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Automated Control Systems SCADA

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Automated Control Systems SCADA

Terminal Objective
Upon successful completion of this module, the operator will be able to describe the use of a Supervisory Control and Data Acquisition system (SCADA) in water and wastewater treatment.

Enabling Objectives
1. Restate the definition of a SCADA system. 2. List the components of a SCADA system. 3. Describe appropriate uses of a SCADA system. 4. Explain the benefits of a SCADA system. 5. Describe the limitations of a SCADA system.

I.

Course Description

Supervisory Control and Data Acquisition (SCADA) systems have become widely used by water, wastewater, distribution, collection and laboratory personnel in the treatment processes of water and wastewater. Water and wastewater treatment plants use SCADA systems to operate, monitor and troubleshoot the components of the plant that may be scattered throughout a municipal district or city. Operators should understand the purpose of these systems, how to work with the systems, and how the information gleaned from the systems can be used to properly maintain water and wastewater treatment processes. In this course, you will learn the definition, components, uses, benefits, and limitations of a Supervisory Control and Data Acquisition (SCADA) system in water and wastewater treatment.

II. SCADA Definition

Supervisory Control and Data Acquisition systems or SCADA (pronounced ss-kay-dah) systems provide electronic data collection and automation of processes and components within a water or wastewater treatment system. This distributed computer system allows for process monitoring and operations automation. A computer-controlled system, using a communications network, monitors water and wastewater controls and plant alarms. Sensors within the system provide operational data that is collected and stored. Stored data can be downloaded to a laptop or handheld personal digital assistant (PDA) for maintenance and reporting purposes. A SCADA system is a tool to monitor and control plant processes and components within the distribution system from a single source. In a very simplified SCADA system, processes are monitored in a treatment plant using a computer workstation that displays most or all parts of the reporting system.

Within the plant, there may be multiple process controllers or programmable logic controllers (PLCs) that monitor individual processes. These are linked with a local area network (LAN) to the main computers in the control room of the treatment plant or even at a public utilities office. Information is communicated from the controllers and from remote terminal units (RTSs) that are located in remote areas of the water or wastewater system to the main computer. Operators can view schematics of the networked parts of the system to monitor the processes and troubleshoot problems (Figure 1). Computer monitoring may be used in the following municipal facilities: Surface water treatment plants (SWPs) Groundwater systems Distribution systems Wastewater treatment plants Collection systems Water and wastewater laboratories

Figure 1: SCADA panel indicating all lift stations in a city

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Typically, the computer system organizes and outlines schematics of the water or wastewater system, providing multiple colored screen images of the system as a whole, as well as individual components and processes (Figure 2). At any time, the facility or entire system can be viewed on the monitor in order to control flow rates, check feed rates, determine turbidity, monitor pumps, investigate alarms, and monitor processes.

control unit initiates communication with remote devices and interfaces with the operator. Control and accessing equipment may include the following: Hardware-based equipmentthe main computer that receives and stores data, graphic displays, alarm indicator lights (annunciator panels), strip chart recorders, and other LED-readout panels. Software-based equipmentincludes workstations, microcomputers, mini-computers, mainframe computers, and other computer-based systems. Combination systemscombinations of hardware and software systems. Present systems include a laptop with graphic display and signal receiver. This system can be portable and used anywhere within a specified range. Field Communications Equipment There are a number of ways that a SCADA system can communicate information; however, the ability to communicate must be uninterrupted between the RTU and the main control unit. From the RTUs to the SCADA control unit or main computer, information can be transmitted via the following modes of field communications: Microwave radio UHF/VHF radio Cellular phones Landline phones Digital data service Wi-Fi Ground station satellites Remote Terminal Units Remote terminal units, also called remote telemetry units or RTUs, gather and relay digital information from their locations to the SCADA control center upon command from the main control unit. RTUs code and transmit information from sensors to the main computer in the SCADA system. The RTUs then receive input from the main computer and implement processes based upon those commands. Many current RTUs have the ability to respond automatically to certain transmitted information without having to interface with the main computer. These smart devices are able to sense and adapt to physical overrides within the system for safety purposes. This provides an automated layer of protection between the distributed control system and human interaction. SCADA Software The software used with SCADA system allows the operator to view all functions and components within the SCADA network. In a water or wastewater treatment schematic, the operator can view current operating conditions, change set points, investigate condition alerts and warnings, and identify trends. Several software packages are available that offer real time graphics and displays.
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Figure 2: High service overview

III. SCADA Components

While no two SCADA systems are alike, the following four major components of a SCADA system are typical: SCADA control unit or master control Field communication equipment Remote terminal units (RTUs) SCADA software Larger municipalities are more likely to have SCADA systems in place due to the availability of funding for these systems. It is possible that some parts of the water or wastewater system are not included in a SCADA communications network. Those areas may not be easily accessible to install sensors or the budget may prevent such installation. Components may be added as a municipality changes or has the capital to invest in the equipment. Sensors can be added to new installations as they are built. SCADA communications devices may be added as equipment or parts are added or repaired. When adding or upgrading SCADA devices, it is necessary to understand the capabilities of the installed system and determine if newer components will interface with the existing system. SCADA Control Unit At the heart of the SCADA system is the control center. This control unit or master terminal unit (MTU) is the center of the SCADA system. This may or may not be located in a water or wastewater treatment plant. They may be centrally located anywhere that is accessible to operators and management. The
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IV. SCADA in Water and Wastewater Systems

A SCADA system is designed to save time and money in water and wastewater treatment by eliminating the need for operators to inspect, measure, log, report, and adjust settings on components within a water or wastewater system or plant. There are many benefits to these automated systems: constant monitoring, remote setting modification, automated reporting and troubleshooting. Each part of a municipal water and wastewater system shares those general benefits; however, it may be valuable to look at some of the benefits specific to water and wastewater treatment systems. In both water and wastewater treatment plants, SCADA systems are used extensively for chlorine and sulfur dioxide distribution. Chlorine is added in mg/L or parts per million (ppm) and the set points (high and low) can be monitored and controlled by the computer system. An alarm indicates that the operator should check the chlorine system to troubleshoot the problems that may be occurring in the chlorine tanks, manifolds, valves, feed line or feed water. If a second alarm sounds, it could indicate that the operator must neutralize the chlorine if it is entering the point source or it could indicate that there may not be any chlorine. Since disinfection prior to release to the point source may be warranted, this type of alarm is particularly useful. Sulfur dioxide is commonly used to remove chlorine. Because state permits may require a certain measurement of chlorine residual before those waters may be released to the receiving source, the SCADA system provides an automated response to this issue. The computer can monitor and record data as proof of state and federal compliance. These are just two examples of the positive impact that SCADA can have, but there are many more ways that SCADA systems positively impact water and wastewater treatment and the role of the operator. Water Distribution System Groundwater Supply SCADA systems can monitor the flow of water from the water well to the storage tank. An RTU may be placed at the well pump or storage tanks that are being fed by the well. The following may be indicated by the SCADA system: Flow rates Disinfection feed rates Power outages and instances of generator use Storage Tanks It is not uncommon for a city to have multiple types of water storage facilities: elevated, ground, standpipe, or clearwells. These storage tanks can range in capacity from 50,000 gallons to 5 million gallons. Each storage facility can be monitored to determine water levels for the city water system (Figure 3 and Figure 4).

Figure 3: SCADA water distribution system overview

Figure 4: SCADA storage tankelevated overview

The following information can be read from the computer screen: Height of the water in each tank The psi of the water line feeding the tank Pump operation and shut-off Automatic valve function near the storage tanks Instances of power surge, power outage or lightning strike Pumps that add water to these storage tanks can be preset to automatically fill when the levels drop to a certain set point. If the pump activates and does not shut off at the set point, the system alarm alerts the operator of an overflow and presents a schematic diagram of the location. Automatic valves within the distribution system, called altitude valves, function based on water pressure. They open and close according to the water pressure in the system lines. Using SCADA, an operator can monitor whether or not those valves are functioning properly via computer screen. If the altitude valves remain open too long, the storage tank will overflow. If the valve is set to open and fill the tank under pre-set conditions and it does not, the tank can run dry.

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As water is transferred from the point source to the water plant, a water line break can occur. When pressure drops in the system, an alarm sounds. Rather than having to send out a maintenance crew to locate the break, the SCADA system illustrates the location of the break. This saves both time and money in man-hours and the cost of lost water. The guesswork of locating the problem is eliminated. Booster Stations If more water is needed in the distribution system, the SCADA system monitors the pressure in the piping system and makes the necessary changes to reach set conditions. Pressure can be measured miles away from the surface water treatment plant. If pressure is low, the computer can activate the number of pumps necessary to adjust the pressure to the correct reading. Pressure readings are evaluated by the computer. Once demand is satisfied and pre-set water pressure readings are met, the control unit can turn off booster pumps, eliminating the need for an operator to physically perform the same task. The operator can monitor the process via computer screen. The computer display may indicate whether pumps in the booster stations are on hand, automatic or off-line. It may also measure how much water demand was needed in gallons per minute (gpm), gallons per day (gpd) or million gallons per day (MGD). Accurate measurements are stored for use by the water facility or city. Data can be retrieved as needed for state or federal reporting purposes. Surface Water Treatment Plant There are many pipes and valves in the distribution part of the surface water treatment plant. Valves can be controlled via the SCADA system. They may be set to open or close by a percentage. This is important in that if valves close too quickly, water hammer occurs. The control unit can eliminate this occurrence by activating on set points on which the valves close. As such, the next shift of operators may not have to go out into the water plant to check those valves. They simply log in to the computer and view the valve network on the main water lines of the city to verify that all is functioning properly. In addition, the chemical feed equipment and rates can be viewed at any time. The SCADA system can monitor the feed rate, dosage in milligrams per liter (mg/L), and operation or non-operation of the chemical pumps. The following may be monitored: Water flow metering Potential hydrogen ion concentration (pH) meters Turbidity meters Particle counters Water and sludge levels Chemical bin levels and pounds per square inch The data is collected and recorded at specific dates and times. Each days measurements can be stored to use
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in trend analysis. It is simple to locate information about system measurements taken a day, a month or a year ago. In addition, printed reports may be generated from the trend data. SCADA is very important in monitoring a membrane system. Some of the parameters that the SCADA system will monitor include trans-membrane pressure, air pressure and air flow during backwash, flow through the membranes, membrane system pressure, status of valves on the membrane system, turbidity and controlling and monitoring what process the membrane system is currently in (forward flow, backwash), controlling and monitoring the cleaning process (pH, temperature, oxidation reduction potential or ORP, and chemical volume). SCADA is important in monitoring membrane turbidity so that they remain at set point. If turbidity levels exceed that point, the SCADA system can notify the operator and shut down the membrane system. SCADA provides central control of data received from the distribution system or treatment plant. RTUs provide access or control to the following: ON/OFF, alternation of pumps, or elapsed daily run-time Operation of valves (OPEN or CLOSED), or any degree of closure, and tank levels and pressure readings System pressure for low pressure complaints and firefighting demand Stoppages or blockages from valve or system maintenance Plant gate control Plant tank levels for control of ON/OFF operation (Figure 5 and Figure 6)

Figure 5: SCADA surface water treatment plant overview

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Record clear well level, fluctuation, and fluctuation time, allowing determination of demand any time of day. Differential of treatment rate and clear well effluent rate is necessary to control raw water flow. Alarm systems that display for pressure, temperature, turbidity, pH, pump or valve failure, disinfectant leaks, tank levels, or any other determined alarm. The light panel should be color-coded yellow or red for type of failure, or blinking. The blinking light indicates the alarm is not acknowledged and, upon acknowledgment, the light remains ON and goes OFF after correction is made (Figure 8).

Figure 6: SCADA level control panel

Temperature, pH and turbidity of the raw and finished water ON/OFF operation and adjustment of chemical feed pumps Adjustment of flow controllers on water treatment trains LED read-outs from zeta meter and streaming current monitors Turbidity and pH of the settled water Filter head loss, filter flow, and filter valve position (Note: Valves are more accurately positioned by instrumentation than manually.) Backwash to operate automatically upon reaching a predetermined head loss and begin after a time interval, or when finished water turbidity rises. After backwash, the filter is programmed to rest for a time to allow the media to settle properly before resuming operation (Figure 7).

Note: Plant security cameras and sensors should be on a separate computer system. Security and SCADA should be totally separate systems.

Figure 8: SCADA water treatment system overview

Figure 7: SCADA backwash monitor

Disinfection to increase or decrease feed rates to satisfy clear well residual. For chlorine dioxide, chloramine, ozone, or ultraviolet light, disinfection is controlled according to manufacturers specifications. Chemical usage can be recorded daily.

Wastewater Treatment Plants SCADA systems can monitor the components and processes of a wastewater treatment plant as well. As the flow of wastewater enters the headworks, passing through the bar screen, it is measured in MGD. This reading (propidium iodide or PI flow) is recorded in the system. In the primary settling tank, sensors can measure and record the thickness of the bio-solids and solids blanket. If adjustments must be made in the sludge blankets, the operator can adjust valves via the computer. Some systems allow the operator to open, close or adjust the valves on the screen display. Valves may also be pre-set to open and close via the computer. In wastewater treatment, the following can be determined with a SCADA system: Liquid levels in the tanks Return Activated Sludge (RAS) Waste Activated Sludge (WAS) Chemical tank usage (in feet and inches) Potable water flow It is possible to monitor all equipment that is moving as well as the speed of belts used in the wastewater treatment process (Fig-

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ure 9). In addition, measurements can be taken to determine the following: Amount of recirculating water Primary effluent (PE) flow Gallons transferred to digesters and from digesters to belt presses

clear, he can call out a standby maintenance crew within the wastewater treatment plant to make necessary repairs. That is just one example of the streamlined management of components and processes in wastewater treatment.

V. SCADA Benefits
There are many benefits to using a SCADA system for water or wastewater treatment. The following represent some of the benefits: Data storageall data from the plant and distribution system are stored in the SCADA memory. If the operator needs to know the number of days the plant exceeded 0.3 NTUs, or the number of days the demand exceeded two million GPD, the information can be printed in minutes. This provides easily accessible information that may be needed for compliance with local, state and federal agencies. Daily recordsdata can be printed at midnight containing chemical and physical characteristics of the raw and finished water, equipment operating and run-time for each, operators in attendance, and other information pertinent to operation. Historical datacollected and stored data can be studied to determine when demand is greatest. The operation can then be programmed to meet demand. Energy savingssavings can be determined by historical data. Service pumps, lights, and other electrical equipment can be programmed to run only to meet demand. Operating information can be displayed for each system, such as in the treatment train, pumping station, storage tanks, and distribution system to optimize energy consumption. Operating costs are then reduced due to more efficient operations. Reduced labor costscosts are reduced when a SCADA system takes over operation, maintenance, and monitoring duties that were performed manually. There are many benefits to reduced labor costs. For example, operation of equipment is automated. Maintenance man-hours are reduced due to computer troubleshooting abilities. (If there is a low water pressure complaint, the area can be displayed, the system analyzed, and corrections made without sending an operator.) The need for physical monitoring of equipment is virtually eliminated, especially to remote sites. Constant monitoringwear and tear on equipment is reduced because components are constantly monitored and problems can be remedied before replacement is necessary. Instant adjustment of equipment or processes is possible. For example, a constant check on the chemical feed system and raw water characteristics allows instant adjustment, eliminating overdosing and saving chemical costs. Maintenance schedulingmaintenance can be scheduled by SCADA according to manufacturers specifications. For example, a printout can list service to be performed that day, week or month. The maintenance records can be maintained in the database for future reference.

Figure 9: SCADA belt press operation

Finally, SCADA systems can help to monitor the following: Hot water boilers Temperature of solids Water that is returned from primary digesters Grease and scum pit levels SCADA systems can control the processes at the wastewater lift stations as well. A series of lift stations can be monitored from the main control center, many miles from the actual lift station. The following five contact points could be monitored for each lift station: High wet well Low wet well No power to the building Pumps not operating Most recent con-stat (power contact to the pumps and controls) For example, lets say that a city has 77 lift stations included in a SCADA network system. The computer system is actively monitoring conditions at each station, one by one. The computer is currently checking conditions on Lift Station #56 and an alarm sounds for Lift Station #14. The computer system immediately evaluates the five contact points listed above for Lift Station #14 and determines that the wet well is high, but the pumps are working. The computer generates a message to the operator at the wastewater treatment plant that there is a problem with Lift Station #14. The operator at the wastewater treatment plant views his computer screen and finds the message concerning Lift Station #14 and manually scrolls to the schematic of that lift station and attempts to clear the alarm. If it does not
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VI. SCADA Limitations

In order to use the system to full potential, it is important that operators understand the SCADA system. With electronic/computer systems of any type, there are some limitations. The following are noted concerning SCADA systems: Lightning strikesoperators should install lightning arresters, ground fault interrupters, or equipment to prevent air to ground lightning from entering the system. Auto-system failureall operators must be able to manually operate the plant in case of auto-system failure. Power failureoperators should have a stand-by generator that automatically starts, and a contingency plan if power fails. Inaccurate data possibilitiesthe data displayed after a power failure may not be accurate. All RTUs and communications equipment must be energized to standard frequencies before the data is correct. Maintenanceoperators should provide regular maintenance for the RTUs and communication equipment. A technology specialist should be available for calibration of equipment, programming, and technical repair. Computer failurethe computer is not correct all the time and will fail due to natural disasters, power failures, or improper care and maintenance. The operator should be trained to question the data displayed and be able to analyze the results. The operator should be trained to investigate plant conditions such as flow, filters, and unusual equipment sounds. The operator should take grab samples and use bench test results to confirm on-line SCADA results. Terrorismthe risk of terrorism is inherent with the use of SCADA technology. The operator should conduct a detailed review of the SCADA security, including access and password protocols. The operator must limit remote access, if possible, to minimize intrusion into the system from unauthorized sources and make sure the systems security measures remain up-to-date with current technology

VII. Summary
Having a SCADA system in a water or wastewater treatment plant streamlines operations and maintenance for the operator. It allows the operator to monitor and control processes via computer that may or may not be housed in the same building as the very parts of the system it controls. SCADA systems can save time and money by eliminating the need for physical inspection, troubleshooting and data collection. This course has reviewed the definition of SCADA, the components of a SCADA system, how they are used in water and wastewater treatment facilities and the benefits and limitations of their use.

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Online Completion

Use this page to review the questions and choose your answers. Return to www.waterworldce.com and sign in. If you have not previously purchased the program select it from the Online Courses listing and complete the online purchase. Once purchased the exam will be added to your Archives page where a Take Exam link will be provided. Click on the Take Exam link, complete all the program questions and submit your answers. An immediate grade report will be provided and upon receiving a passing grade (70%) your Verification Form will be provided immediately for viewing and/or printing. Verification Forms can be viewed and/or printed anytime in the future by returning to the site, sign in and return to your Archives Page.

Questions
1. SCADA is the acronym for ________.
A. System-wide Control and Data Analysis B. Supervisory Center of Daily Analysis C. System-wide Center for Data Acquisition D. Supervisory Control and Data Acquisition

8. SCADA and security should ________.

A. use the same computer system B. be on totally separate computer systems C. work together to maintain constant operations D. never be operated simultaneously

2. SCADA is a _______ to control the plant and distribution system from a single source.
A. software B. watchdog C. tool D. hardware

9. Operators must know that data displayed after a power failure may not be accurate and RTUs and communication equipment must be energized to ________ before the data is correct.
A. B. C. D. low frequencies CB radio channels high frequencies standard frequencies

3. A typical SCADA system is comprised of a ________ of the water system, showing each line, pump station, ground storage, elevated storage, pressure plane, and the water treatment plant.
A. B. C. D. slide show graphics panel time zone all listed

10. Operators must know that the computer is not ________ all the time.
A. working B. correct C. on line D. all listed

4. A SCADA systems four major components are SCADA controls, RTUs, ________, and field communications.
A. command control units B. hand held units C. software D. graphics editor

5. Ground station satellites, cellular telephones, and microwave radio are methods of __________ to send a signal from the RTU to the SCADA control unit.
A. B. C. D. data transfer field communications transient interference command interfaces

6. Hardware-based equipment, softwarebased equipment, and combination systems are types of ________.
A. B. C. D. field-mounted sensors remote terminal units field communications SCADA controls

7. The ________ transfer data to the main computer.

A. telephones B. flow regulators C. remote terminal units D. coaxial cable battery powered radio

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Automated Control Systems SCADA

PROGRAM COMPLETION INFORMATION
If you wish to purchase and complete this activity traditionally (mail or fax) rather than Online, you must provide the information requested below. Please be sure to select your answers carefully and complete the evaluation information. To receive credit, you must receive a score of 70% or better.

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Requirements for successful completion of the course and to obtain 1 professional development hour (PDH): Read the entire course. Take the test online at: www.WaterWorldCE.com A score of 70% on this test will earn you 1 PDH. Optional: Complete course evaluation below and return to: PennWell, James Laughlin, 1421 S. Sheridan Rd., Tulsa, OK 74112 or [email protected]. Payment of $30.00 will be required to take the test. Charges on your statement will show up as: PennWell

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WaterWorld is partnering with the Texas Engineering Extension Service (TEEX) to provide online training material for operators. The Water and Wastewater Training Program at TEEX is the one of the largest water and wastewater operator training organizations in the United States. TEEX provides training to thousands of operators every year. TEEXs mission is to provide continuing education in engineering and engineering-related applied sciences. TEEX is a member of The Texas A&M University System, one of the largest systems of higher education in the United States. Through a statewide network of 11 university campuses, seven state agencies and a comprehensive health science center, the A&M System educates more than 120,000 students, conducts more than $730 million in research and reaches another 22 million people through service and outreach programs each year. teex.org/www [email protected] 800-SAFE-811 (800-723-3811)

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