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treated water.
Dwayne Backus of American Structurepoint, right, reviews control systems in the command center with electrical maintenance supervisor Tom Yuranin. East Chicago uses control systems from Rockwell Automation and SCADA software from Wonderware (Invensys).
arately as well as an overall plant operations session, says Heather Cheslek, P.E., engineering manager with Black & Veatch. We had quite a bit of vendor-specic equipment training with two to four hours of classroom time, plus hands-on work. The major pieces covered included the raw-water and high-service pumps, the traveling water screen, valves, the plate settler, the chemical feed systems, the membrane ltration system, and the SCADA system. The operations and maintenance teams both took essentially the same training. Many of the vendors broke their training into sections with operations focus and maintenance focus, but the city chose to have all its people attend all of the classes, says Webb Bernhardt, P.E., major projects construction administrator for American Structurepoint. Baranyai notes that the maintenance staff from the citys wastewater
division also took the water plant training for cross-training purposes, so that they are prepared to assist with troubleshooting and problem-solving, if needed. Siemens contract included extensive training on the membrane ltration system. When the Siemens team changed out membrane modules that displayed leaks during initial testing, city operations and maintenance personnel were there with them, assisting, so they would learn how to do that, says Bernhardt. The membrane control system is programmed to automatically test the membranes on a regular basis and will detect changes in pressure that can indicate when there are leaks or tears in membranes. When an alarm condition is reached, the operators need to know how to isolate a membrane cartridge and take it out of service, and they also need to know how to replace that cartridge. So they went through both of those procedures. In addition, although the lter backwash, air scouring and cleaning processes are fully automated, operators needed to be trained to understand and respond to indications on the control panel.
Count Pete Baranyai among those who shake their heads at the practice of buying bottled drinking water. I dont understand it, says Baranyai, utilities director for the City of East Chicago, which recently commissioned a new membrane ltration plant. Our treatment process here, starting with Lake Michigan water, probably exceeds bottled water in terms of cleanliness, disinfection and the whole nine yards, Baranyai says. As if to reinforce the point, inside the plants main entrance is a spigot where residents can ll their own water bottles. As they walk into the building people think, Oh, theres a place to wash your boots off, says Baranyai. But its really set up as a place where people can bring in maybe a 5-gallon container, ll it up with water, and take it with them.
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The Nathaniel Ned Ruff Water Treatment Facility produces 17 mgd and is designed for expansion to 30 mgd.
The old water treatment plant didnt have a SCADA system. Mostly it was a case of local stations to turn things on and off. Now everything is done off a keyboard. So it was a major learning process.
PETE BARANYAI
MORE INFO:
American Structurepoint Inc. 317/547-5580 www.structurepoint.com Black & Veatch 913/458-2000 www.bv.com Caterpillar, Inc. 309/675-1000 www.cat.com EnPro Technologies Ltd. 816/795-6333 www.enpro-tech.com Fairbanks Morse 913/371-5000 www.fmpump.com Meurer Research, Inc. 303/279-8431 www.meurerresearch.com ProMinent Fluid Controls Inc. 412/787-2484 www.prominent.us R.P. Adams 800/896-8869 www.rpadams.com Rockwell Automation 414/382-2000 www.rockwellautomation.com Siemens Water Technologies Corp. 866/926-8420 www.water.siemens.com
backs up, and how reports are generated. For SCADA viewing in the operations room, the city installed a widescreen at-panel TV. It makes eminent sense, and it creates an excellent impression when people walk in and see something like that, says Baranyai. Besides training on individual devices, the engineers taught the team how to operate each of the plants systems and optimize overall performance. The team made sure that as much of the training as possible was approved by the Indiana Department of Environmental Management so that it could be applied toward operators continuing education requirements for licensing. We submitted several of the classes for CEUs, says Cheslek. Since the operators were spending so many hours in the classroom or on the oor learning about these new pieces of equipment, we thought CEU credit was very appropriate. Bernhardt notes that nearly all classroom and hands-on sessions were videotaped and catalogued by the citys multimedia team. They have some talented videographers, he says. They were in the right place at the right time to capture the essence of the training. I think it will be very useful. For example, if the maintenance team needs to repair a pump or other equipment, they can review the video as well as the vendor-provided manuals and have a solid understanding of what needs to be done. The multimedia department also videotaped walking tours of the facility for presentation on the citys local-access cable station to help give the public a basic understanding of the new plant and treatment process.
Looking ahead
Now that the new water plant is fully online, Baranyai sees a modern facility with a well-trained team strongly positioned for the future. Knowing the city faces a wave of retirements in the not-too-distant future, Baranyai plans to work with the Indiana Vocational College in East Chicago toward establishing a water and wastewater program. We need to get an infusion of younger people in here, he says. Meanwhile, he sees possibilities for expanding the treatment process and selling water to neighboring communities a source of revenue that would help the city in a time when budgets are under stress. He is pleased with the water plant staff and the results of the training: I have to give a lot of credit to the trainers theyve done a good job. Our staff has responded extremely well. Theyve taken the training to heart and I am condent that they will run this plant in a way that takes full advantage of the new technology. wso
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fter a survey showed that fewer than half of Mesa Consolidated Water Districts customers knew the independent utility was their water provider, the utilitys leaders decided in 2009 to step up communications. Their decision was rewarded with the California Special District Association (CSDA) 2011 Exceptional Public Outreach award for large districts. Mesa Water is a special district with more than 110,000 customers in suburban Orange County. The 18-square-mile district serves most of the City of Costa Mesa, parts of Newport Beach, and some unincorporated areas, including John Wayne Airport. Mesa Water is governed by an elected ve-member board of directors. Still the 2008 survey found that many customers assumed their water service came from the city. That confusion was a problem for several reasons, says Stacy Taylor, the communications manager hired to improve the districts visibility.
Mesa Consolidated Water District operations supervisor Stan Kennedy demonstrates how a well works while conducting a tour for alumni of the water districts Water Issues Study Group at Mesas operations yard.
Building knowledge
Mesa Water, established in 1960, has a strong nancial record, and its leaders worried that customers were lumping it in with a city that, like many in California, was having nancial difculty, leading to reduced services and a loss of jobs. It became apparent that it was important to get the districts story out, Taylor says. That story, the board concluded, needed to include a history of the district, a report on its record of providing a safe and reliable water supply, and its nancial stability. Plans included programs to establish brand awareness, extend existing outreach, improve day-to-day communications with the public, and establish transparency about nancial matters. With water shortages facing many California communities, the board added a goal to increase consumer knowledge of water issues in general. Foremost, however, was to establish the districts identity. People didnt know who was providing their water, and if they dont know where their tap water is coming from, its hard to get their attention with a water conservation message, Taylor says.
Multiple channels
Taylor worked closely with media outlets, supplying news releases and background papers to keep them aware of Mesa Waters activities and plans. According to the CSDA contest entry, the districts print and online media coverage in 2010 was 30 times better than in 2009. Taylor used multiple routes to reach customers, from a bimonthly newsletter delivered with water bills to conservation tips offered in print and on the districts website. Taylor even posted time-lapse webcam images of progress at a major construction project. To bolster the conservation message, Mesa Water established a Water Use Efciency Award to recognize non-residential customers who reduce annual water consumption. The district also maintains two Water-Wise
The rst Water Issues Study Group sponsored by Mesa Consolidated Water District sat down for a group photo at its nal session in 1985. Many returned for their 25th class reunion in 2011.
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It is used to detect broken reinforcement wires within PCCP mains. It is propelled through the pipeline with the ow of the water. As it passes through the pipeline, it detects those wire breaks. By doing so it enables the utility to do some further analysis, calculate the condition of the pipeline with engineering methods, and determine whether to repair or continue to operate it.
that allows the water to push it through the pipe. Typically, it moves at about 95 percent of the ow velocity, which is about one to ve feet per second depending on the ow velocity within the system.
wso: How is the tool introduced to the pipeline? Livermore: It can be inserted via a hot tap connection and insertion sleeve or an existing access or open chamber. Once inside the line, it travels with the ow of the water to an extraction point, which could be a hot tap connection and insertion sleeve, an existing access, an open chamber, or a reservoir.
wso: How does this technology assess pipe condition? Livermore: The technology emits an electromagnetic eld into the walls of the pipeline and then detects how that eld passes through the wires that reinforce the pipe. This technology will help us identify pipes that are comproWhat were looking for are breaks in the circuit of mised and get them repaired or replaced in a timely fashion. how that energy ows through those wires. Those indicate points where there are broken wires in the Our goal is to not ever have another transmission main break. pipe reinforcement. The data is stored in the device KEITH COOMBS until it reaches the extraction point, where it is taken out and connected to a computer that downloads the data. ment program for PCCP. Shortly after that, we initiated a program to inspect all 100 miles of our PCCP mains ranging from 24 to 60 inches over a 10-year period. We are now in our third year of that program. wso: How is the data analyzed and used? Livermore: Using the data, were able to go through and check for breaks. The information is used to provide a report telling the client wso: Why did you use the PipeDiver technology for the assesswhich pipe sections have damage, if any, and quantifying it so they can go ment on the 8.8-mile main last year? forward and repair the pipeline or take other action as warranted. Coombs: There are parts of that pipe that dont have redundancy.
wso: What immediate steps were taken after that event? Coombs: We hired Pressure Pipe Inspection Co., which has since merged with Pure Technologies, to inspect as much of that main as we could while we had it shut down. They manually inspected about three miles of pipe using electromagnetic technology and found three other sections that had signicant wire breaks. We dug up those sections and applied steel bands to the outside of the pipe. At that point we decided we needed to accelerate our condition assess-
wso: How does the system record the location of the breaks? Livermore: Each piece of pipe has a unique signature. The tool counts the number of sections from the insertion point to the extraction point by detecting certain anomalies in the magnetic eld. Then, using background information from the utility, such as lay schedules and asbuilt drawings, we can determine where those anomalies are. That gives us a relatively accurate picture of the pipe and where the breaks are. wso: How does this technology provide return on investment for the utility? Livermore: Compared to the consequences of breaks that can occur in these mains, it is considerably less expensive to inspect a pipeline versus going forward, allowing a break to occur, and then repairing the pipeline and the related damage. wso: In what sizes of pipes is this technology used? Livermore: It is used primarily in lines 24 inches and larger. In the United States, we have assessed pipelines as large as 72 inches with the PipeDiver tool. wso: If this is a free-swimming device, how is the speed of travel controlled? Livermore: The utility controls the ow velocity based on parameters we agree upon in the planning process. The device is neutrally buoyant and has ns that come out of the cylinder sections where the electromagnetic tools are. The ns help keep the tool centered and provide resistance
wso: What were the logistics of performing that assessment? Coombs: We had to coordinate with the operations people because the PipeDiver relies on the ow of water. Youve got to push that water somewhere. We drew one of our tanks down to a low level, and when they were ready to launch the PipeDiver, we started pumping water to the tank. In the meantime it was pushing the PipeDiver through the pipe. It took a lot of coordination. You can imagine the amount of water you have to push through a pipe to maintain a speed of about 1 to 1.5 feet per second. Thats a big volume of water to push for six to eight hours. wso: About what percentage of your PCCP mains will you be inspecting using the PipeDiver technology? Coombs: Probably about one-third. On the remaining sections we will probably use robotic equipment. It also provides high-denition video capability, and so wherever we can were going to try to use that tool. The combination of video and wire breakage information is a good approach to use where possible. wso: What have you learned so far from the PipeDiver investigation? Coombs: Data collected over the past eight to 10 years shows that in a typical PCCP pipe system, anywhere from 3 to 4 percent of joints may be compromised due to wire breakage. On the main we just assessed, we had a wire breakage percentage of about 3.1, so we are toward the lower end of the range. That was somewhat reassuring to us. Based on the draft report, we found three sections that were signicantly compromised and had a great number of wire breaks more than (continued on page 33)
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PRODUCT FOCUS:
Pressure transmitter
The Valueline from Keller America is a high-accuracy, general-purpose pressure transmitter that uses microprocessor technology to provide high Total Error Band (TEB) accuracy, with fully conditioned analog output over a wide compensated temperature range. Available with various electrical connections, custom pressure ranges, and voltage or current outputs, the device integrates into new and existing systems, including PLC, VFD, SCADA, and most commercially available displays/controllers. 877/253-5537; www.kelleramerica.com.
Multichannel transmitter/controller
Burkert Fluid Control Systems offers the MultiCELL Type 8619 multichannel controller for water treatment. In reverse osmosis systems, the controller monitor functions as a ow indicator, to measure the ORP value or percentage retention value. It can also be used for control tasks, such as regulation of pH, chemical dosing and ratio control. The modular controller is adapted at the factory to the application and customer specications. The large, congurable graphic display with backlighting can display up to four readings simultaneously. Further parameters and user-specic pages can be displayed by scrolling. The digital and analog signal outputs enable the transfer of process data and status signals. All process values can be stored on SD cards with an optional data logger package for computer analysis using any standard software package. 800/325-1405; www.burkert-usa.com.
Control valve
The Hydro Instruments OV-110 Omni-Valve automatically controls chemical feed based on one or more electrical input signals and is compatible with gases or liquids. It can operate in seven control modes including ow pacing, residual set point, compound loop (PID), dual input feed forward, step feed, dual set point and manual. It can also handle a wide range of chemicals and a wide range of feed capacities. Microprocessor technology eliminates the need for feedback potentiometers. 888/384-9376; www.hydroinstruments.com.
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Fume hoods
The UniFlow SE Aire-Stream fume hood from HEMCO Corporation is a series of fume hoods UL 1805 certied and offered in 48-, 60-, 72- and 96-inch widths in constant air volume or restricted bypass models. The hood is constructed of chemical resistant, ame retardant, non-metallic composite resin and features unitized construction that does not require screws, bolts, rivets, or metallic hardware to assemble. The fume chamber is a molded one-piece white surface with all corners covered for easy cleaning and light reectivity. The hood has a 36-inchhigh extended view height, slotted VaraFlow bafe system, aerodynamic sash lift with perforated air-sweep feature, and molded-in belled outlet collar for reduced airow resistance. 816/796-2900; www.hemcocorp.com.
Gas monitor
The CTX300 gas monitor from Oldham is enclosed in a high-grade, explosion-proof plastic housing, with an IP66 rating to resist corrosion. Its advanced design makes it durable in harsh environments. Additional features include 4-20 mA output analog transmitter with optional backlit display; plug-in and pre-calibrated sensors; electrochemical, infrared or semi-conductor sensors; detection of O2, CO2, toxic and refrigerant gases; compatibility with more than 30 sensors; and an infrared version for CO2. 800/338-3287; www.oldhamgas.com.
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One exceptional resource on SCADA security is US-CERT the operational arm of the National Cyber Security Division at the Department of Homeland Security.
gained access to control technology for the U.S. governments Amundsen-Scott Pole Station in Antarctica, which ran life-support technology for scientists. A SCADA system attack at the Maroochy water system in Australia disrupted wastewater treatment for two months. Much more recently, in November of 2011, a hacker connected to a South Houston water facility to demonstrate the simplicity of an attack. Although the culprit claimed he did not vandalize any equipment or systems, the fact he could demonstrate connectivity, and possibly control, brings this type of security aw to the foreground. These are only a few examples. What can a water or wastewater utility do to use SCADA technology effectively while maintaining or increasing security? Unfortunately, no single standardized solution will cover all agencies. Depending on the organizations size, the availability of trained support staff or nancial resources may be limiting factors. However, there are a number of low-cost and relatively simple solutions that any agency can implement to start minimizing risk from outside attacks. Most novice computer users are already familiar with a number of security methods that can be applied to more complex systems.
Increase awareness
Subscribe to a free online technology publication. Subscribe to US-CERT to monitor nationally important risks and threats. Investigate user groups and develop relationships with sister agencies.
General to specic
The rst step is to address a series of fundamental questions, starting at a macro level and then narrowing down. The rst focus should be on personnel and policies and may include these questions: What is the staffs level of security awareness? What is the staffs technical level? Are technology-based security policies and procedures in place? Are these procedures and policies routinely reviewed and exercised? Is the agency staff properly trained on a regular basis? Focus can then shift to the actual assets and specic processes to assist in analyzing security at the component level. These questions may include: What assets or processes require protection? What level of protection is needed? How might an asset or process be compromised? What is the impact if protection fails? Once these are answered, more specic questions can be asked. Is the SCADA system accessible from outside by phone or Internet, or is it part of a larger corporate network? If yes, the next question is whether it needs to be connected or integrated. If there is no real benet to having phone, Internet, or corporate network access, the SCADA can be made into a closed system although this may be impractical, as it inhibits sharing of process data. If there is a need for corporate network access, the technical security effort increases and becomes more holistic. Is there a proper and secure rewall (hardware and software) in place on the network that is routinely managed? Are strong passwords in place for the SCADA system? And the entire corporate network? Are strong information security procedures and policies in place for the entire cor-
porate network that cover a full range of issues, including the use of thumb drives by employees or vendors? Is there a policy or procedure to handle vendor or employee PC connections to the corporate network?
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NEWS
Koch Membrane Systems launches website
Koch Membrane Systems Inc.s new website, www.kochmembrane. com, focuses on the companys two major business segments: industrial and life sciences, and water and wastewater.
INDUSTRY
Calgon Carbon Corp.s Ultraviolet Technologies Division received conditional acceptance of its C3500D wastewater disinfection system from the California Department of Health. CDH determined the UV system meets the coliform and virus disinfection criteria found in Title 22 of the California Code of regulations for recycled waters that have received treatment through a tertiary ltration process. Recycled waters meeting the microbiological standards can be used for the irrigation of crops and golf courses, recreational waters and other non-potable applications.
Paul Overbeck
Geoffrey Whynot
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Mounted on the tank roof, the mixers power system includes solar panels, a digital control panel, and a battery to store current for continual operation.
Sean Stabler
four feet. It saved money in the long run, says Barbieri. If the machines need servicing, SolarBee technicians just lift them out instead of working on them in the tanks. The units have a stationary intake assembly that remains on the tank oor. An expandable hose connects the intake to the oating impeller, enabling it to self-adjust to varying water levels. Rotating at 80 rpm, the impeller moves 2,500 gpm in a near-laminar ow pattern that Weve eliminated completely mixes the water colshort-circuiting and umn. The pattern also ensures stratication. Chlorine consistent dispersal of chlorine at usage at the booster the walls, in the bottom three feet of the tank, and at the oor. pump station is down by Mounted on each tank roof are more than 50 percent, solar panels, a digital control panel, and although THMs and a battery to store energy for continual operation. The panel has are still forming, it isnt daily and seasonal run-time algohappening as quickly. rithms and includes programming BILL BARBIERI for auto-reverse, anti-jam, and selfcleaning. The mixers in the tanks are driven by a high-torque, direct-drive, permanent-magnet motor with no gearbox to reduce energy consumption. The city accepted the companys maintenance and service program. Technicians come on a regular schedule and take care of everything, says Barbieri. It makes life simple, enabling us to focus on other things.
Installation
The technicians installed one mixer per day. The biggest part of the setup was maneuvering a crane into position to lower the units into the tanks, says Barbieri. They are a mile from the Main Street plant and in an isolated area. Before the technicians turned on the units, they did basic temperature testing to check for stratication. They returned after three days to retest the tanks and found no stratication. It took a few days to stabilize everything, but the numbers have remained consistent since then, says Barbieri. Weve eliminated shortcircuiting and stratication. Chlorine usage at the booster pump station is down by more than 50 percent, and although THMs are still forming, it isnt happening as quickly. wso
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