Proposal for SCADA System Improvements
City of Pittsburg Water Utilities Department 300 Olympia Drive Pittsburg, CA 94565 Attn: Walter Pease
July 14, 2010
Table of Contents Scope of Work ......................................................................................................................................... 1 Project 1
Define Framework ................................................................................................................ 1
Task 110
Document Current State ................................................................................................... 1
Task 120
Define SCADA System Requirements............................................................................... 1
Project 2
Master Station Upgrade ........................................................................................................ 2
Task 210
Design Master Station ...................................................................................................... 2
Task 220
Configure SCADA Application........................................................................................... 2
Task 230
Perform Master Station Factory Acceptance Test.............................................................. 3
Task 240
Perform System Cutover and Site Testing......................................................................... 3
Task 250
Prepare Master Station O&M Manual ................................................................................ 4
Project 3
Remote Site Design.............................................................................................................. 4
Task 310
Conduct Site Visits ........................................................................................................... 4
Task 320
Prepare Radio Path Analyses ........................................................................................... 4
Task 330
Design Communication System ........................................................................................ 5
Task 340
Develop Remote Site Hardware Design Technical Memorandum ...................................... 5
Task 350
Develop Remote Site Programming Design Guide ............................................................ 6
Task 360
Develop Implementation Plan ........................................................................................... 6
Project 4
WTP Controls Upgrade......................................................................................................... 6
Task 410
Assess WTP Control System Needs ................................................................................. 6
Task 420
Design Chemical Feed Controls........................................................................................ 6
Task 430
Design HLPS-1 Controls ................................................................................................... 7
Task 440
Configure and Test WTP Controls..................................................................................... 7
Task 450
Startup WTP Control Programs......................................................................................... 7
Task 460
Develop WTP Controls O&M Manual ................................................................................ 7
Project Management................................................................................................................................ 8 Task 510
Project Administration ....................................................................................................... 8
Task 520
Quality Control.................................................................................................................. 8
Project Schedule ..................................................................................................................................... 9 Fee Proposal ......................................................................................................................................... 10 Project Team ......................................................................................................................................... 11 Appendix A – Resumes ......................................................................................................................... 11
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Scope of Work The City of Pittsburg (City) desires to improve their Supervisory Control and Data Acquisition (SCADA) system to enhance service and reliability for existing customers and to prepare for potential growth. These improvements must be cost-effective and designed for simplicity in maintenance and support. For the City of Pittsburg, these improvements will focus on improvements in three business drivers: Regulatory Compliance, Automatic and Supervisory Control, and Energy and Chemical Management. Westin recently developed a SCADA System Assessment Technical Memorandum that describes the overall SCADA System Upgrades for the City of Pittsburg. This plan defined four projects to improve the City’s existing SCADA System over a 2-year timeframe. The projects focus on defining the SCADA design framework, upgrading the SCADA Master Station, designing and implementing improvements to the SCADA Remote Sites, and revising the Water Treatment Plant (WTP) controls. Each project will strive for consistency in SCADA design, implementation, and documentation, so that the City will be able to maintain the SCADA system with at minimum cost. The highest priority project is upgrading the SCADA Master Station. This is the heart of the overall SCADA system and will establish the basis for all other SCADA system improvements and enhancements, including the addition of new remote sites in the future. Completion of this project will also provide a framework for effective alarm management. The next highest priority project is improving the remote site radio communication and control system. This project will achieve more reliable and higher throughput communications between the SCADA Master Station and the remote sites. Finally, the WTP control system project will consolidate and improve WTP controls, including the chemical feed systems. By implementing flow rate and/or concentration control strategies, this project will help to optimize chemical and energy management at the WTP.
Project 1 Define Framework Task 110
Document Current State
Westin will develop accurate block diagrams for each of the three major components of the existing SCADA System; the Master Station, Remote Sites, and WTP Controls. We will document the current state of the SCADA system through interviews and field investigation to develop a list of high-level SCADA system needs. Deliverables: •
SCADA System Block diagrams (3)
Task 120
Define SCADA System Requirements
Westin will conduct a workshop with the City’s SCADA System Stakeholders to review current SCADA System functionality and performance and to discuss areas that require upgrade and enhancement. Westin will work with the City’s PM to determine the appropriate functional groups and specific participants that will attend the workshop. Westin will distribute a SCADA System Requirements Checklist to the participants in advance of the workshop. This checklist summarizes the major issues that should be considered when defining requirements for SCADA System upgrades and enhancement and, by reviewing it, the workshop participants should be better prepared to contribute to the workshop. Westin will prepare a structured workshop agenda which will help the City’s staff focus on the operational requirements for the new/upgraded SCADA Systems. We will review the current conditions and existing City of Pittsburg – SCADA System Improvements Westin Proposal No. P10-188
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functionality (sometimes referred to as the “As-Is” state). Typically, there are many features and functions of the existing systems that work well and which should be retained in any new systems. We will also discuss features and functionality that are missing or not ideal in the current installation, including system expansion capability (“To-Be” state). We will also identify system components that are in need of near term replacement by virtue of their age, obsolescence, or their functional limitations. During the requirements workshop, Westin will lead City staff in a discussion of the steps necessary to improve the functionality and performance of their existing SCADA and communication systems. These discussions will be mindful of the existing systems and the need to maximize the City’s return on their existing SCADA investments, but with a forward-looking vision for moving their SCADA Systems toward industry best practices. The workshop will also include discussions of specific SCADA System implementations by other Utilities of similar size. Deliverables: •
List of SCADA system requirements
Project 2 Master Station Upgrade Task 210
Design Master Station
Master Station Hardware and Software Design Westin will develop a SCADA Block Diagram and supporting Bill of Materials (BOM) and Catalog Cut Sheets for the SCADA Master Station hardware and network equipment. The hardware and software specified will include SCADA servers, Historian, iFIX, SCADAlarm, and Reporting Tools. Network equipment will include switches for SCADA network control. The design will include functional descriptions of major components, a transition plan for cutover of the SCADA Master Station, Factory Acceptance Test (FAT) and Site Acceptance Test (SAT) procedures, and documentation requirements. It is assumed that the hardware and software products specified in the BOM will be procured by the City and shipped to Westin’s Sacramento office for software configuration.
Application Software Design Guide Westin will conduct a 1/2 day workshop with the City to define the SCADA application guidelines for the HMI database, graphic standards, alarm management, and reports. Westin will then submit draft Software Design Guide for the City’s review and approval before proceeding with the SCADA Master Station application development. The draft Software Design Guide will include an HMI Database List, navigation schemes, graphical objects, and graphic templates. Deliverables: •
Workshop preparation and materials
•
Draft SCADA Block Diagram, Bill of Materials, Functional Descriptions, Transition Plan, SAT Procedures, Documentation Requirements, Application Software Design Guide
•
Final SCADA Block Diagram, Bill of Materials, Functional Descriptions, Transition Plan, SAT Procedures, Documentation Requirements, Rack Layout Diagram, and Application Software Design Guide
Task 220
Configure SCADA Application
Application Software Development Westin will perform initial system setup including communication drivers, access privileges, etc. Westin will convert the HMI database using information from the existing FIX32 system. We have based
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our proposal on defining up to 2,500 I/O points in the HMI database. HMI database set-up will include defining the following parameters for each I/O point: •
Tag name
•
Point descriptor
•
FIU address
•
Alarm/event status
•
Up to 4 alarm limits for analogs (high-high, high, low, low-low)
•
Alarm priority
•
Range and engineering units for analogs
•
Active state for discrete
Westin will develop new HMI Graphic displays to depict the existing remote facilities and WTP. We have assumed up to 20 graphic displays will be developed and that standard graphic templates will be used for similar equipment.
Alarm Management Based on the alarm management guidelines in the Application Software Design Guide, SCADA alarms will be assigned one of three priority levels, depending on the severity of the alarm: •
High: potential hazardous or permit compliance condition, requiring immediate response
•
Medium: potential performance deviation, requiring prompt attention
•
Low: alert to abnormal condition, requiring acknowledgement
Once the alarms are identified, Westin will configure the HMI software to provide local alarm display and annunciation and remote notification. The alarm system will call-out to designated City employee contacts (email, text, or voice).
Historian Westin will configure the Historian to capture information for all analog values. This historical information will be available for use in system reports and trends. We have included budget to develop five (5) reports to be defined during the reports workshop. Deliverables: •
SCADA Master Station application software, including HMI database, 20 graphic displays, alarm management system, communication drivers, access privileges, historian, and 5 reports.
Task 230
Perform Master Station Factory Acceptance Test
Westin will conduct a Factory Acceptance Test (FAT) of the completed HMI application at our Sacramento, CA office. The City PM and representatives of their project team should attend the FAT. At the conclusion of the FAT, Westin will address any punch list items and then prepare the system for shipment to the City’s WTP facility. We have assumed that the City will be responsible for all shipping costs (both to and from Westin’s office).
Task 240
Perform System Cutover and Site Testing
Westin will assist the City install the new Master Station hardware and software at the WTP facility. Then, following the transition plan defined in Task 210, Westin will cut over the SCADA application software to
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operate the City’s WTP and remote sites. Once the cutover has been completed, Westin will conduct a System Acceptance Test using the procedures defined in the Master Station Hardware and Software Design.
Task 250
Prepare Master Station O&M Manual
Westin will prepare an Operations and Maintenance Manual for the upgraded Master Station SCADA system. The O&M Manual will contain an update of the Master Station Hardware and Software Design to reflect as-built configuration of the Master Station. It will also contain an update of the Application Software Design Guide to reflect as-built system configuration at the time of final acceptance. SCADA Master Station maintenance procedures will be added to the as-built documentation to complete the O&M Manual. Deliverables: •
As-built Master Station Design
•
As-built Application Software Design Guide
•
Master Station Maintenance Procedures
Project 3 Remote Site Design Task 310
Conduct Site Visits
Westin will conduct a meeting with City staff to identify information to be gathered during each site visit. These site visits will update existing control system documentation (PLC code, panel layouts, etc.). We have assumed that City staff will participate in the site visits and will be responsible for gathering this additional site information. A team of City staff and Westin staff (one) will visit each of the twelve (12) remote sites. Westin will work with City staff to categorize the sites and determine the most efficient routes for the site visits. We have assumed that an average of six (6) sites can be visited each day. A total of two (2) days will be utilized for site visits. Westin will develop a brief Site Visit Report that summarizes the radio communication and control system information gathered during the site visits. Deliverables: •
Site Visit Reports
Task 320
Prepare Radio Path Analyses
Westin will prepare computer-generated radio path profiles to support conversion of the two existing leased line connections to spread spectrum. Each radio path will be categorized in one of three ways: 1) reliable, 2) marginal or 3) blocked. A summary table will be produced that lists for every path, the end points, length, and clearance category. The radio path profiles will show how much clearance there is between each radio path and the terrain along the path, with the antennas as currently installed. From this, it will be determined whether or not the path has sufficient clearance above the terrain, buildings and/or trees along the path (an assumption will be made regarding the average height of buildings and trees in the area). For paths that do not have sufficient clearance, the summary table will list the necessary antenna heights needed to obtain a clear path.
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Deliverables: •
Radio Path Profiles
Task 330
Design Communication System
Westin will conduct a half-day workshop to discuss the requirements for the redesigned radio system. Items that will be discussed include: •
Redundant paths to key sites
•
Data update rate requirements
•
Potential repeater sites
The requirements identified in the workshop will be included in the Communication System Design Technical Memorandum. Westin will utilize the information gathered in the Site Visits, Radio Path Profiles, and Design Workshop to develop the Technical Memorandum. The Technical Memorandum will include the following: •
A brief description of the existing system architecture and the current state of the system.
•
A summary of the design criteria established.
•
Radio path profiles and summary spreadsheet.
•
Summary of findings during the Site Visits.
•
Discussion of alternatives available to resolve path reliability and throughput issues.
•
The recommended steps to establish reliable communications for those paths that are marginal or blocked.
Westin will submit a Draft Technical Memorandum to the City for review and comment. Westin will conduct a two-hour review workshop to develop the Final Technical Memorandum. Deliverables: •
Draft Communication System Design Technical Memorandum
•
Final Communication System Design Technical Memorandum
Task 340
Develop Remote Site Hardware Design Technical Memorandum
Westin will develop a technical memorandum that outlines the design requirements for the remote site hardware improvements. The TM will contain a Remote Site Block Diagram and supporting Bill of Materials (BOM) and Catalog Cut Sheets for the Remote Site PLC and radio equipment. The equipment specified will include GE 9030 PLC processor, I/O modules, and 900 MHz spread spectrum radio and antenna. The TM will also include functional descriptions of major components, Site Acceptance Test (SAT) procedures, and documentation requirements. Deliverables: •
Draft Remote Site Hardware Design TM
•
Final Remote Site Hardware Design TM
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Task 350
Develop Remote Site Programming Design Guide
Westin will conduct a 1/2 day workshop with the City to define the Remote Site programming and configuration for the PLC controls and radio communications. Westin will submit a draft Remote Site Programming Design Guide for the City’s review and approval. The draft Remote Site Programming Design Guide will include a PLC Database List, control program objects, and communication configuration settings. Deliverables: •
Workshop preparation and materials
•
Draft Remote Site Programming Design Guide
•
Final Remote Site Programming Design Guide
Task 360
Develop Implementation Plan
Based on the Communication System Design TM, the Remote Site Design TM, and the Remote Site Programming Design Guide, Westin will develop a Remote Site Implementation Plan. This plan will include prioritization criteria for sequencing of remote sites for upgrades, and opinions of cost and schedule to upgrade each site. Westin will submit a draft and a final Remote Site Implementation Plan for the City’s review and approval. It is assumed that the City will procure the equipment specified in the BOM. The approach for installation and programming of the remote site improvements will be determined as part of the implementation plan; however, no costs for these services have been included in this proposal. Deliverables: •
Draft Remote Site Implementation Plan
•
Final Remote Site Implementation Plan
Project 4 WTP Controls Upgrade Task 410
Assess WTP Control System Needs
Building on the WTP block diagram and high-level list of needs developed in Project 1, Westin will conduct further interviews and field investigations to develop a list of detailed WTP control system needs and a BOM for WTP control system improvements. This list will include descriptions of existing controls, documentation needs, and process control narratives for the chemical feed systems and High Lift Pump Station 1 (HLPS-1) controls. Deliverables: •
WTP Control System Needs Assessment
•
Chemical Feed Systems Control Narratives
•
HLPS-1 Control Narrative
•
WTP BOM, including instrumentation and one GE PLC
Task 420
Design Chemical Feed Controls
Westin will develop a Process & Instrumentation Diagram (P&ID) for up to seven (7) chemical feed systems. The P&ID will identify equipment to be controlled, hardwired and soft I/O, equipment
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permissives and interlocks, and operator inputs, including control commands and setpoints. The chemical feed control systems will use flow rate or concentration feedback to automate chemical dosing. The design will include a startup plan based on using the existing GE PLC. Deliverables: •
Draft and Final P&IDs, one each for up to 7 chemical feed systems
•
Startup Plan
Task 430
Design HLPS-1 Controls
Westin will develop a Process & Instrumentation Diagram (P&ID) for the HLPS-1. The P&ID will identify equipment to be controlled, hardwired and soft I/O, equipment permissives and interlocks, and operator inputs, including control commands and setpoints. The HLPS-1 control system will be based on the current control strategy used in the Toshiba PLC. The design will include a transition plan based on a new GE PLC replacing the existing Toshiba PLC. Deliverables: •
Draft and Final P&ID for the HLPS-1
•
Transition Plan
Task 440
Configure and Test WTP Controls
Based on the control narratives and P&IDs, Westin will develop control logic programming using GE’s Proficy Logic Developer and operator graphic screens using GE’s Proficy iFIX Application Software Developer. Up to seven (7) new screens will be developed for the chemical feed systems. The existing screen for the HLPS-1 will be modified to reflect any changes to the HLPS-1 controls. This application development includes modifications to the alarm and historian databases. Westin will conduct a bench test of the completed chemical feed system controls and HLPS-1 controls at our Sacramento, CA office. At the conclusion of bench testing, Westin will address any punch list items and then proceed with installation of the completed programming and software application on the PLCs and Master Station in the City’s WTP facility.
Task 450
Startup WTP Control Programs
Following the Startup Plan and Transition Plan defined in the chemical feed system and HLPS-1 designs, Westin will startup the chemical feed systems controls and cutover the HLPS-1 controls. System Acceptance Test procedures defined in the Master Station Hardware and Software Design will be followed at the site acceptance test at the WTP.
Task 460
Develop WTP Controls O&M Manual
Westin will prepare an Operations and Maintenance Manual for the upgraded WTP controls. The O&M Manual will contain an update of the PCNs and P&IDs to reflect as-built configuration of the WTP controls. The O&M Manual will also include an update of the Application Software Design Guide to reflect as-built system configuration at the time of final acceptance. PLC and instrumentation maintenance procedures will be added to the O&M Manual. Deliverables: •
As-built PCNs and P&IDs
•
PLC Program Documentation
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•
As-built Application Software Design Guide
Project Management Task 510
Project Administration
Progress Reports will be submitted to the City Project Manager every month for the duration of the project. The progress reports will be formatted to summarize the work completed for the current month and the work planned for the following month. The progress reports will also provide a task-by-task analysis of budget expended versus progress to date. If the expenditures for any task are significantly out of proportion to progress, the report will include a discussion of the contributing factors and a proposed plan for correcting the situation. Progress reports will also include an updated Action List and Project Schedule. Westin will maintain a decision log, documenting significant decisions made during the progress meetings and an action item list, tracking assigned action items and required completion dates. The decision log and action item list will be reviewed during the monthly progress meetings.
Task 520
Quality Control
To support Westin’s QA/QC program, an independent Westin Principal Engineer will conduct a review of all project deliverables. The QA/QC review will follow Westin’s guidelines and procedures that have been established to ensure the application of industry design practices.
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Project Schedule The proposed schedule follows the schedule outline in the SCADA Assessment Technical Memorandum. It assumes an August 1 start date and substantially completes the SCADA system upgrades in 13 months.
Figure 1 - SCADA Upgrade Projects Gantt Chart
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Fee Proposal Table 1 presents a fee proposal for services to be provided by Westin. This fee proposal is based on a Time and Materials (T&M) services contract with monthly progress payments. We assume all recommended products and materials necessary for completion of the SCADA Improvements project will be procured by the City of Pittsburg directly. We also assume all field construction work requiring a contractor license will be performed either by City of Pittsburg staff or a licensed contractor under direct contract to the City.
Table 1 – Fee Proposal
Task Description Project 1 – Define Framework 110 Document Current State 120 Define Desired State Project 2 –Master Station Upgrade 210 Design Master Station 220 Configure SCADA Application 230 Perform Master Station FAT 240 Perform System Cutover and Site Testing 250 Prepare Master Station O&M Manual Project 3 – Remote Site Design 310 Conduct Site Visits 320 Prepare Radio Path Analyses 330 Design Communication System 340 Develop Remote Site Hardware Design TM 350 Develop Remote Site Prog Design Guide 360 Develop Implementation Plan Project 4 – WTP Controls Upgrade 410 Assess WTP Control System Needs 420 Design Chemical Feed Controls 430 Design HLPS-1 Controls 440 Configure and Test WTP Controls 450 Startup WTP Control Programs 460 Develop WTP Controls O&M Manual Project Management 510 Project Administration 520 Quality Control Total Fee
City of Pittsburg – SCADA System Improvements Westin Proposal No. P10-188
Labor $10,768 $3,992 $6,776 $55,464 $13,184 $25,368 $6,040 $6,040 $4,832 $31,304 $2,416 $2,416 $6,040 $3,624 $6,040 $10,768 $109,160 $5,824 $21,240 $13,960 $48,096 $13,360 $6,680 $23,114 $17,628 $5,516 $229,840
Travel $330 $0 $330 $495 $0 $0 $0 $495 $0 $330 $330 $0 $0 $0 $0 $0 $1,265 $275 $0 $0 $0 $990 $0 $0 $0 $0 $2,420
Total $11,098 $3,992 $7,106 $55,959 $13,184 $25,368 $6,040 $6,535 $4,800 $31,634 $2,746 $2,416 $6,040 $3,624 $6,040 $10,768 $110,425 $6,099 $21,240 $13,960 $48,096 $14,350 $6,680 $23,114 $17,628 $5,600 $232,260
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Project Team Figure 2 shows the proposed project team and their respective roles for your SCADA System Improvements Program. Mr. Michael Johnson, who authored the SCADA System Needs Assessment, will provide project management services and ensure continuity of recommendations through to successful achievement. Phil Gaberdiel will provide Quality Assurance oversight. Mr. Kelly Pennington will be the primary engineer for most control system design, development, testing and startup. Mr. David Babinger will be the secondary engineer if necessary for schedule constraints or specialized skills.
Figure 2 - Project Organization Chart
Appendix A – Resumes Michael Johnson Kelly Pennington David Babinger Phil Gaberdiel
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