SCADA Upgrades to Otay Water Treatment...

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SCADA Upgrades to

Otay Water Treatment Plant

2012 ISA Water & Wastewater and Automatic Controls SymposiumAugust 7-9, 2012 – Orlando, Florida, USA

Speaker: Dr. Noune Garounts

2012 ISA WWAC Symposium Aug 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.


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

2012 ISA WWAC Symposium Aug 7-9, 2012 – Orlando, Florida, USA

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

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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.

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Existing Otay WTP

• The Otay water treatment plant (WTP) was originally built in 1979 and the plant was last upgraded and expanded in 1986.

• 31 MGD Conventional

• 2 Flocculation/

Sedimentation Basins

• 16 Self-Backwashing

Filters (6 gpm/sf)

• 2 - 6.9 MG Clearwells

• Free chlorine added at end of sedimentation basin

• Ammonia added at end of filters


Existing SCADA Control Room

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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

• 3rd 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

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Otay Water Treatment Plant Phases

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Chlorine Vapor Scrubber

Clearwell Storage

Phase I

Phase II


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

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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.

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Work in Progress

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Work in Progress

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SCADA Control Room in Operation

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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.

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Construction Challenges

• Maintaining Operation throughout Construction

• Major Rehabilitation to Existing Filters

• SCADA System Upgrades/Transition

• Extensive Electrical Relocations

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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

•

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Feedback From the Operators

• 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.”

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• Main Control Room improvement was great change for the operators.

• The operation of the Plant is more efficient and effective.


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.

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Phase I and II Upgrades Project Completion

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Questions…

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SCADA Upgrades to Otay Water Treatment...

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