Course 1-Day 2 High-Tech Operator Certificate Program Course 1: Treatment and Distribution.

Course 1-Day 2

High-Tech Operator Certificate Program Course 1: Treatment and Distribution

Copyright © 2009 AWWA 2

● This is day 2 of the first course in a series of three that leads to a High-Tech Operator Certificate.

● Today we’ll look at the components of a SCADA system, the facilities/environment the system requires, and the benefits it provides.

Welcome Back


Before we begin let’s review

● What did you learn yesterday?

● Introduce yourself

● Your name

● Where you are from

● Share one thing from yesterday that really stuck out for you

Introductions and Review


By the end of today, you will be able to:● Describe the 4 basic components of a SCADA system and

their primary functionality

● Communicate the difference between control modes and the value of each

● Explain the value of collecting and evaluating trending data

● Discuss alarm management as used by the high-tech operator

● Identify the differences between various organizations that generate industry standards used by high-tech operators

● Describe the requirements of SCADA system components

Goals


● Welcome Back & Review

● SCADA Systems - Function/Operation

● Control Modes

● Tracking Process Performance

● Alarm Management

● Standards

● Control Rooms, Environments, Enclosures

● Course Conclusion

Agenda Day 2


SCADA - Overview

● What is SCADA?

● Supervisory Control And Data Acquisition: A large-scale, distributed measurement and control system that performs data collection and control at the supervisory level

● Where is it used?

● To control all kinds of processes

● Why use SCADA?

● Real-time monitoring and control

● Improved efficiency


SCADA – What does it do?

● A SCADA system

● Collects information

● Transfers it back to a central site

● Carries out necessary analysis and control

● Displays this data on a number of operator screens

● Monitors and controls a plant or equipment

● Automatic or operator initiated commands


SCADA vs. DCS

● DCS

● Distributed control system

● Usually located within a confined area

● Uses high-speed communication (LAN)

● Uses a significant amount of closed loop control

● SCADA

● Centralized control system

● Covers larger geographical areas

● Uses a variety of communication links (radio)

● Closed loop control is not often a high priority


SCADA – Command Central

From this

To this


SCADA – 4 Kinds of Components

● Field Instrumentation and Sensor Devices

● Remote Telemetry Units

● SCADA Master Stations

● Communication Network


SCADA - Field Instrumentation

● Field Instrumentation refers to the sensors and actuators that are directly connected to the plant or equipment

● They generate the analog and digital signals that will be monitored by the Remote Station

● Signals are also conditioned to make sure they are compatible with the inputs/outputs of the RTU or PLC at the Remote Station


SCADA Field Devices

SCADASystem

Inputs Outputs


SCADA - Remote Telemetry Units

● The field devices are connected to the system through Remote Telemetry Units (RTUS)

● Receive data from sensors and iver commands to control devices

● Have microprocessor s capable of executing simple programs autonomously

● Communicate with Human – Machine Interfaces (HMI), Historians, Engineering Workstations, and Master Units

Receive data deliver commands

microprocessors

Communicate


SCADA - What does an RTU do?

● An RTU scans its inputs

● It processes changes of state, times-tamps changes, and stores data awaiting polling from the SCADA master

● When polled by the SCADA master, it responds to the request, which may be as simple as "give me all your data" to executing a complex control function


SCADA – Master Station

● The Master Station is the system’s central processor

● Provides a human interface to the system

● Automatically regulates the managed processes in response to sensor inputs

● Continuously monitors all sensors and alerts the operator when there is an “alarm”

● Presents a comprehensive view of the entire managed system

● Presents more detail in response to user requests

● Processes data gathered from sensors

● Maintains report logs and summarizes historical trends

human interface

sensor inputs

alerts

comprehensive

more detail

report logs summarizes


SCADA – What does a Master Station do?

● Communicates with the RTU/PLC in the field and the HMI software running on workstations

● Dual-redundant or hot-standby configurations provide continuous control and monitoring in the event of a server failure

● Varies in size and complexity

● May be a single PC

● May have multiple servers, distributed software applications, and disaster recovery sites


SCADA – Human – Machine Interface

● The HMI graphically presents information in a schematic of the process being controlled

● Workstation HMI display all processes

● Local panel HMI display only processes in the immediate area

● HMI graphics include real-time data (run status, flow rate, etc.) obtained from the Master Station

● Includes a drawing program for modifying the graphics


SCADA – An HMI Example

● Continuously monitors all sensors and alerts the operator when there is an alarm

● Comprehensive view of single reference point

● Performs data processing on information gathered from sensors


SCADA – What is telemetry?

● The function of transmitting and receiving data over a medium

● Data are measurements (e.g., voltage, speed, flow) or statuses (e.g., on, off, open, closed)

● Data are transmitted through a medium such as cable, telephone or radio

● Since information usually comes from multiple locations, a way of addressing these different sites is incorporated in the system


SCADA – Communication

● RTU to Master Station communication can use one or more technologies

● Serial cables

● Local Area Networks (LANs)

● Phone lines

● Radios

● Internet

● Communication with critical processes/sites often uses redundant paths or communication technologies


SCADA – Communication Network

Redundant Core Switches

HistorianServer

Gateway to CMMSand other applications

Firewall

To Internet

WorkstationRedundant SCADA

Server Pair

Switch (typ)

OIT WirelessAccess Point

RedundantCore Network Comm Server

OIT

RadioTransceiver

MAJOR FACILITY

(HUB)

Modem

PLC

RadioTransceiver

Workstation

DSLModem

CellularTransceiver

DSL

RadioTransceiver

REMOTESITES

RTU

Radio

Radio

Cellular

CellularTransceiver

Phone


SCADA – Control Hierarchy

● Control the entire treatment and distribution process

● Can run completely automatically

● Can manually override the automatic controls from the master station

Corporate LAN

Data

Supervisory LAN

Control WAN

Corporate Level

RTU or PLC RTU or PLC

SCADA Master

SCADAWorkstation

Supervisory Control &Monitoring Level

Direct Control & MonitoringLevel

Data

CMMS, AM/FM, GIS,etc.

Central IntegratedDatabase

Financials, HumanResources

Corporate Workstation

SCADA Historian Process Optimisation

Device Level

Fieldbus (Profibus,DeviceNet, etc.)

PIT FIT LIT DIDO

PT FT LT DIDO

Firewall

4-20 mA

FY


SCADA – The System

Redundant Core Switches

Historian ServerTerminal Server

CMMS

Electrical Sys SCADA

LIMS

To Internet

Thick Client

Redundant SCADA Server Pair

Switch (typ)

Thin Client

Redundant Core Network

Collection System Communication Server

Firewall

OIT

PLC

From 900MHz Transceiver

From Cellular Transceiver

From DSL Modem

From Collection System

PLC

Historian Server• Records and stores data • View historical or real time data• Analyze plant intelligence

Terminal Server• Bidirectional channels• Aggregates multiple communication channels together

Programmable Logic Controller • Digital computer• Used to automate industrial processes• Multiple inputs & output arrangements

Human-Machine Interface• Input, user directs the system• Output, system complies w/use

Thin Client• Conveys input and output between users and server • Processing occurs on server

Thick Client• Has application software loaded• May have data stored• Allows data/application uploads

Redundant SCADA Server Pair• Duplication of critical functions• Work in parallel•Fail-safe back-up

Other Destinations• CMMS• Electrical System SCADA• LIMS

Communication Server• Carrier-grade common platform for wide range of communication applications


SCADA – What do Redundant Servers do?


SCADA – What does a Historian do?

Provide long-term, on-line storage of historical process data that is utilized to support business decisions

Performed as close as possible to the data source to minimize the possibility of data loss

Historian

Data Capture Program (DCP)

Process Control System

(PCS)

Controls and monitors the output to the Historian




● Control Modes



● Standards



Agenda Day 2 – Control Modes


Control Modes – Local

● Local – within sight of the equipment, usually includes controls for only a single device

● Manual – operator action required for every change (except permissive initiated change)

● Automatic – feedback loop used to initiate change


Control Modes – Remote

● Remote – location does not matter; usually includes controls for several devices

● Manual – operator action required for every change (except permissive initiated change)

● Automatic – feedback loop used to initiate change




● Control Modes



● Standards



Agenda Day 2 – Tracking Performance


Tracking Performance - Trending

● Live processes - useful for seeing results of a change made or anticipating a future change

● Historical data - useful for assessing impact control actions had under specific conditions and understanding how processes behave over time

● Multiple variables - usefulfor seeing interactions between process variables and/or control actions

Across Time

Water Demand

Historical Usage

ProjectedProjected High

Across Time

Water Demand

Historical Usage


Across Time

Water Demand

Historical Usage



Tracking Performance – Old Technology

● Circular or strip charts

● Limitations

● No opportunity to select trending data

● Can’t zoom in on specific times for more detail

● Can’t narrow range for a closer look


Tracking Performance – New Technology

● Computer-based

● Access to real time data

● Access to historical data through historians

● Operator configurable display data


Tracking Performance – Line Graph

March 2008

0.02

0.5

0.14

0.26

0.38

Drinking Water Turbidity

NTU


Tracking Performance – Bar Graph

Water Filters


Tracking Performance – Layered


Tracking Performance – Reports

● Reporting

● Data collection and recording

● Data manipulation

● Data interpretation

● Old technology - operator entered readings; manual calculations and results entry

● New technology - electronic reports, with format set, required data fields identified and calculations included


Tracking Performance – Reports

● Reports can be standardized

● Reports can be customized

● Reports can be ad hoc

Historian records the data

RTU collect the data

Report tool processes the data




● Control Modes



● Standards



Agenda Day 2 – Alarm Management


Alarm Management

An effective alarm management system will:

● Be available at operator workstation

● Present alarms in and at a rate that can be handled by the operator

● Direct the operator’s attention to the most important problem using a to indicate the alarm’s importance

● process and systems alarms

● Be enabled and provide notifications via a variety of high-tech devices

● Manage nuisance alarms alarms are displayed

● Provide a alarm analysis

every

real time

Separate

Web

Before

historical

priority system


Alarm Management – Process/System

● Process alarms indicate problems with equipment or measured variables (e.g., flows, pressures, analyzed characteristics)

● Usually indicated on the associated process graphic

● System alarms indicate hardware or networking problems

● PLC or RTU failure

● Communication failure


Alarm Management – Old Technology

● Announced by alarms, horns, flashing lights

● Presented only at alarm annunciation stations

● No record of alarm response

● No alarm priority notification

● Nuisance alarms required same initial response as other alarms


Alarm Management – New Technology

GoodPlant Area AHi/Hi991Arm Torque is too high, may cause damage12/28/200712:25:40 PM

ACK 12:28:32 PMGoodPlant Area AHi572.46VCR_Pump okay now12/28/200712:24:05 PM

GoodPlant Area AHi/Hi77/+Awx\Deviation\temp\HiHi+/12/28/200712:24:10 PM

ACK 12:28:32 PMGoodPlant Area BHi691Valve 3 pressure exceeds 9012/28/200712:24:10 PM

ACK 12:28:32 PMGoodPlant Area BHi/Hi891PSI in tank 1 is high12/28/200712:24:10 PM

Bad-SignalPlant Area BHi56.76VCR_Station Value exceeds 6.212/28/200712:24:10 PM

GoodPlant Area BLo/Lo32/+Awx\limit\temp\LoLo+/12/28/200712:24:10 PM

AcknowledgedQualityAreaTypePriorityValueDescriptionDateTime Time Date Description Area QualityValue AcknowledgedTypePriority

Acknowledge Reset

Describes why alarm was triggered

Color Coding

Red bar/white text = Alarm triggered

White bar/red text = Operator acknowledged not resolved

Green bar/white text = Resolved

Device location

Quality of signal

Nuisance alarm

System recorded time and date




● Control Modes



● Standards



Agenda Day 2 – Standards


Standards – IEEE

● Institute of Electrical and Electronics Engineers

● Consensus-based industry standards involving today's leading-edge electro-technology

● www.ieee.org or http://standards.ieee.org

http://www.ieee.org/

http://standards.ieee.org/


Standards – ISA

● Instrumentation, Systems, and Automation Society

● Symbols and nomenclature, equipment safety in non-hazardous and hazardous environments, communications standards

● www.ISA.org

http://www.isa.org/


Standards – NEMA

● National Electrical Manufacturers Association

● Environmental ratings and requirements

● Three main areas of focus

● Developing standards and reducing market barriers

● Influencing public policy

● Tracking the economy

● www.nema.org

http://www.nema.org/


Standards – ANSI

● American National Standards Institute

● Compiled standards from the above organizations

● www.ansi.org or http://webstore.ansi.org

http://www.ansi.org/

http://webstore.ansi.org/


Standards – AWWA

● American Water Works Association

● www.AWWA.org

● Over 140 Water Industry Standards

● Prophylaxis

● Ductile-iron pipe & fittings

● Steel pipe

● Concrete pipe

● Asbestos-cement pipe

● Valves and hydrants

● Pipe installation

● Groundwater and wells

● Filtration

● Softening

● Disinfection chemicals

● Coagulation

● Scale & corrosion control

● Taste & odor control

● Disinfection of facilities

● Meters

● Service lines

● Plastic pipe

● Storage

● Plant equipment

● Utility management

http://www.awwa.org/


Standards – Benefits

● Standards foster:

● Sound engineering practices

● Increased product quality and safety

● Reduced risks

● Reduction of misunderstandings

● Protection against obsolescence

● Other benefits:

● Market growth for new and emerging technologies

● Reduced development time and cost

● Decreased trading costs and lowered trade barriers




● Control Modes



● Standards



Agenda Day 2 – Control Rooms, etc.


Environmental Risks – Temperature

● Excessive temperatures

● Burn up, fail to perform properly, or weaken and fail later

● Freeze up and fail

● Swelling and shrinking leads to cracking

● Metal movement creates opening for dust and buildup of corrosion creates weakening connections

● Some solutions beyond HVAC

● Fan or heat exchanger cooled enclosures


Environmental Risks – Moisture

● Moisture problems cause three kinds of damage

● Short circuits

● Corrosion

● Swelling


● Humidity-waterproof enclosures and sealed cabinet penetrations

● Select materials that are manufactured using conformal coatings and airtight seals


Environmental Risks – Corrosion

● Corrosion problems are site specific

● Hydrogen sulfide is the most common corrosive


● Corrosive atmospheres - sealed enclosures and conduits

● Instrument enclosures should have an appropriate NEMA rating


Environmental Risks – Nature

● Static Electricity

● Lightning Strikes

● Ground Potential Rise (GPR) Events

● Power Surges




● Control Modes



● Standards



Agenda Day 2 – Course Conclusion


Review & Evaluations

● Review

● Identify 2-3 things we discussed today that were key information for you

● Identify 1-2 things you would like to know more about

● Share what you wrote with other members of your table

Course 1-Day 2 High-Tech Operator Certificate Program Course 1: Treatment and Distribution.

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Transcript of Course 1-Day 2 High-Tech Operator Certificate Program Course 1: Treatment and Distribution.