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Master Metering using your SCADA System

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An educational presentation of the latest technology for integrating master flow meters into a SCADA system.

Three case studies are presented, each detailing a different SCADA communication backbone: FM Telemetry Radio-Modem, Cellular/GSM/GPRS Modem, and Extraterrestrial Satellite Modem.

The metered liquid in the case studies is potable water, although the technology is applicable to wastewater, oil, gas, steam, etc..

Published in: Engineering

Master Metering using your SCADA System

  1. 1. Jim Mimlitz SCADAmetrics Master Metering Using Your SCADA System A Briefing to the AWWA Midwest Water & Wastewater Technology Conference 05 June 2014 Grayslake, Illinois © 1995-2014 COPYRIGHT SCADAMETRICS ALL RIGHTS RESERVED. 0 1 0 0 10 1 110 0 1 1 1 0 0
  2. 2. Why Integrate Master Meter Data Into The SCADA System? • Track Distribution System Flows In Realtime. • Bulk Customer Billing & Automatic Reports. • Detect and Zone Transmission Line Leaks. • Increase Employee Safety. • Improve Data Accuracy. • Leverage Already-Existing SCADA System Infrastructure. The Bottom Line: Reduce Operational Costs ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics
  3. 3. Track Distribution System Flows In Realtime… SCADA Systems Excel At: • Collecting Large Amounts of Sensor Data Within Short Time Intervals • Graphical Presentation of Data • Alarming Unusual Conditions (Audible Alerts, Text Messages, etc.) • Graphical Presentation of Historical Trending Charts ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics GPM GAL 477724330 GALLONS 950.2 GPM
  4. 4. Bulk Customer Billing & Automatic Reports… Connect SCADA Database to: • Billing Software System • Excel Spreadsheets ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics
  5. 5. Bulk Water Customer (RE Water Corporation) Purchase Point From Supplier (City of Albion, IL) Standpipe Storage Pump Station #1 Flow – RE Water (Bulk Customer) System Flow – Standpipe Storage Flow = Approximate Residential And Business Usage Pump Station #1 Water Company SCADA Server Residential And Business Customers ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Detect and Zone Transmission Line Leaks… Pump Station #2 Flow (gpm) Overnight Usage Trends Provide A Useful Measure Of Potential Water Leaks
  6. 6. ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Increase Employee Safety… • Meter Vaults – Safety Hazard. • OSHA Confined Space Compliance.
  7. 7. ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Improve Data Accuracy… SCADA/Meter Instrumentation Saved The Utility $14K On This Month’s Bill. 4 Below-Grade Master Meters Eyeball-Read By Human Meter Reader. (Errors) 4 Master Meters Machine-Read By SCADA System. (Error-Free)
  8. 8. ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Leverage Already-Existing SCADA Infrastructure… • Computer Hardware • Computer Software • Communication Infrastructure (Radio, Fiber-Optic, Etc.) • Remote Sites (eg Water Towers, Pumping Stations)
  9. 9. How To Integrate Master Meters Into A SCADA System? • Case Study I – Licensed FM Radio Telemetry • Case Study II – Cellular Ethernet Telemetry • Case Study III – Extraterrestrial Satellite Radio Telemetry ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics
  10. 10. • Collect Data From 34 Master Meters (Various Brands) Using SCADA System. • 4 Readings Per Day. • Revenue-Grade Accuracy Of Meter Readings. • Accelerated Leak Detection. • Minimize Recurring Costs: Low Energy Footprint (Solar Solution) Eliminate Manual Read Payroll Reduce Fuel and Vehicle Wear/Tear Reduce Data Entry and Reporting Time • Increase Employee Safety. • 3 Year Investment Payback. 0 105 miles Case Study I – Licensed FM Radio Telemetry ABS Water Cooperative (Clayton, IL) ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Project Goals:
  11. 11. • Several Meter Brands Mixed Throughout System • Customer Desired To Utilize Existing Meters Sensus Badger 34 Master Meters… ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics
  12. 12. • Utilize Absolute Encoder Technology No Pulse Signaling (Pulse-Counting Errors) No 4-20mA Signaling (Integration Errors) • Required Register Retrofits: Sensus – ICE Registers Badger – ADE Registers Revenue-Grade Accuracy… ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Sensus ICE Register Badger ADE Register
  13. 13. Minimize Recurring Costs… ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Solar-Power Eliminated Need For Electric Utility Service: • No Up-Front Utility Hookup Charges • No Monthly (Minimum) Usage Charges
  14. 14. Lexan Window “Visual Read” Backup Telemetry Hardware Diagram… ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Solar Panel (50W) and Battery Charge Controller EM-100 EtherMeter SCADA/Meter Gateway DL-3400 FM Telemetry Radio Fusing 12V Battery Radio Communications Using RS-232 and Modbus/RTU Industrial Protocol Water Towers Were Natural Repeaters For Meters In Low-Lying Areas.
  15. 15. • Software Library Created That Linked the SCADA Database To Excel Spreadsheets. • Automatic and Fast Report Generation. • Data Analytics Quantifies Usage Anomalies/Leaks. • Data Transcription Errors Eliminated. Reduced Data Entry and Reporting Time… ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics
  16. 16. • Collect Meter Data From 20 Custody Transfer Meters (Various Brands) Using Cellular Ethernet Technology and the Existing SCADA System. • Main Purpose = Billing. Revenue-Grade Accuracy Required. • Readings Every 15 Minutes. • Minimize Recurring Costs: Low Energy Footprint (Use Solar Wherever Power Not Available) Eliminate Ineffective Legacy System and Associated Monthly Contract • Interface With Bulk Customer Telemetry Equipment. Case Study II – Cellular-Ethernet Telemetry Utility: Missouri American Water Company (Saint Louis, MO) Project Goals: ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics
  17. 17. Water Company HQ Cellular Carrier Master Meters Retrofitted with Encoder-Type Registers IMPROVED MASTER METERING SYSTEM Local Cellular Tower Infrastructure Private Cellular Network Industrial Ethernet Protocols Cellular Ethernet System… ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics • Private Cellular Network For SCADA Security. • Data Communications Using KepServerEx. • Nice Extra: Modbus/UDP Industrial Protocol (not Modbus/TCP). • UDP Protocol Achieved Order-of-Magnitude Decrease In Billable Cellular Kilobytes.
  18. 18. ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Cellular Master Meter Site…
  19. 19. Cellular Telemetry Hardware Diagram… ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Cellular Antenna EM-100 EtherMeter SCADA/Meter Gateway AC/DC Power Supply (24V) Raven-E Cellular Gateway (Modem) ADAM-4024 4-20mA Output Module (Signaling To Bulk Customer Telemetry)
  20. 20. ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Case Study III – Extraterrestrial Satellite Radio Telemetry… • Collect Meter Data From Custody Transfer Meters (Various Brands) Using Extraterrestrial Satellite Modem Technology. (Cellular Not Available, FM Radio Insufficient Range). • Main Purpose = Billing. Revenue-Grade Accuracy Required. • Readings Every 6 Hours. • Minimize Recurring Costs: Low Energy Footprint (Utility Power Not Available). Utility: Northwest Area Water Supply District (Bismark, ND) Project Goals:
  21. 21. ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Case Study III – Extraterrestrial Satellite Radio Telemetry…
  22. 22. ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Satellite Telemetry Hardware Diagram… JouBeh 9602W Satellite Transceiver Satellite Antenna EM-100 EtherMeter SCADA/Meter Gateway
  23. 23. ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Satellite Telemetry Typical Site… Hardware Diagram… Solar Panel. Telemetry Enclosure. Below-Grade Master Meter: Badger w/ ADE Register (Absolute Digital Encoder).
  24. 24. ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Satellite – SCADA Integration Nice Extras (Self-Diagnostics): Satellite Signal Strength Battery Voltage
  25. 25. ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Satellite – Automatic Report Generation…
  26. 26. SCADA Useful For… • Tracking Distribution System Flows In Realtime. • Alarming. • Historical Trending. • Data Visualization. • Assisting With Bulk Customer Billing • Generating Reports Automatically. • Detecting and Zoning Transmission Line Leaks. • Increasing Employee Safety. • Improving Data Accuracy (Eliminating Human Reading and Transcription Errors). Key Technology Components… • Absolute Encoder-Based Meter Registers. • Leverage Existing SCADA Infrastructure. • Utilize Most Suitable Communication Method (eg. FM Radio, Cellular, Satellite). • May Utilize Solar Power When Needed. ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics Summary & Key Points –
  27. 27. Jim Mimlitz SCADAmetrics Saint Louis, Missouri scadametrics.com ISAWWA Training © 1995-2014 COPYRIGHT SCADAMETRICS. ALL RIGHTS RESERVED. SCADAmetrics

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