Getting the Most from Your SCADA Data

Transcription

1 Getting the Most from Your SCADA Data Standards Certification Education & Training Publishing Conferences & Exhibits Speaker: Emile Richard 2015 ISA Water / Wastewater and Automatic Controls Symposium August 4-6, 2015 Orlando, Florida, USA

2 Presenter Emile Richard, P.E., Senior Project Engineer 16 years with the Portland Water District (PWD) 31 years of Process Control Experience Manager of PWD s SCADA System & Instrument Group BS/MS Chemical Engineer Aug 4-6, 2015 Orlando, Florida, USA 2

3 Presentation Outline Portland Water District - Fun Facts Why Would Want to Use the Data? Leveraging the SCADA Investment Examples: Wastewater Pump Station Inspections Water Distribution System Monitoring RTU Troubleshooting (One Year Trends) Pump Station Predictive Maintenance Combining SCADA with Lab Data Tips Summary Aug 4-6, 2015 Orlando, Florida, USA 3

4 Portland Water District (PWD Fun Facts) Chartered in 1908 Drinking Water to 11 Communities Serving a Population of 200,000 Primary Water Source Sebago Lake (995 billion gallons, Safe yield 100 MGD) Employees: 178 Customers: 50,000 Connections Drinking Water Treatment Plant: 1 Water Delivered: 21 MGD (130 yrs.) Water Mains: 1000 Miles Wastewater Pipe: 95 Miles Wastewater Pump Stations: 75 Wastewater Treatment Plants: 4 Wastewater Treated: 20 MGD Aug 4-6, 2015 Orlando, Florida, USA 4

5 History of SCADA at PWD Current Statistics 145 PLCs (Built-out) Growing Number of Historian Data Points Issues Managing Data & Network Security New Technology Demand for Remote Access Aug 4-6, 2015 Orlando, Florida, USA 5

6 Why Would You Want to Use the SCADA Data? Leveraging the SCADA Investment Going Beyond the Typical SCADA Functions Make the Data Available to Everyone in the Organization Leverage What If Taking the Data Safely Out of the Control Room May Need to have a Separate Platform (i.e. Data Historian, DMZ, Firewall, Admin Clients, etc.) Taking Your Operation to a New Level of Performance Greater Process Knowledge - Optimization Enhanced Troubleshooting Tools Data Directed Predictive Maintenance Aug 4-6, 2015 Orlando, Florida, USA 6

7 Leveraging the SCADA Investment - Try to Reach Out to All Levels of Personnel Easy to get Managers and Technical Staff to use Historian Harder to get Operations Staff involved The War Room Projector Facilitate the Ability to Look at SCADA Data Continuous Access Fosters Buy-In and Cultural Changes SCADA Guy Attends the Weekly Meetings Eliminate Buy-In Road Blocks Clear Up Issues Quickly John Chief Operator Aug 4-6, 2015 Orlando, Florida, USA 7

8 Example: Wastewater Pump Station Inspections Site Inspection frequency reduced Daily offsite monitoring in the Office Enhanced troubleshooting ability with Data Historian Enhanced emergency response and alarm prioritization with Remote Access Aug 4-6, 2015 Orlando, Florida, USA 8

9 Example: Water Distribution System Monitoring RTU Data - Create Calculated Values From Raw Data Pressure Transient less than a second Technique for capturing data at a Radio Telemetry Site Valve Turning Event (spike was 55 to 85 PSI, Normal Pressure was 78 PSI) Verification of a Normal Maintenance Activity Other Uses: Main Break Analysis Super Bowl TV News Spot Frank Old Salt Aug 4-6, 2015 Orlando, Florida, USA 9

10 Example: RTU Troubleshooting (One Year Trends) 2 Day trend of First Event One Year RTU Loop Time Analysis 1 Day Trend of the Second Event One year trends can yield data patterns not seen on shorter time spans. The use a historian facilitates this kind of analysis. Aug 4-6, 2015 Orlando, Florida, USA 10

11 Example: The Power of Ad-hoc Trends Setup The Tools Get the Right Software Pack the Displays Plant Management Dashboard Developed by the operations engineer Train People How to Create Ad-hoc Trends Scott Operation Engineer Aug 4-6, 2015 Orlando, Florida, USA 11

12 Example: The Power of Ad-hoc Trends Add Data Points That Will Facilitate Ad-hoc Trends (i.e. Plant Flow, Data From Related Sub-Processes, Etc.) User Just has to Click (Select) the Data Points Click on the Trend Icon: Then Look at the Trend Aug 4-6, 2015 Orlando, Florida, USA 12

13 Example: The Power of Ad-hoc Trends Clearly Shows the Relationship between the Raw Water Flow (Blue) into the Plant and the Ozone Destruct Sub-process Aug 4-6, 2015 Orlando, Florida, USA 13

14 Example: Pump Station Predictive Maintenance Aug 4-6, 2015 Orlando, Florida, USA Steve Chief Operator 14

15 Example: Combining SCADA with Lab Data Combining SCADA Data with Lab Data to Create the State MOR Aug 4-6, 2015 Orlando, Florida, USA 15

16 Example: Combining SCADA with Lab Data Developed by the Operations Staff Over 200 Reports Aug 4-6, 2015 Orlando, Florida, USA 16

17 Tips Develop a SCADA/Historian Structure that allows users to access Data at their desktop or remote device Reach Out to the Staff for Ideas Make Sure the Data is Secure (i.e. DMZ) User Training & Mentoring is Critical Aug 4-6, 2015 Orlando, Florida, USA 17

18 Summary All of the previous examples were from employee from all walks of life at the District All of the examples had a direct impact on the business Benefits: Putting the Data to Work Report Generation Decision Making Troubleshooting Merge with Lab Data Predictive Maintenance Remove Barriers Only Limited By User s Imagination Easy to Use Aug 4-6, 2015 Orlando, Florida, USA 18