation, Inc. All rights reserved. 24
25 Medium and Low Voltage Equipment Copyright 2011 Rockwell Automation, Inc. All rights reserved. 25
26 Chemical Filtration Report Copyright 2011 Rockwell Automation, Inc. All rights reserved. 26
27 Sample Reports Generated by VantagePoint Copyright 2011 Rockwell Automation, Inc. All rights reserved. 27
28 Sample Trend Copyright 2011 Rockwell Automation, Inc. All rights reserved. 28
29 Delivered Outcomes On budget and on time!!! No service interruptions Expandable platform Quality control audit trail via VantagePoint and AssetCenter 15 year life cycle Common programming standards Elimination of non functional equipment from process logic and HMI Secure network environment modeled to NERC and FERC guidelines Copyright 2011 Rockwell Automation, Inc. All rights reserved. 29
30 Delivered Outcomes Reduction in operating costs Single operator per shift Lone operator/man down system Wi-Fi / tablet Elimination of unnecessary paperwork Perimeter security Customer contact issues resolved Power monitoring Allowing us to participate in Ontario Power Authority program aimed at increasing pump efficiencies Copyright 2011 Rockwell Automation, Inc. All rights reserved. 30
31 Lessons learned Manage sub projects Manage network design and configuration Manage network architecture and purchases early Add slack time in schedule Authorizing authorities Project management and management of expectations Copyright 2011 Rockwell Automation, Inc. All rights reserved. 31
32 ? Questions and Answers Copyright 2011 Rockwell Automation, Inc. All rights reserved.
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