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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 District’s operations Is flexible, expandable, reliable, secure, and optimized Is adaptable to changes in technology Leverages the District’s 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