Process Automation Upgrade of the Gilder Creek WWTP: Results

Transcription

1 Process Automation Upgrade of the Gilder Standards Certification Education & Training Publishing Conferences & Exhibits Speakers: Scott Whitmore, P.E. CDM Smith, Maitland, Florida Sothorn Khel, P.E. MR Systems, Norcross, Georgia 2014 ISA Water / Wastewater and Automatic Controls Symposium August 5-7, 2014 Orlando, Florida, USA

2 Presenters Scott Whitmore, P.E., is an Automation Engineer working out of CDM Smith s Southeast Regional Design Center in Maitland, Florida. He graduated as Bachelor of Science in Mechanical Engineering from the University of Central Florida, and has 17 years of experience in the design and construction of instrumentation and controls for water treatment and reclamation facilities. Scott has been an ISA member since Sothorn Khel, P.E., is a Regional Manager with MR Systems in Norcross, Georgia. He earned a Bachelor of Science in Electrical Engineering at the Georgia Institute of Technology, and has 7 years of experience in the design, installation, and integration of instrumentation and control systems, supervisory control and data acquisition (SCADA) systems, and remote telemetry systems for municipal water and wastewater facilities. 2

3 Renewable Water Resources (ReWa) Overview 5 counties Laurens, Anderson, Spartanburg, Greenville, and Pickens 10 Wastewater Treatment Plants 61 Pump Stations Over 300 Miles of Trunk Sewer 17 Subdistricts with 1,750 Miles Collector Sewer and Over 1,500 Connections 3

4 Gilder Creek Wastewater Treatment Plant (WWTP) Overview The plant is located along the Enoree River in eastern Greenville County, South Carolina Commissioned in 1987 at 4.0 mgd Upgraded to 5.0 mgd in 2003 Expanded to 8.0 mgd in 2006 Re-rated to its current capacity of 11.3 mgd in 2008 Most recent controls upgrade was in process upgrade design identified critical control needs 4

5 Project Schedule Date January 2011 April 2011 December 2012 Planned: September 2012 Action Preliminary design: scope of work developed out of previous process upgrade (Phase IIIA) design Final design, bidding and contract award January 2013 March 2014 Planned: October 2012 July 2013 Scheduled: February 2013 January 2014 Construction 5

6 Project Scope Existing Control System Plant processes are divided into two fiber optic rings, North Loop and South Loop, each controlled by a redundant pair of Virtual Logic Controllers (VLCs) running on PC hardware Each process area contains Remote I/O (input/output), reporting to VLC using Profibus DP over fiber Operator human-machine interface (HMI) in control room on PCs, and in panel-mounted PC workstations VLCs and HMI communicate using Ethernet over fiber 6

7 Project Scope Upgrade Activities Select the right control systems integrator (CSI) Maintain plant operations throughout construction Replace old VLCs and remote I/O with new programmable logic controllers (PLCs) and I/O for each process area Retain existing panels, with a few exceptions Replace old HMI PC servers and workstations Upgrade old version of HMI software Retain existing control programming and operator functionality, with a few exceptions Extensive training 7

8 Project Scope Upgrade Activities Select the right control systems integrator (CSI) Maintain plant operations throughout construction Replace old VLCs and remote I/O with new programmable logic controllers (PLCs) and I/O for each process area Retain existing panels, with a few exceptions Replace old HMI PC servers and workstations Upgrade old version of HMI software Retain existing control programming and operator functionality, with a few exceptions Extensive training 8

9 Select the Right Control Systems Integrator (CSI) A point scale was developed for prequalification of candidates Experience with the specific VLC and HMI software was important but couldn t be too important Ultimately, three candidates were approved The winning CSI partnered with the CSI firm that did the previous upgrade in 2006 The CSI acted as prime contractor, requiring additional responsibilities 9

10 Project Scope Upgrade Activities Select the right control systems integrator (CSI) Maintain plant operations throughout construction Replace old VLCs and remote I/O with new programmable logic controllers (PLCs) and I/O for each process area Retain existing panels, with a few exceptions Replace old HMI PC servers and workstations Upgrade old version of HMI software Retain existing control programming and operator functionality, with a few exceptions Extensive training 10

11 Maintain Plant Operations Throughout Construction Original scope called for the upgrade of process areas one at a time, one loop (North and South) at a time, in order of increasing size and complexity, with HMIs running side by side CSI proposed a similar plan, but in three sequences, to stagger the design, implementation and testing efforts More cost in mobilization, but benefits in utilization and engagement of CSI and Owner staff, and less plant downtime Plant operational disruption was minimal 11

12 Project Scope Upgrade Activities Select the right control systems integrator (CSI) Maintain plant operations throughout construction Replace old VLCs and remote I/O with new programmable logic controllers (PLCs) and I/O for each process area Retain existing panels, with a few exceptions Replace old HMI PC servers and workstations Upgrade old version of HMI software Retain existing control programming and operator functionality, with a few exceptions Extensive training 12

13 Replace Old Controls in Existing Panels Original scope called for replacement of subpanels in existing enclosures CSI proposed replacing control devices (I/O, VLCs, PLCs) only Replacement was easier and quicker overall, and much less costly Anticipated possible wiring issues turned out to be negligible Unexpected hardware glitches caused delays during testing 13

14 Replace Old Controls in Existing Panels Example: PCS 9 (Digester Bldg) Before and After 14

15 With Exceptions SW3 RDT (rotary drum thickener) panels, containing local controls and remote I/O, were redesigned and replaced entirely, as scoped 15

16 Slide 15 SW3 Sothorn, do you have a good shot of an RDT panel interior "after"? Scott Whitmore, 4/5/2014

17 With Exceptions RDT (rotary drum thickener) panels, containing local controls and remote I/O, were redesigned and replaced entirely, as scoped 16

18 Project Scope Upgrade Activities Select the right control systems integrator (CSI) Maintain plant operations throughout construction Replace old VLCs and remote I/O with new programmable logic controllers (PLCs) and I/O for each process area Retain existing panels, with a few exceptions Replace old HMI PC servers and workstations Upgrade old version of HMI software Retain existing control programming and operator functionality, with a few exceptions Extensive training 17

19 New rack-mounted servers and up-todate PC workstations provide a modern platform for a modern HMI 18

20 Process Automation Upgrade of the Gilder After considering alternatives, the Owner selected a photorealistic HMI with 3D modeling that was not originally scoped Development added not much cost, but did add time to the original project schedule 19

21 Process Automation Upgrade of the Gilder Project Scope Upgrade Activities Select the right control systems integrator (CSI) Maintain plant operations throughout construction Replace old VLCs and remote I/O with new programmable logic controllers (PLCs) and I/O for each process area Retain existing panels, with a few exceptions Replace old HMI PC servers and workstations Upgrade old version of HMI software Retain existing control programming and operator functionality, with a few exceptions Extensive training 20

22 Process Automation Upgrade of the Gilder Retain existing control programming and operator functionality, with a few exceptions This commitment significantly reduced the scope, schedule and budget of the design, and therefore also the construction Manuals from the previous controls upgrade, and experienced operators, were valid and readily available resources Wish list items were kept to a minimum Thorough testing of some systems was difficult or impossible under the circumstances 21

23 Process Automation Upgrade of the Gilder Project Scope Upgrade Activities Select the right control systems integrator (CSI) Maintain plant operations throughout construction Replace old VLCs and remote I/O with new programmable logic controllers (PLCs) and I/O for each process area Retain existing panels, with a few exceptions Replace old HMI PC servers and workstations Upgrade old version of HMI software Retain existing control programming and operator functionality, with a few exceptions Extensive training 22

24 Process Automation Upgrade of the Gilder Extensive training New controls products bring with them a steep learning curve Training included vendor courses in new PLC and HMI products, and O&M courses customized for this installation by the CSI Vendor courses presented logistical difficulties in personnel scheduling and travel best handled by Owner and staff directly Three-part construction sequence allowed staff a lot of hands-on time with the system Contributions of all parties during all phases of construction resulted in operations staff having deep familiarity and ownership 23

25 Process Automation Upgrade of the Gilder What We Would Do Again What We Would Do Differently Panel and controller upgrade concept Plan to replace only the minimum required (controllers and I/O) Construction sequence concept Tight schedule left little room for unforeseen circumstances HMI upgrade concept Flesh out the HMI style in advance Extensive training on new equipment Procedure for administering vendor factory training CSI selection and contract admin Focus: minimize other changes to controls Involve Owner staff at all stages 24