2014 HDR Architecture, Inc., all rights reserved. 2014 HDR, Inc., all rights reserved. Developing a PCS Master Plan for the NEORSD PLANNING NOW AND FOR THE FUTURE Overview Master Plan Goals Wastewater Conveyance and Treatment Services for the Greater Cleveland area Three Treatment Facilities Easterly WWTP 94 MGD Southerly WWTC 400 MGD Westerly WWTC 70 MGD Extensive Collection System 115 Remote Sites NEORSD OVERVIEW The Northeast Ohio Regional Sewer District Process Control and Automation Systems will provide our staff and facilities with the technology to provide exemplary environmental stewardship, as economically and effectively as possible. PCS MISSION Operations will be equipped with modern, highly resilient and dependable control systems that provide the information needed to make the best process decisions, the control capabilities to act on those decisions through clear and intuitive interfaces, and extensive and appropriate application of automation and information technologies for stable control and rapid response to changing conditions. Technical staff will have far-reaching, accurate and easily accessible data for modeling, reporting and analysis, from the most remote site in the collection system to the receiving water itself, effecting the soundest possible planning and engineering. NEORSD PCS VISION Management will have fast and powerful systems that provide the information needed to support regulatory compliance, conserve energy and chemicals, guide staff through process emergencies, make enlightened strategic decisions, and enable effective resource planning. Our customers, our fellow citizens, will benefit from applied technology designed to improve their quality of life by delivering reliable service while protecting their health and their investment in our utility. NEORSD PCS VISION Guide development of a Process Control System that: Fully supports the mission of the Districts operations Is flexible, expandable, reliable, secure, and optimized Is adaptable to changes in technology Leverages the Districts past and planned investments Can integrate with other enterprise systems (GIS, LIMS, WAM) Supports Inter-departmental synergy Is built on consistent specifications for software, hardware, functionality and communications for new capital projects. GOALS FOR THE MASTER PLAN In-Plant Rockwell Automation PLCs Mostly aging Allen-Bradley PLC5 platform Fiber Optic Based Networks Cimplicity and Wonderware HMI systems Collection System Rockwell Automation PLCs Mixture of PLC5 and MicroLogix Mixed communication systems (leased lines, some cellular) Limited Cimplicity HMI Separate Telog data logger system (operating on cellular) OVERVIEW OF PCS SYSTEMS Key Features Redundant Servers Virtualization Technology Geographically Distributed Extensive use of PCS HMI clients for support of field operations Key Technical Challenges Running two HMI systems Limited data collection and reporting Aging Hardware and Software OVERVIEW OF PCS SYSTEMS TYPICAL WWTP PCS COLLECTION SYSTEM PCS Key Assumptions Standardized on Rockwell Automation PLC/PAC Hardware Standardized on Wonderware HMI Leverage Telog data logging system PCS MASTER PLAN Challenges leading to the need for a plan Transition to Wonderware. Poorly Planned Implementation challenges led to issues with operator engagement Limited in-house expertise and resources Proprietary (and aging) enterprise-wide ODMS PCS MASTER PLAN Current State Assessment Requirements Analysis Gap Analysis System Assessment Compilation of Master Plan MASTER PLANNING PROCESS Current State Assessment Site Visits Visited each Plant Representative sites in Collection System Reviewed / Gathered Existing System Documentation PLC infrastructure Network Infrastructure PCS Servers/Workstations Developed Current State Technical Memorandum MASTER PLANNING PROCESS Requirements Analysis Extensive set of Requirements Workshops 8 workshops with multiple stakeholders Operations/Superintendents Operations Electrical/I&C/Mechanical Maintenance PC&A Technical (Two workshops) Collections WQIS/Lab Data Flow MASTER PLANNING PROCESS Requirements Analysis Requirements Categories MASTER PLANNING PROCESS Alarm Event Management Control Philosophy Data Management and Reporting HMI HW / SW Functionality Instrumentation / Control Equipment Network Systems PCS Architecture PLC/RTU Design and Functionality Process CCTV Organization / Practices Disaster Recovery / Business Continuity System Documentation Requirements Analysis Consolidated and Prioritized Requirements Critical High Medium Low Initially 89 individual requirements Consolidated to 55 Reviewed and Validated with Core Team MASTER PLANNING PROCESS System Assessment / Gap Analysis Evaluated the Current State against Validated Requirements Developing the Recommended Actions to Implement Requirements Preliminary Project List MASTER PLANNING PROCESS System Assessment Refined Project List Short-Term Projects 6 month or less implementation period Small cost, potentially by internal resources Longer-Term Initiatives Longer Design/implementation Initial Projects 14 short-term, 14 longer-term After Reviews/Discussions 18 short-term, 19 longer-term MASTER PLANNING PROCESS System Assessment Developed Project Descriptions Scope Schedule Budgetary Estimates Project Prioritization Critical / High / Medium / Low MASTER PLANNING PROCESS NEORSD PCS MASTER PLAN Master Plan Development Shift from Individual Projects into an Overall Program Budgetary Program Planning Development of Non-Project Related Master Planning Issues MASTER PLANNING PROCESS Overall Program Schedule NEORSD PCS MASTER PLAN Summary / Success Factors Detailed up-front work to understand existing systems was critical to success Good working relationships across the entire team Willingness to consider new ideas NEORSD PCS MASTER PLAN