CITY OF INDIANAPOLIS DEPARTMENT OF PUBLIC WORKS · A wealth of resources to master a common goal....

A wealth of resources to master a common goal.

CITY OF INDIANAPOLIS DEPARTMENT OF PUBLIC WORKS

Item 10—Supervisory Control and Data Acquisi)on (SCADA)

Monitoring System reloca)on

March 2, 2017


7256 Company Drive, Indianapolis, IN 46237

Ph: 317-888-1177 - Toll Free: 800-289-1177

Fax: 317-887-8641 - www.commonwealthengineers.com

City of Indianapolis Department of Public Works Item 10 - Supervisory Control Data Acquisi)on (SCADA) Monitoring System Reloca)on

Toby Church, PE, CEA

Project Manager

Greg Bryan

Infrastructure (MBE) 15%

Lori Rushin, PE

Eilts (WBE) 8%

James R Gill

Precept Surveying (VBE) 3%

Rachel Wilson, PE

Dept. of Public Works

Senior Project Manager

Chris Means

Electrical Designer


Toby Church, P.E., CEA

Senior Electrical Engineer

EXPERIENCE & EXPERTISE

Toby has been involved in the design and implementa1on of electrical and control systems for

over 25 years. With his educa1ons and work experience, he possesses exper1se in the

electrical and control field and is able to evaluate and design cost-effec1ve electrical and

control systems. He prides himself on being able to discuss with the owner their needs and

design a cost-effec1ve electrical/control system that meets those needs.

RELEVANT PROJECT EXPERIENCE:

• Newburgh Indiana—WWTP Improvements Design: Designed the improvements

including the mechanical screening, grit removal, and biosolids facili1es. The project

included the powering and control of 11 Centrifugal blowers with variable frequency

drives on Dissolved Oxygen control.

• Indianapolis Indiana—Buck Creek LiA Sta)on 313: This project included both the

evalua1on of and design upgrades to Li; Sta1on 313. The modifica1ons project

addressed exis1ng deficiencies of the li; sta1on and included the implementa1on of new

electrical and controls for the City of Indianapolis’ largest li; sta1on. The sta1ons capacity

was increased to approximately 60 million gallons per day.

• Indianapolis Indiana—Indianapolis Water Fall Creek Filter Control Replacement:

Replaced exis1ng relay and solenoid valve controls with new Allen Bradley PLC based

controls. Maintained plant opera1on during en1re construc1on project.

• Kokomo Indiana—VFD: The exiting antiquated reduced voltage motor starters were

replaced with new Variable Frequency Drives (VFD’s) providing the City of Kokomo with

needed energy savings motor speed control. The new VFD’s allow the City to control the

speed of the motors to maintain the needed dissolved oxygen and thus reducing energy

consumption. The VFD’s also increase the life expectancy of the blowers and their motors.

Current Limi1ng also allowed the re-use of exis1ng generator to save on capitol costs.

• Indianapolis Indiana—Belmont WWTP Plant Drain: New plant drain pump controls

networked to exis1ng Ethernet.

• Lowell Indiana—WWTP: New SCADA system with WWTP upgrades. Fiber op1c

Ethernet, PLC’s, and RS-View front end so;ware.

• Madison Indiana—WWTP: New SCADA System with remote sites via spread spectrum

radio and local Ethernet network.

• South Bend Indiana—CSO: Eight CSO monitoring sights communica1ng to SCADA via

spread spectrum radios.

• Terre Haute Indiana—LiA Sta)on Telemetry: Spread Spectrum communica1ons from li;

sta1ons to front end SCADA computer.

EDUCATION &

CREDENTIALS:

Electrical Engineer

B.S. Purdue

University, 1992

AEE Cer1fied Energy

Auditor

Licensed Master

Electrician

Power Quality

Analysis Training

REGISTRATION:

Indiana Professional

Engineer

PE 11300603

KEY SKILLS

Controls System

Design

Electrical System

Design

Blueprints &

Schema1cs

Generators &

Transformers

Switches & Circuit

Breakers

Electrical Code

Troubleshoo1ng

Tes1ng Instruments

Motors & Conduit


• Fishers Indiana WWTP Energy Audit and Aera)on Evalua)on: The exis1ng Aera1on

System consists of three 250HP Mul1 Stage Centrifugal Blowers on Variable Frequency

Drives (VFD’s) and five 75HP Constant Speed Mul1 Stage Centrifugals. A plan was

developed to modify the exis1ng piping and header. These modifica1ons provide for a

common aera1on header allowing the control system to modulate the exis1ng blowers

and controls to maintain much 1ghter DO control lowering energy costs. Capitol costs are

$65,000 yielding annual savings of $48,000.

• Osgood Indiana WWTP Upgrades: The project consisted of wastewater collec1on

system rehabilita1on and wastewater treatment plant improvements directed toward

increasing opera1onal efficiency and increasing peak wet weather flow rate capability by

providing offline flow equaliza1on. The project included 7 PD blowers on variable

frequency drives with various control techniques implemented to op1mize energy

savings.

• Terre Haute Indiana WWTP Improvements Design: Designed the septage/grease

receiving facility and expanded and improved sludge treatment processes with the

addi1on of Centrifuges.

• Carmel Indiana WWTP Digester Gas Burner: New digester/burner control system

integrated into exis1ng SCADA.

• Evansville Indiana LiA Sta)on Controls: New controls and electrical for nine (9) li;

sta1on upgrades and replacement.

• Crown Point Indiana Water and Wastewater Electrical and Control Projects: Designed

electrical and control upgrades for various water and wastewater projects including CSO

redirec1on, li; sta1on replacement and upgrades, blower control, ter1ary filter electrical

control, and collec1on surcharging control.

Addi)onal projects can be provided upon request.

Toby Church, P.E., CEA

Senior Electrical Engineer EDUCATION &

CREDENTIALS:

Electrical Engineer

B.S. Purdue

University, 1992

AEE Cer1fied Energy

Auditor

Licensed Master

Electrician

Power Quality

Analysis Training

REGISTRATION:

Indiana Professional

Engineer

PE 11300603

KEY SKILLS

Controls System

Design

Electrical System

Design

Blueprints &

Schema1cs

Generators &

Transformers

Switches & Circuit

Breakers

Electrical Code

Troubleshoo1ng

Tes1ng Instruments

Motors & Conduit


EXPERIENCE & EXPERTISE

Chris has over 7 years experience with Commonwealth Engineers in areas such as water

distribu1on systems, sanitary sewer collec1on systems, and wastewater treatment. As an

Electrical Designer, Chris is involved in Generator Sizing, Conduit/Wire Sizing, Instrumenta1on

and Control, and SCADA

RELEVANT PROJECT EXPERIENCE

• Nappanee, Indiana - Wet Weather Treatment Facility: Designer

• Terre Haute, Indiana - Wet Weather Treatment Facility: Designer

• Crown Point, Indiana - LTCP Improvements Project: Designer

• Fishers, Indiana - Allisonville Road LiA Sta)on Parallel Force Main Project: Designer

• Nappanee, Indiana - CSO Interceptor Project: Designer

• Madison, IN - Madison State Hospital Complex Wastewater Collec)on System

Improvements: Designer

• Logansport, Indiana - High Flow Wet Weather Abatement: Designer

EDUCATION:

Bachelor of Science

in Construc1on

Technology

Indiana State

University

Chris Means

Electrical Designer


Sub Consultant Informa)on—Infrastructure Engineering


Sub Consultant Informa)on—Eilts Consul)ng Services

LORIRUSHIN,P.E.

PROJECTMANAGER

AREASOFEXPERTISE:ProjectManagement,ConstructionInspection,Topographic

Survey&ConstructionEngineering,

Related Project Experience:

IAA-I-12-018 – Pavement Rehabilita�on New Indianapolis Airport, Indianapolis, IN

Design services included topographical survey data collec1on and pavement evalua1on of

perimeter roads at the New Indianapolis Interna1onal Airport.

IAA-11-014 Federal Express Cargo Apron Expansion –Indianapolis, IN

Inspec1on services included reinforcing & concrete pavement tes1ng services for Phase I as

well as stormwater inspec1on services for Phase II.

BL-33-053ASoutheastern/RaymondSTEPCitzensEnergyGroup,Indianapolis,IN

Inspector for the construction of sanitary sewers ranging from 8” to 18” in diameter

includingthelateralinstallationfor372homes.

CS-26-12BPoguesRunCSO143BasinSewerSeparation,.Indianapolis,IN

Review of the installation of storm sewers to separate stormwater runoff from the

combined sewers involving approximately 7,700 LF of storm sewer pipe, 12” to 54” in

diameter, storm inlets, and water quality basin & bioswale to treat stormwater before

dischargingintoPogue’sRun.

SS-28-003EastMarionCountyInterceptorManholeRehabilitation,Indianapolis,IN

InspectorfortherehabilitationofmanholesthroughoutMarionCountyincludingcement

liningexistingstructures,providingnewsealsandleaktesting.

INDOT R-30351 - Illinois St. Rehabilita�on, Indianapolis, IN

Project involved the inspec1on of new installa1on of curbs, islands, sidewalks, handicap ramps

coordinated with the Cultural Trail in downtown Indianapolis.

INDOT R-30159 - 10th & Shadeland Intersec�on Improvements, Indianapolis, IN

Project involved inspec1on for the new installa1on of curbs, ramps, driveways and new

intersec1on light poles and traffic signals.

INDOT R-30926 Canal Road Bridge Rehabilita�on Terre Haute, Indiana

Construction Engineering services included horizontal and vertical control including

stakingfortheroadwayaswellasallstructuresandmonuments.

INDOT RS-32856 ARRA Resurfacing-Franklin, Raymond & Southeastern, Indianapolis, IN

Inspection services for existing road reconstruction project included new asphalt overlay & handicap ramp installation.

BM-35-015 – Bridge Rehabilita�on Prospect St. over Grassy Creek, Indianapolis, IN

Inspection services included review of concrete bridge deck overlay and erosion control measures.

E i l t s C o n s u l t i n g S e r v i c e s

EDUCATION

B.S.C.E.Purdue

University

B.A.DePauw

University

CERTIFICATIONS

IWEAWater&

SewerConstruction

InspectionCerti<ied

INDOTNEPA&

Categorical

ExclusionTraining

INDOTSiteManager

INDOTPrequali<ied

Consultant8.1

PavementDesign;

13.1Construction

Inspection

INDOTProject

Engineer/Project

SupervisorTraining

INDOTStormwater

InspectionCerti<ied

ATSSATraf<ic

ControlSupervisor

&Technician

Certi<ied

ESSWICerti<ied

Erosion,Sediment&

Stormwater

Inspector

CPESCCerti<ied

Professionalin

Erosionand

SedimentControl

Professional

Engineer-IN

WBE-DBEIndiana,

Illinois,&Kentucky


Sub Consultant Informa)on—Precept Surveying, LLC


CLIENT City of Indianapolis

COMMONWEALTH

PERSONNEL Toby Church, P.E.

Project Responsibili1es:

System Design

Project Management

PROJECT HIGHLIGHTS • Rehab controls for 12 filters

• Exis1ng control panels had

become obsolete and needed

to be replaced

• Design build project with

Ci1zens Energy and Bowen

Engineering

PROJECT DESCRIPTION

The exis1ng control panels were beyond their useful life span, were

unreliable, difficult to find replacement parts for, and in need of

replacement. The exis1ng filter control panels had been modified

mul1ple 1mes over the years, and were built into the block walls,

which dictated the size of the replacement panels. Due to the

necessity to maintain produc1on in order to provide clean drinking

water to the City of Indianapolis, each filter had a maximum down 1me of one week.

As a solu1on to these challenges custom control panels were manufactured to fit into the exis1ng control panel

loca1ons, housed in the block walls. This provided an aesthe1cally pleasing solu1on that was func1onal and provided

for room to service the new controls.

The short down 1me required that the control panel be built, tested, and programmed before shut down. The conduit

and wire to the field instruments had to be complete, leaving only the final connec1ons to the new control panel when

it was set in place. Addi1onally, the new filter controls required wiring and programming modifica1ons to the exis1ng

blower control panel. An Ethernet network was installed to each filter and a new computer with Intellu1on Fix32 was

provided to display the status of each filter. The exis1ng SCADA computer was modified to communicate to the new

networked PLC's. PLC’s are Allen Bradley Micrologic with Allen Bradley HMI touch screens.

Similar Experience

Fall Creek Filters Control Upgrade - Indianapolis, Indiana


CITIZENS FILTER PANEL REHAB

BEFORE AFTER

Fall Creek Filters Control Upgrade - Indianapolis, Indiana (Con)nued)


CLIENT City of Indianapolis

COMMONWEALTH



System Design

Project Management

PROJECT HIGHLIGHTS • New Electrical

• New Variable Frequency

Drives

• Redundant U1lity Services for

backup power

• New Allen Bradley Controls

• Redundant PLC Processors

• Redundant communica1ons

paths

• Redundant instrumenta1on

• Surge protec1on

PROJECT DESCRIPTION

This project included both the evalua1on of and design upgrades to Li; Sta1on

313. The modifica1ons project addressed exis1ng deficiencies of the li; sta1on

and included the implementa1on of new electrical and controls for the City of

Indianapolis’ largest li; sta1on. The sta1ons capacity was increased to

approximately 60 million gallons per day.

The project included five (5) new 380 HP Flygt pumps with the associated new

electrical and controls with the necessary backup and redundancy for such a cri1cal

Li; Sta1on.

The new electrical and control system consists of Allen Bradley (AB) PLC controls

with variable frequency drives on all pumps. The Allen Bradley ControlLogix system

consists of redundant PLC processors capable of hot backup. Backup instruments

include redundant level transmiNers and redundant bubbler level sensors. The AB

Control System is integrated into the City of Indianapolis SCADA System via MDS

radios capable of mul1ple communica1ons paths for redundancy. Flygt CAS pump

safety equipment is integrated into the control logic.

Buck Creek LiA Sta)on (LiA Sta)on 313) - Indianapolis, Indiana


Newburgh Wastewater Treatment Plant Improvements - Newburgh, IN

CLIENT City of Newburgh

COMMONWEALTH



System Design

Project Management

PROJECT DESCRIPTION

The waste water treatment plant was required to remain in service during the

en1re length of the project including the demoli1on of the exis1ng controls and

installa1on and startup of the new controls. Due to the new controls being

Ethernet-based and the project schedule dicta1ng the installa1on of new

controls being staged months apart, new PLC controllers on Ethernet and

exis1ng PLC controllers on DH+ had to be able to pass informa1on back and

forth to keep all systems opera1onal.

As a result of the system requiring con1nuous opera1on, temporary Operator Interface Touchscreens (OIT’s) were

added to new control panels that were not connected to the new SCADA system allowing the plant operators to have

full control of the new equipment. Temporary PLC’s had to be added in certain loca1ons to pass cri1cal informa1on

from the DH+ network to the new Ethernet network using the serial ports and message commands of the new and

exis1ng PLC’s. Since the new controls were replacing exis1ng PLC controls that were in service, all new control panels

had to be thoroughly tested with programming and graphics complete before replacing the exis1ng equipment. The

exis1ng SCADA computers were upgraded from Windows NT machines with Wonderware 7.0 graphics so;ware and

DH+ communica1ons. The new system was upgraded to Windows XP with Wonderware 10.1 graphics so;ware and

Ethernet communica1ons. Trending, alarming, and repor1ng had to be completely func1onal on the new SCADA

computers that were communica1ng with the new controls being installed in different stages.

PROJECT HIGHLIGHTS • The exis1ng Newburgh WWTP

consisted of five Sequence

Batch Reactor (SBR) tanks that

were designed to handle

14.4mgd.

• With the improvements project,

an addi1onal three SBR tanks

were added to the system to

increase the intake of the plant

to 19.2mgd.

• The improvements project also

replaced the exis1ng Allen

Bradley DH+ PLC network with

an Ethernet network with a

fiber op1c backbone providing

for faster and more reliable

SCADA Communica1ons.


Blower VFD Upgrade - Kokomo, Indiana

CLIENT City of Kokomo

COMMONWEALTH



System Design

Project Management

PROJECT DESCRIPTION

The VFDs were to be installed in the exis1ng Motor Control Center (MCC)

enclosure. Only one blower at a 1me could be out of opera1on during

the installa1on. The main supply power bus had to remain energized

throughout the equipment installa1on. Ven1la1on had to be added to

each motor control enclosure to ensure adequate cooling of the new

Variable Frequency Drives (VFD’s). The new VFD’s operate in conjunc1on with the exis1ng blower control panels and

the plant-wide SCADA system.

The exis1ng reduced voltage equipment was removed and the main control circuit breaker was moved to allow for

installa1on of the new Variable Frequency Drives. A dv/dt filter (electrical noise filter) was added to the load side of

the VFD to provide electrical noise reduc1on to extend the life expectancy of the exis1ng motors. The 700 Amp

power wiring was installed u1lizing flexible insulated busbar. The exis1ng control wiring was connected to the

exis1ng PLC and SCADA system and each blower was back in service within 48 hours.

PROJECT HIGHLIGHTS • The scope of the blower VFD upgrade

included the replacement of obsolete

reduced-voltage starters with new

variable frequency drives (VFD).

• With the exis1ng starters, the

blowers ran at full speed and the air

volume was controlled with inlet

dampers on each blower.

• The VFD replacement allows air

volume to be controlled by

modula1ng the blower speed. This

reduces wear on the motor and

blower bearings and has reduced the

electrical consump1on by an average

of 25-30%.

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