Cs09 Detroit Water Sewage District Psug 2012

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Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

City of DetroitPlantPAx Process Library and WWW Accelerator Toolkit Save $ for Integrator and City of Detroit

Hassan AjamiPCI General Manager

Date – 11/5-6/2012




PCI is a System Integration firm established in 2000 to serve the MetroDetroit region.

Offices in Detroit, Cleveland, Louisville and Shreveport.

Industry focus is on Water/Wastewater and Automotive

Involvement in projects encompasses both design and constructionphases.

Clients include both public and private utilities, major automotivecompanies, and petro-chemical companies.

Process Control &Instrumentation




The Detroit Water and Sewerage Department (DWSD), one of the largestwater and sewer utilities in the United States, has a rich history as a publicutility dating back to 1836.

Serves 35% of Michigan’s Population including Detroit and 76 other communities.Fresh Water System - 5 water treatment plants pump an average of 596 million gallons of clean drinking water each day. Maximum capacity1.2BGD

Wastewater System - Treats an average of 707 million gallons of flowper day. Maximum capacity 1.65BGD




Process Networks and SCADA SystemsDivision – WWTP & CSO Equipment

Operational Support:21 freshwater and 10 wastewater pump stations5 Water and 1 Wastewater treatment plant5 Combined Sewer Overflow basins

Process Controls equipment from Emerson/Ovation & Rockwell/AB > 95%21,000 Hard I/O Points > 200,000 Total Points282 PLC/Controllers

92 PC Workstations




Common industry situation

Multitude of HMI solutions:Ovation, Wonderware, Ifix, RSView32

Large variety of systems integration implementationsDisparate process control implementationsUsually only hardware platform specifiedPLC Code developed using only written narrativesNo standard control software strategies

No standard graphics, other than color standardImplementation varies by Contractor/SI/Programmer

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Goals - Accelerator Tool kits

Reduce the engineering time requiredto create standard, repeatable process applicationsYou can focus your energies on the custom aspects of your applications.

Increase control system quality and reliability .The reuse of well tested code conforming to industry standards reduces the likelihood of

code bugs.Drive logical and visual consistency

The Process Library aids in producing standard Graphics formats that increase theconsistency of your HMI thus reducing the need for Operator Training.

Superior diagnostics

Built in process diagnostics will make applications easier for operators and maintenance totroubleshoot and debug without requiring PAC programming tools

Scalability – You can build ever larger systems using the same reusable modules.





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Contents of an Accelerator

• An Accelerator provides a package of tools, which significantly simplifies theDesign, Manufacturing, Start-Up andSupport of Rockwell Automationcontrol systems.

• An Accelerator CD provides the – selection tools and – basic panel layout, – wiring diagrams, – Logix program,

– HMI screens and – Quick Start manual



Copyright © 2012 Rockwell Automation, Inc. All ri ghts reserved.Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 9

The Process LibraryHigh-efficiency suite of Control Modules

Mode Selection

Standard AlarmAI w/ Scaling & Alarms

DI w/ Alarms

Single-Speed Motor

Permissives with Bypass

Protectives with First-Out,Bypass

Run Time and StartAccumulator

Re-start Inhibit for LargeMotor

Date/Time Blocks • Solenoid-Operated 2-stateValve

• Motor-Operated 2-stateValve

• PIDE-based PID withStandard Modes andDeviation Alarms

• Analog Output

• Variable-Speed Drive(e.g., PF70-style)

• 2-Speed Motor

• Reversing Motor (e.g., FVR)• Pulse-Input flow meter dosing

with pre-act and in-flightadjustment

• Analog-Input flow meterdosing as above

• Weigh-Scale dosing (Loss-In-

Weight and Gain-In-Weightsupported)

• Controller CPU Utilization

• Hand-Operated ValveMonitor

• Hand-Operated MotorMonitor

• Cascade and Ratiosupported PID

• Advanced AI with HighRate of Change Alarm,Square Root Extraction,and Deviation Alarms


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Benefits of Using Accelerator Toolkit

Standardized scalable integrated architectureSingle hardware and software platformStandardized controller logic and HMI graphics

Single Scalable HMI Platformbased on FactoryTalk

FactoryTalk SOA - Services Oriented ArchitectureStandards Based – Use of common reusable code and engineering

templates

Creates standards for HMI graphic symbols and operation

Significantly enhanced systems diagnosticsLeverages diagnostics built into AOP and HMI Templates

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Case Study City of Detroit- DWSD

PC-761 Control System Upgrade at 2 CSO basinsReplacement of obsolete Bailey DCS system

Issues

Obsolete WorkstationSpare Parts AvailabilityOld Tape BackupLack of Local SupportComplicated ABB PLC Interface between Bailey & Rotork valvesystem

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Hubbell/Southfield CSO

Hubbell-Southfi eld CSO RTBThe Hubbell-Southfield CSO RTB is one of DWSD’s most active, longest operating CSO facilities and the largest on theRouge River. Since August 1999, it has been effectively capturing and treating combined sewage through screening,settling and disinfection to meet discharge permit requirements that protect public health. Sized to fit into the available

land and site constraints, the basin has a 22 million gallon storage capacity. Located next to the Tournament PlayersChampionship Golf Course (TPC) in Dearborn, this RTB serves as an example of how these facilities can be goodneighbors and blend in with the surrounding environment. The facility features an innovative design component thatenables three different operational modes within the RTB and prevents resuspension of solids during large storms withhigh flow rates.





Existing Bailey Infi 90/OIS40



Control System Options

1. Bailey Upgrade

2. HMI 3rd Party Upgrade with Bailey hardware

3. Rip & Replace1. Emerson Ovation DCS2. Rockwell/Allen Bradley3. WonderWare/Allen Bradley4. Intellution/Allen Bradley



Considerations

Cost (Initial & Life Cycle)

Functionality - DCS vs PLC

MaintainabilitySystem Downtime

Support & Support Options

How many platforms to support:PartsTraining



PC-761 Contract

Scope:Hubbell Southfield CSO Total Points 643Puritan Fenkell CSO Total Points 374

PlantPAx solution including:Redundant ControLogix L73 PAC with Enhanced RedundancyRedundant Ethernet Network- Stratix 8000Redundant FTViewSE Windows 7 WorkstationsProcess Library V1.5

W/WW Accelerator ToolkitRotork Master Stations Added Prosoft Modbus CommsInterface to DWSD Ovation System



Water/WastewaterAccelerator Toolkit Implementation

Utilized 12 Symbols and FaceplatesPump, ValveMO, ValveSO, ValveHO, Conveyor, Mixer, Agitator,P_Ain, P_Din, P_AinAdv, P_AinDual, P_AoutRequired some modification of graphics to meet DWSD HMI

standardsUtilized Chemical Feed and Lead/Lag pump application

Editing the Toolkit StandardRed vs Green for RunFace Plate Control Modes-symbolsRockwell Enhanced Toolkit – Added Color Change Tool







New Rockwell Overview ScreenHubbell Southfield



Flushing System Screens

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Chemical Feed Control Screen

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Lead / Lag Pump Control Screen

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System Status Screen

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Construction Issues

Failed field wiring in existing conduit duct bank Added Head Works Building PLC/Panelview Control Panel with fiber optic connectivity.

Instrumentation and final elements failuresNot in original project scopeDelayed project construction



Results-Total construction costssignificantly below estimate

Reduced Deployment Time• Resulted in a 50 percent reduction in design time, contract oversight, and post-contract

documentation and support.• Provided process control with advanced networking and diagnostic capabilities• Increased access to process data for better preventive and predictive maintenance

Reduced Engineering Hours and Costs• Saved estimated $120,000 in configuration and systems integration time• Saved $90,000 in factory-acceptance testing and Startup/commissioning

Drove standardization for DWSD wide graphics FTViewSE/ME platform

Advanced HMI without the associated development cost

Software configuration that is fully documented and tested



New Operators Control Room



New PLC Panel in Control Bldg.




New PLC Head Works Control Panel




Water Wastewater Accelerator Toolkiton the AB.com IA Tools Website

W/WW Accelerator Toolkit CD-IASIMP-SP012B




City of Detroit DWSDSuccess Story

Further documentation on:Hubbell Southfield CSOPuritan Fenkell CSO

Publication Number WATVP-AP014A-EN-P

April 2012

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QuestionsHassan AjamiProcess Control & Instrumentation [email protected], MichiganPh 313-874-5877

PlantPAx Process Library

Documents

Cs09 Detroit Water Sewage District Psug 2012