Steps to a Successful SCADA Upgrade

Transcription

1 Steps to a Successful SCADA Upgrade Automation Seminar August 24 th, 2017 Deep River Event Center, Greensboro NC Dan McLaughlin Introduction Brief Speaker Bio Hometown: Mentor, OH BEE, Physics & CIS minor: Cleveland State University 8 months: Montgomery Watson Harza, 14 years: RoviSys Currently living in Cary, NC with wife and 3 kids Invited to speak by the AWWA-WEA Automation Committee Brief Company (RoviSys) Bio Systems (SCADA) Integrator providing programming services to industrial and municipal clients globally Project Management, Automation Planning, Networking, HMI, PLC, Enclosure Design, Startup, Support, Digitalization, Data Collection & Visualization Outline SCADA Defined Success Defined Reasons for Upgrade The SCADA Upgrade Process Some Takeaways Questions & Answers 1

2 SCADA Defined Supervisory Control And Data Acquisition Success Defined Factors contributing to a successful upgrade Success - the accomplishment of an aim or purpose. Price (as compared with original budget) Schedule (as compared with original milestone targets) Minimized outages Resulted in an easy to use & maintain system Routine manual functions now automatic Reasons for Upgrade Reduced failure potential Additional features and capabilities Readily available support Cost of replacement parts Ease of communication and information transfer 2

3 The SCADA Upgrade Process Preliminary Project Activity Automation Master Plan Who: Plant Personnel, Engineering Firms, SCADA Integrators, Vendors What: Plan the future of your automation When: Before your next project Why: Reduced TCO by utilizing standards for consistency, minimizing training, & minimizing spare parts How: System & Personnel Audit, Assess Risk & Criticality, Seek Expert Input Don t assume others know what you want from SCADA write it down! Preliminary Project Activity System Audit Log anything with LCD, IP, Smarts Assess life cycle status Personnel Audit Current Understanding Current & Future Needs Platform Selection Support Network Existing System(s) Important Features New or Desired Features Virtualization 3

4 Preliminary Project Activity Types of Upgrades Phased/Staged Approach Rip & Replace Simultaneous operation Migration/Migration with improvement Scope, & RFP Development Document the project goals (additional remote monitoring, easier use) Document project requirements (platform options, turnover documentation) Document project milestones (Kickoff, Panel FAT, Software FAT, Installation, Startup) Get help if unknowns Assess/Estimate the cost before you start Project & Quality Planning Detailed Schedule Milestones All deliverables including drafts Off-Location meetings and testing Define Documentation & Testing Requirements Sequence of Operations/Functional Requirements Specification Panel FAT, Software FAT, SAT Internal Testing Functional Definition & System Design Document Functionality Review with operations & maintenance staff Document Enclosure Details Layout, power wiring diagrams, field terminations, network architecture Finalize Bill of Materials & Submittals Review each line item thoroughly Discuss programming & graphics standards Colors, templates, reuse 4

5 System Implementation Detailed Programming of SCADA (PLC, HMI, Network) Update or expand upon initial documentation Monitor schedule Review progress (demos, inspections, presentations) Test software against documentation (FAT) Startup, Testing & Training Software, Hardware, personnel converge on final location Plant operation switched (manual, semi automatic, bypass, partial outage) Level of detail in planning led by areas of risk Previously tested in simulated environment, now tested in reality Training led by operator manual, multiple sessions if required to cover shifts Support & Maintenance Congratulations on your upgraded SCADA! Many vendors willing to do maintenance/support contracts Drive storage, Processor utilization, Physical Inspection, Network traffic On call when required Remote access Monitor spare parts Monitor trends and reports Prepare for next upgrade 5

6 Some Takeaways If you don t have experts at your facility, find one and solicit their advice Document User Requirements (Automation Master Plan) Plan Revise Proceed Maintain involvement throughout entire SCADA upgrade process Questions & Answers Dan McLaughlin, PMP daniel.mclaughlin@rovisys.com (919)