Rockwell Autoamtion TechED 2017 - AP24 - Stratus Technologies Three Rivers Water Authority Modernization

AP24 - Stratus Technologies
Three Rivers Water Authority Modernization
Steve Andrews, Automation Engineer, AET

Frank Hill, Director Industrial Automation BD, Stratus Technologies
June 2017
PUBLIC
Rockwell Automation TechED 2017 @ROKTechED #ROKTechED Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 1
Agenda
History & Overview of Three Rivers Wastewater Plant
The Technical Decision
Project Design & Owners Engineer
Technical Obstacles Overcome
Project Completion

PUBLIC Rockwell Automation TechED 2017 @ROKTechED #ROKTechED Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 2
Advanced Electrical Technologies (AET)
Rockwell Automation System Integrator located in Longview, WA

UL 508A Panel Shop
75 Industrial electricians, controls and instrument technicians
Design and manufacturing
Focus on control and instrumentation
Decades of process control experience
Three Rivers Regional Wastewater Treatment Authority (TRRWA)
Longview is a city of 36,000 residents

Longview is home to many large industrial water users:
Nippon Paper paper and lumber mills
Kapstone Paper
Norpac Newsprint
Weyerhaeuser Sawmill
NW Hardwoods
Foster Farms
Port of Longview & Log Export Terminal
Three Rivers Waste Water Treatment Plant Aerial Plant Overview
Three Rivers Waste Water Treatment Plant Schematic Overview
SCADA History at Three Rivers and Challenge
1990s Bristol Babcock-Emerson DCS and Wonderware

Challenge:
Upgrade or replace?
Reduce Total Cost of Ownership (TCO)
Improve connectivity and security between Admin and SCADA
Networks
Legacy System Problems
Dependency on one engineer for technical assistance

Limited national technical support
HMI technical support problems
No single point of contact
Ethernet storming, connectivity issues
Limitations of dial-out alarm system
Conglomerate of various VFD manufacturers with limited support options.
Hardware at End-Of-Life
Technical, Commercial Bid & Final Decision
Answering the question, Upgrade or replace?

Considered latest system technologies
CH2M hired to develop new system specification
Replacement chosen
PlantPAx, no equal
AET won bid in field of many
PlantPAx System Implemented
Characterized system using tools and libraries to improve integration

HMI thin clients (FactoryTalk View SE server/clients) with mobility
FactoryTalk Historian SE with VantagePoint reporting
FactoryTalk AssetCentre for event logging and asset management
Stratix-based network infrastructure
Majority of in-panel content is Rockwell, supplied by local Columbia
Electrical Supply (CES)
Other Infrastructure Components
Stratus ftServer based computing infrastructure

33 Virtual Machine servers (VMware)
ACP Thin Manager and 11 HMI thin clients
Mobile computing using ACP Relevance
Win 911 alarm dialer
Five Fortigate 100D firewalls
Two Cisco 3850 switches
Fiber optic backbone completely replaced
Other Infrastructure Components
Fourteen layer 2 switches

Device Level Ring (DLR)
Two transport layers, six VPNs to three pump stations
11 control panels with Logix L72 Processors Ver. 24
12 Network Interface Panels
Remote VPN access for approved plant personnel
Rockwell variable frequency drives
Characterized PlantPAx IAB/PSE
13
PlantPAx Control & I/O Definition
Project Design: IAB System Architecture
Stratix Switch Level Ring
Project Design: IAB Control Building Stratix Switches
PlantPAx Network Overview
Original Control Room Panel
Stratus ftServer & Logix Rack replaced existing Control Room Panel
A Modern Computer Infrastructure Approach
Assure
Monitoring
Server Virtualization
Thin Clients
Fault-Tolerant Computing
2016 Stratus Technologies Confidential 21

Stratus ftServer Platform Overview
Fully redundant hardware

Lockstep Technology
Single System - Single License
No failover time
No data loss
Operational simplicity
Hot-swappable components
24/7/365 support service
System Life 10+ years
Lowest TCO
Eliminates Risk and Dramatically Simplifies Deployment and Maintenance
Stratus ftServer Platform Overview
Fully redundant hardware

Lockstep Technology
Single System - Single License
No failover time
No data loss
Operational simplicity
Hot-swappable components
24/7/365 support service
System Life 10+ years
Lowest TCO
Eliminates Risk and Dramatically Simplifies Deployment and Maintenance
Repaired in 3 easy steps
System automatically identifies the failed

1 component and phones home to a Stratus
Customer Assistance Center
Normal processing continues
throughout process!
System automatically orders replacement part
2 Next Day Delivery Service
The component is installed by customer without tools

3 and is automatically resynchronized without touching a
keyboard
Panel Installation
Representative Existing TWAS Control Panel
New TWAS Rockwell Panel
Control Building Video Wall and Desk
Use of Add-On Instructions
PlantPAx HMI ISA 101 Gray Scale
PlantPAx HMI ISA 101 Gray Scale
Process Library Used Extensively
VantagePoint Reporting
Technical Challenges Overcome
Critical processes had to be cutover live in brief low-flow window of time

Pump station transport layer communication
Win 911 alarming, POTs and VOIP
Bridging the office and SCADA networks with strong security
Five firewalls
Routing policies
VPN and remote desktop implementation
Thin-client management
Project Completion Review
Successfully coordinated project management between CH2M, Three

Rivers, AET, CES and Rockwell Automation
Smooth cut-over
Project completion months ahead of schedule
Total integration at every level with a complete Rockwell solution
No change orders except by request of Three Rivers management
Rockwell PlantPax Improved TCO
Seamless plant-wide AET is less than 2 miles from site

communications & open with local support resources
architecture
Plant staff can troubleshoot and Rockwell Distributor, Columbia
optimize the process themselves Electric Supply (CES)
Plant staff can create their own Stocking distributor, sales &
reports on the fly technical resources
Centralized traceability for
troubleshooting Rockwell Automation local field
Integration with third party engineers, Solution Architects, etc.
vendors and Encompass partners
Duane Leaf, Plant Superintendent: Upgrade or Replace?
Duane Leaf: Bidding Process
We chose CH2M to oversee the engineering, using the public selection process,
who had extensive experience with Rockwell PlantPAx
CH2M developed sole-source bid specs for a Rockwell PlantPAx system
Bid specs included an evaluation system weighted for local installation,
integration and support
Bid specs included multiple cutover planning meetings
Bids specs included scheduling for peak and low flow seasons
Bid specs included staff training opportunities as system was developed and
installed
Project was put out to bid and AET was the successful bidder
Duane Leaf: Project Highlights
No significant issues of any concern during design and cutovers

Communication throughout project was excellent
Project done about 4 months ahead of schedule
Project was completed on budget
Have built a strong ongoing relationship with AET for service
CH2M is pleased with project
Three Rivers staff is very pleased with the project
The board and management is pleased with project quality and timeline
Strategic Rockwell People in the Project
Kevin DeWitt: Global Process Technical Consultant

Mike McInroe: Process Sales Leader
Jenna Ryan: Industry Account Manager
Mike Burroughs: Global Process Technical Consultant
Chris DiBiase: Network and Virtual Infrastructure
Ken Knutson and Dustin DeMars, our Local CES Support
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Username: Last name

Password: Email address used to register
Locate the session in the Schedule icon

Click on the Survey icon in the lower right corner of the session details
Complete survey & submit
Thank you!

Rockwell Autoamtion TechED 2017 - AP24 - Stratus Technologies Three Rivers Water Authority Modernization

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AP24 - Stratus Technologies

Three Rivers Water Authority Modernization

Steve Andrews, Automation Engineer, AET

History & Overview of Three Rivers Wastewater Plant

The Technical Decision

Project Design & Owners Engineer

Technical Obstacles Overcome

Rockwell Automation System Integrator located in Longview, WA

Longview is a city of 36,000 residents

1990s Bristol Babcock-Emerson DCS and Wonderware

Dependency on one engineer for technical assistance

Answering the question, Upgrade or replace?

Characterized system using tools and libraries to improve integration

Stratus ftServer based computing infrastructure

Fourteen layer 2 switches

2016 Stratus Technologies Confidential 21

Fully redundant hardware

Eliminates Risk and Dramatically Simplifies Deployment and Maintenance

Fully redundant hardware

Eliminates Risk and Dramatically Simplifies Deployment and Maintenance

System automatically identifies the failed

The component is installed by customer without tools

Critical processes had to be cutover live in brief low-flow window of time

Successfully coordinated project management between CH2M, Three

Seamless plant-wide AET is less than 2 miles from site

No significant issues of any concern during design and cutovers

Kevin DeWitt: Global Process Technical Consultant

Download the ROKTechED app and login:

Username: Last name

Locate the session in the Schedule icon

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