Three SCADA Technologies That Won't Break the Bank
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Three SCADA Technologies That Won’t Break the Bank AWWA Conference Spring 2016 Helix Water District • 1885 Cuyamaca Water Company • East County of San Diego • 106 MGD WTP / Ozone • 50 Site distribution system • System storage of 68.5 MG • 50 square miles • 268,000 population • 722 miles of pipeline • Supply three other districts • 3 Connections • Up to 36 MGD Helix’s SCADA Modernization • 1986 VAX , RTUs and phonelines • 1996 – 1998 Wonderware TP / Dist • 1998 to 2002 plant expansion • 2002 – 2004 MCC PLC bricks project • 2006 – 2007 Master Plan New Data Historian • 2009 New SCADA Cluster • 2010 Ignition SCADA and use of OPC-UA • 2013 – 2014 Radio pilot project • 2014 – 2015 Radio project phase one • 2015 – 2016 Radio project phase two 3 Water Utilities Need Better Solutions • The utility’s informational needs • Stringent regulation • Better summary reports • Better historical storage • Economic pressures • Drought and conservation • Fixed cost and rates • Better business model on purchase • One that doesn't age like legacy systems 4 SCADA Technology is Expensive • Designed, built and maintained by outside staff • Some districts are moving to in house solutions • Reducing the cost of ownership – Commercial off-the-shelf (COTS) – Moore's law – Open source • Younger staff understands technology • Less than 20 cent on the dollar solutions exist – Solution moves the risks to in house staff – Phased approach (learn and pay as you go) 5 Conversation with a SCADA Designer • Wonderware, AB PLC and Dell servers – Vary any one and they ask “what are you doing?” – Stable designs but they use very old technology – Designer’s, not the utilities best interest – May not be the most open, powerful or cost effective • Understanding the long term cost of supporting a system like this • A paradigm shift may be a good thing 6 Conversation with a SCADA Integrator • Real world SCADA outside support person • SCADA integrators need to make a profit • Won’t recommend $99 PLC • My programing fee = the PLC cost 7 About 1/10th the Cost Helix Legacy Helix Now SCADA software $60K SCADA software $6K IWR Radio $1,200 Radio $89 to $139 SLC504-L541 $3,920 DL250 CPU $286 1746 four Ch AI $1,340 AI $83 to $207 1746 Gateway $5,091 MB Gateway $189 RS500 Pro $4,190 Free to $395 InSQL $$,$$$ SQL Historian free Money saved allows us to fix other issues http://www.1sourcedist.com http://www.automationdirect.com 8 Three Parts of a SCADA System • Central hardware and software – Including data historian • Communication network – TP Ethernet cable and fiber – Dist. wireless or radio • Programmable Logic Controller HWD PLC Infrastructure • District PLC and radio 1998 – 1999 – Fifty Direct Logic 250 PLCs • Plant upgrade 1998 – 2002 – Eleven Direct Logic 340 and 450 PLCs – Now considered legacy PLCs 10 Current Low Cost PLC Options • Not from the big four – AB, Schneider Electric, GE, or Siemens – Not value based automaton providers – Multinational companies • Lower cost at the PLC level – Redesigned CPUs – Micro PLCs – Stackable PLC – PLC and HMI in one unit Legacy Direct Logic 450 PLC 12 Low Cost Do More Replacement 13 3 PLC Replacement Side by Side 14 Next Generation of IP Radios • Designed for WISP market • Easily interfaces to SCADA • Higher power radio and high gain antennas • Bandwidth supports video on demand • Powerful, secure and very low cost • Web page administration • Power over Ethernet • Several good vendors 15 HWD Ethernet Radio Network • Radio cost $89 to $300 • Real throughput 30 to 100 Mbps • Can view and edit ladder remotely • 802.11 G/N/AC • Antenna diversity 16 Radio Configuration and Antenna Alignment Requires direct line of sight Rifle Scope on T-Square = $200 Use of red balloon = $10 18 Antenna Alignment Tool 19 RF Armor Antenna Shield • Reduces unwanted RF interference • Increases throughput 20 HWD OSPF Mesh Network 21 21 SCADA Technology Time and Money • 1986 BBI VAX based $1.2M • Full turn key system • 1997 Wonderware $335K • BBI tag-server issues (16/32 bit) • Full system done in house • 2007 IA SCADA total cost since ‘07 $47.2K • Used AB and Modbus UA tag-server • Open systems reduce investment losses • Full system done in house • Reused PLCs and radios (phased plan) 22 Our New SCADA System • Centrally administrated • Web based (uses an Apache web server) • Licensed by the server and not tags or clients • High availability built in • Cross platform • Totally open database options • Zero client software to install or license • Open communications UA with DA support • Lower lifecycle cost compared to other options 23 NEW SCADA TECHNOLOGY 24 Lakeside Water District • Lowest water rates in San Diego county • Very small district • Resourceful • Narrow radio re-banding causing issues • Legacy Wonderware software • Downtime in the system • Radio proof of concept – Three site plan 25 Lakeside Water District • Not line of site (used tank as a repeater) • Lakeside staffing – Distribution superintended – Six Utility workers • one with some electrical experience Path Doesn’t Have Line of Site 27 28 Lakeside Water District • Work started Oct 2015 (two radio sites) • Proven the radio links work • SCADA communicating over the links • Logging tank levels • MySQL used as the data historian • Converting HWD pump station screen • Adding HOA contact blocks to the PS • 11 sites with radios, 4 more in progress 29 Three SCADA Technologies That Won’t Break the Bank Questions? 30.