Page 1
By
Jim MimlitzNavionics Research, Inc.
Illinois SectionAmerican Water Works Association
Training Course
O’Fallon, Illinois03 March 2015
TelemetryA Detailed Look At Telemetry
ISAWWATraining
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Today’s Course…
Telemetry TechnologyBreak
Telemetry ComponentsBreak
Tailoring Your Telemetry SystemBreak
Telemetry SecurityBreak
Troubleshooting Your Telemetry System
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ISAWWATraining
Part I
Telemetry Technology
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Telemetry Technology…Big Picture… What is the Purpose of Telemetry?
1. Automatic Control of Water Treatment and Distribution Processes.
2. Data Collection and Historical Trending.
3. Alarm Notifications.
4. Automated / Semi-Automated Report Generation.
5. Remote Access To Data.
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1. Automatic Control of Water Treatment and Distribution Processes.
• Tower Level Sensing• Pump, Well ON/OFF Control• Valve OPEN/CLOSE Control• Flow Monitoring• Pressure Monitoring• Water Quality Monitoring: Chlorine, Turbidity, pH• Chemical Pump Control
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2. Data Collection and Historical Trending.
• Water Consumption Reviews• Overnight Analysis – Leak Detection• Pump Flows Consistent With Past Performance?• Water Quality Checks – Chlorine, Turbidity, pH• Pressure Reviews – Too High Or Too Low?• Temperatures (Room, Cabinet) – Too High Or Too Low?• Utility Power Quality Trending• Treatment Chemical Tracking
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3. Alarm Notifications.
• Automatic Delivery: SMS, Email, Telephone• Tank Levels: Too High, Too Low• Pressures: Too High, Too Low• Chlorine Levels: Too High, Too Low• Turbidity Levels: Too High• pH Levels: Too High, Too Low• Temperatures: Too High, Too Low• Power: Outages, Brownouts, Generator Run• Flood Detection: Buildings, Underground Vaults• Safety Alarms: Chlorine Gas Detection• Physical Security: Entry & Motion Detection
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4. Automated / Semi-Automated Report Generation.
• Meter (Total Consumption) Readings• Water Quality: Chlorine, Turbidity, pH• Tank Levels• Pressure Readings
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Manual Data-Entry Eliminated.History Data Permanently Stored On Telemetry Server.
Automatic Generation Of Regulatory Compliance Reports (EPA).
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5. Remote Access To Data.
• Alarms Delivered To Smart Phones• History Trends Available On Smart Phones, Laptops• Consultants Can Advise From A Distance
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Example SmartPhones:
• Microsoft SmartPhone
• Apple iPhone
• Blackberry
• Droid
• Others…
View Status, History, Alarms.
Sample iPhone
Graphics
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Telemetry Technology…Big Picture… What Are The Benefits Of Telemetry?
• Transit-Time Is Substantially Reduced.Overtime Is Minimized.
• With An Alarm System Integrated With Smart-Phones,The Detection Of Costly System Faults Is Accelerated.
• Physical Security At Unmanned Facilities Is Enhanced.
• Quality-Of-Life For The System Operators Is Improved.
• System Documentation Is Automated and Centralized.Access Is De-Centralized.
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Tank LevelPressurePressure Filter Head LossPressure/Level Transducer Status (Working/Fault)
Power (Monitor 3-Phase Voltages)Power ConsumptionPump Feedback (ON/OFF/FAIL)Accumulated Pump RuntimeGenerator Status (Running/OFF/Low-Fuel)Accumulated Generator Runtime
Meter ReadingFlow RateValve Position:
• Fully-Open• Fully-Closed• Open %
Chlorine ResidualTurbidityChemical Scales
FloodEntry (Physical Security)TemperatureCommunication Status
Chlorine / Miox Generation SystemsFilter SystemsVFD Systems
ISAWWATrainingTelemetry Technology…
What Does A Telemetry System Typically Monitor?
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Pump:• ON• OFF• VFD Speed
Valve:• Open• Close• Variable Position (Throttle)
Chemical Pump:• ON• OFF• Variable Speed (Flow-Proportional, Residual-Dependent)
Filter System:• Backwash
Automatic Failover Systems:• Pump Control• Low-Suction Cutout• Valve Control
Generator (Load Shedding)Enclosure Heater (Outdoor Units)
ISAWWATrainingTelemetry Technology…
What Does A Telemetry System Typically Control?
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ISAWWATraining
Part II
Telemetry Components
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Telemetry Components… ISAWWATraining
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Computers, RTUs, PLCs
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I/O Modules/Channels:Discrete Digital I/O (Inputs/Outputs)Discrete Analog I/OGrouped I/O – EthernetGrouped I/O – Serial (RS-232 Point-To-Point, RS-485 Multi-Drop)Isolation
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Telemetry Radios
• Licensed (VHF, UHF)• Non-Licensed (Spread-Spectrum)
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Modems
Translation of Binary (1’s and 0’s) Into Signal Suitable For Transmission Over Radio, Fiber-Optic, Telephone Lines.
• Radio• Fiber Optic• Telephone Line
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Antennas
• Radomed and Non-Radomed• Directional• Omni-Directional
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Directional Yagi,No Radome
Omni-Directional,Radomed
Directional Yagi,Radomed
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Power Supplies
• Convert 120VAC Line Power Into Lower DC Voltages• For Electronics, Instrumentation, Computers, Radios.
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Switching Power Supply Technology (Electronic-Based) Linear Power
Supply Technology (Transformer-Based)© 1995-2014 COPYRIGHT
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Battery Backup
• UPS (Uninterruptible Power Supply)
• Computers Require Clean, Glitch-Free Power.Why?
• Eliminate Race Conditions
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Generators
• Automatic Transfer Switch?... Or Manual?• Fuel Options: Diesel, Natural Gas, LP
Monitoring/Alarming:
• ON/OFF Status• Fault Status• Accumulated Runtimes (Odometer)• Fuel Status• Automated Weekly Exercise
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Coaxial Cable
• Selected By Radio Frequency Band• Higher-Frequencies Thicker/Lower-Loss Cable Required
• Connectors: Recommend Soldering Over Crimping (Longevity)
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Grounding Systems
• Safety• All Major Components Grounded Prevents Ground Loops• Transient Voltage Surge Suppression Assistance
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Coaxial Lightning Arrestors
• Arrests Surges Due To Direct Lightning Strike On Antenna and/or Coaxial Cable
• Gas-Tube Technology
• Installed On Building or Enclosure Bulkhead
• Diverts Transient Energy To Ground
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Power Lightning Arrestors
• Installed On Incoming Utility Power• 3-Phase or Single-Phase• Diverts Transient Energy To Ground• Typically Feature ‘Working’ LED
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Pressure Transducers
• Non-Waterproof (In-Station)• Waterproof (Below-Grade Pit)• Submersible (Submerged In Tank)• Insulation, Oil-Seals, Heat Tape (Freeze Prevention)• Pressure Snubbers (Situational)• Differential (Filter Loss)• Temperature Compensation Technology For Consistent Accuracy• Generally Higher Cost ~ Better Accuracy
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Pressure Switches
• ON/OFF With Pressure• Low-Pressure: Switch Turns ON• High-Pressure: Switch Turns OFF• Adjustable Pressure• Adjustable Differential (Deadband)• Useful As Backup Control To Telemetry
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Flow Meters
• Totalization• Encoder Versus Pulse• Rate-of-Flow Measurement• Best Verification of Pump and Valve Operation• Feed Chemicals Proportional To Flow.
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Dual-Telemetry Systems For Transmitting
Metering Data To Seller’s And Buyer’s
Telemetry Systems.
Both Systems “See” Identical Data.
Enhances Communication & Collaboration.
Gateway Water Company /
Raccoon Water Company
Interconnect RTU’s
Interconnect
Master Meter
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Sensus 10” Propeller Meter
With “ICE” Encoder-Type Register.
Connected To EtherMeter™.
• Standard AWWA-Type Turbo & Mag-Meters
Combined With EtherMeters™.
• MODBUS-Based.
• Allows Absolute-Encoder-Based Totalizers
(No Pulse-Counting Errors)
• Plant & BPS Influent & Effluent Meters.
• Master (Custody-Transfer) Meters
In Distribution System.
• Daily Production And Process Monitoring.
• Satellite District Realtime Consumption
Monitoring.
Gateway Water Plant
(Sandoval, IL)
EtherMeterFlow MeterGateway
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SensusBadger
Neptune
Itron/Actaris
Master Meter
… And Others…
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Solar-Power Intensive ProjectReduced Energy Costs ForWater District
Solar-Power Eliminates Electric ServiceHookup Fee And Monthly Bills.
Sensus
Badger
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Reduced Physical & Carbon Footprints For Master Meters.
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Monitoring Of Major FlowsAssists Early Leak-Detection…
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Relays
• Isolation• Logic Implementation
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Time-Delay Relays
• Isolation• Logic Implementation• Time-Delay To Filter Out Transient Pressure Effects
(eg Water Hammers)• Useful As Backup Control Component To Telemetry
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Temperature Sensors
• Thermocouples• Thermistors• RTDs
Monitor:
• Building Temps• Cabinet Temps• Pump Temps,
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Motors and Pumps
• ON/OFF Status• Fault Status• Accumulated Runtimes (Odometer)
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ACL (Across-The-Line) Starters
• Simple• Relatively Inexpensive• ON/OFF Only
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Soft-Starters
• Ramp Voltage During Startup/Shutdown• Cost: ACL < Soft Starter < VFD
• Cannot Adjust Speed During Run
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VFD’s: Variable Frequency Drives
• State-Of-The-Art.• Ramp Voltage and Frequency During Startup/Shutdown• Can Regulate Speed At Any Time During Run Cycle
(Not Only During Start-Up and Shut-Down)• Reduces Water Hammer• Adjustable Parameters:• Discharge Pressure Limiting• Back Pressure Sustaining• Flow Limiting• Digital Interface – Horsepower, Voltage, Amps, Fault Info
• Up-Front Cost: ACL < Soft Starter < VFDFuture Payoff In Energy Savings
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VFD Energy Savings…• Reduced Flow = Reduced Friction Losses• GPK: Gallons per Kilowatt-Hour (Derived from Flow Meter & VFD)• Utility Rebates Often Available
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• Pump GPK ~ Auto MPG• See Blog Series
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2 Wall-Mounted VFD’s
Page 48
Motorized Fully-Open/Fully-Closed Valves
• Butterfly (1/4 Turn Actuator)• Gate (Multi-Turn Actuator)
Sample Applications:
• Elevated Tank Altitude Valve• Ground Storage Tank Altitude Valve
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Solenoid Valves
• Control Small-Pipe Flows (Pilot Tubes)• Often Used As Component In Diaphragm Valves
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Position-Controlled Valves
• Telemetry Controls Valve Position
• Motorized Butterfly – More robust remote control, power-dependent.
• Diaphragm/Solenoid – power fault-tolerant, more difficult to remote control via telemetry)
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Digitally-Controlled, High Performance Electric Butterfly Valves
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Advantages:Easily Controlled Via Telemetry.Parameters Easily Modified By Operator:
Back-Pressure Sustaining SettingFlow-Limiting SettingOpen/Close Pressures/Levels
Long Travel Time To Open/Close Possible.
Disadvantages:Requires Power (Generator)
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Advantages:Power-Independent (Sometimes)
Disadvantages:Requires Frequent Cleanings/Maintenance
(Especially With Hard Water).Digital Control Is Expensive/Complex.Limited Travel Time To Open/Close.
Diaphragm-Based Control Valve
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Hybrid Throttled Valves
• OPEN/CLOSE Telemetry Control• Valve Either: (1) Fully-Closed or (2) Valve Partially-Open• No Throttling/Regulation Action
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Chemical Feeders
• Liquid Chemical Pumps• Chlorine Gas Feeders• Chem Feed-Rate Feedback Possible
Feed Rate:
• Constant Flow• Flow-Proportional (Telemetry)• Flow/Demand-Proportional (Telemetry)
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Chemical Scales
• Telemetry-Monitored Chemical Scales Provide Chemical Consumption Historical Data
• Chlorine (Liquid, Gas), Ammonia, Fluoride
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Panel Heaters
• Protection Against Freezing• Protection Against Condensation• Heat Tape For Sensing Lines• Light Bulb Heater
Design Notes:
• Telemetry Systems Electronic-Intensive(Computers, VFD’s, Interfaces, etc)
• New Building Designs: AC and Heating• Ensure Adequate Ventilation
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Programmed Control Logic
• Provides Rules Of Operation• Sequential Instruction List• Ladder Logic
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Control Panel Operator Input
• Push Buttons• Selector Switches• Keypads
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Control Panel Operator Display
• Pilot Lamps• LED/LCD Displays• Flat-Panel Graphical Displays
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Industrial PC-Compatible
RTU Processor
Biddleborn Booster Pump Station
Washington County (IL) Water Company
Metering Inputs
Discrete Inputs & Outputs
Analog Inputs & Outputs
Industrial I/O
Industrial
Radio-Modem
Battery Backup (UPS)
NEMA-Rated Industrial
Motor Control Center
TVSS (Surge Suppression)
Thin-Client
UNIX Terminal
Interface
Regulated DC
Power Supplies
Operator Interface /
Troubleshooting Port
Manual
Controls
Automatic Failover
Backup Control System
Programmable Logic
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Desktop Computer/Server
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Software For Desktop Computer/Server
• Data Collection• Graphical Presentation• History Trending• Alarm Delivery• Remote Access Server• Vendor Service Console
(Updates, Upgrades,…)
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Firewalls / Routers
• Provides Security Buffer Between SCADA Computer and Internet
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Operators
Engineer
Telemetry Vendor
and Technicians
Field
Personnel
The Internet
Desktop (Traditional)
Telemetry ServerCommunication, Command
& Control
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Firewall
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ISAWWATraining
Part III
Tailoring YourTelemetry System
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Tailoring Your Telemetry System… ISAWWATraining
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Expandable or Fixed-I/O?
• Fixed I/O Less Expensive Up FrontNot Easily GrownLess Logic Flexibility
• Expandable I/O More Expensive Up FrontMore Easily GrownMore Logic Flexibility
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Base Hardware
• RTU• Computer• PLC
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Communication Infrastructure?
• Radio• Fiber Optic• Telco Line• Cellular
Considerations:
• Up-Front Costs• Ongoing (Monthly) Costs• Reliability
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I/O Points List
• What points do you want to monitor?• What equipment do you want to control?• I/O Count: 1st Major Cost Driver For Project
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• Control Logic Laws / Sequencing
• The Automated Decision-Making Aspect Of The Telemetry System.
• Any Expected Logical Variations Should Be Handled By A Generous Collection Of Operator Setpoints.
• Complexity Of Control Logic: 2nd Major Cost Driver For Project
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Define Control Panel Interfaces
• Pilot Lamps• Computer LCD Displays• Manual Selector Switches (eg. Hand-Off-Auto)• Push Buttons
Strongly Recommended:
• Any Station Should Be Able To Be CompletelyOperated Using Only Manual Controls(In Case Of Telemetry Fault).
ISAWWATraining
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Define Desktop/Server Computer Interfaces
• Realtime Display Windows• History Trending Windows• Setpoint Modification Windows• Alarm Modification Windows
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Failover Operations
If The Telemetry System (Or A Component) Fails, How DoesThe System Operate?
• ManualSelector Switches, Push-Buttons, Gauges
• Semi-AutomaticOperator Must Visit Station To Enable Backup Automatic Controls
• AutomaticTelemetry System Self-Detects Fault, And Automatically TransfersInto Backup Control Operation. Example – Tower Transducer Fault.
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Protecting Against Power Transients & Loss
• Grounding
• Transient Voltage Surge Suppression
• Not A Question Of “Should I Implement?”…But Rather “How Much Should I Implement?”.
• Battery Backup (UPS) At All Sites.
• Generators At Critical Sites: Plants, Wells, Intakes, Pumping Stations.
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Documentation and Training
• Component Documentation(Helps With Future Maintenance & Replacements)
• Wiring Diagrams(Helps With Future Troubleshooting)
• Logical Operation Description(Helps For Training Future New-Hire Operators)
• Security Procedures
• Training At Startup/CommissioningFollow-Up Training Also Recommended
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ISAWWATraining
Part IV
Telemetry Security
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Telemetry Security… ISAWWATraining
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Physical Security
• If No Physical Security, Then Cyber-Security Cannot Be Implemented. Why?
• Door & Padlock Keys
• Combinations
• Smart-Cards
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Remote & Local Access Security
• Username/Strong-Password Credentialed Authentication
• Software & Hardware Firewalls Prevent Undesirable Types Of Access
• Water Utility Controls All User Access
• Multiple Activity Logs Should Detail Operator Access Sessions
• Various Permission-Levels For Operator Access
• Minimize List Of Personnel Authorized For System Access
• Security Procedures & Training Must Be Followed !!!
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Local Communication Infrastructure Security
• Secure The RTU-RTU Communications That Take Place Via Radio, Telco, Cellular, Fiber-Optic
• Authentication (No Man-In-The-Middle Attacks)
• Encryption (If Transmitted Data Is Sensitive)
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Computer Security Procedures
• Must Be Documented
• Review & Re-Evaluate The Procedures Regularly
• Security Procedures Should Evolve. Why?
ISAWWATraining
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1. DO NOT USE THE TELEMETRY COMPUTER FOR NON-TELEMETRY PURPOSES!
2. INSTALL SECURITY UPDATES FROM THE OPERATING SYSTEM VENDOR (EG MICROSOFT) FREQUENTLY AND REGULARLY.
3. DO NOT INSTALL 3RD PARTY SOFTWARE ON THE TELEMETRY COMPUTER. DO NOT ADD EXTRA HARDWARE TO THE COMPUTER.
DO NOT PLUG USB MEMORY STICKS INTO THE COMPUTER.
4. NEVER REVEAL A USERNAME/PASSWORD PAIR TO ANOTHER PERSON.
5. IF A USERNAME/PASSWORD PAIR IS SUSPECTED TO HAVE BEEN COMPROMISED, OR IF AN EMPLOYEE WHO HAD ACCESS TO
THE SYSTEM IS TERMINATED – THEN DELETE HIS/HER USERNAME/PASSWORD FROM THE SYSTEM IMMEDIATELY... AND UNTIL THIS ACTION IS TAKEN, DISCONNECT THE SCADA SYSTEM FROM THE INTERNET OR TELEPHONE LINE IMMEDIATELY.
6. DO NOT ADD EXTRA USER ACCOUNTS TO THE COMPUTER’S OPERATING SYSTEM.
7. ONLY PROVIDE TELEMETRY SYSTEM ACCESS TO PERSONNEL WHOSE JOB REQUIRES IT; AND ONLY PROVIDE THE MINIMUM
FUNCTIONALITY THAT EACH PERSON REQUIRES.
8. REGULARLY REVIEW THE ACCESS & ACTIVITY LOGS.
9. IF UNCERTAIN, CALL YOUR TELEMETRY VENDOR OR CONSULTANT FOR A CONSULTATION.
10. IF SECURITY TELEMETRY SECURITY PROCEDURES ARE NOT BEING FOLLOWED, THEN DISCONNECT FROM THE INTERNET!
Example Telemetry Security Procedures (Condensed):
ISAWWATraining
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ISAWWATraining
Part V
Troubleshooting YourTelemetry System
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Troubleshooting A System… ISAWWATraining
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Step 1: Determining The Problem, & Who To Call
Telemetry ContractorElectricianPower Utility
ISAWWATraining
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In-Panel Troubleshooting/Analysis?
Know Your Limitations.
Qualified and Comfortable Working WithinA Control Panel With A Volt-Meter?
If Not, Do Not Risk Injury – Call In Support.
ISAWWATraining
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Eyeball View:
Power In The Control Panel?Which Lights/LED’s ON?Which Lights/LED’s Blinking?Error Codes?
ISAWWATraining
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Common Issues –A telemetry site (water tower, pumping station, plant) stopped communicating or working.
RTU Equipment ON?Radio Equipment ON?UPS (Battery Backup) ON?
Did failure occur during a storm?• RTU Electronics Lightning-Damaged?• Antenna and/or Coaxial Cable Wind-Damaged?
ISAWWATraining
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Common Issues –Pressure Transducer Failed.
Did failure occur during a storm?• Transducer Electronics Lightning-Damaged?
Transducer Submerged In Below-Grade Pit?• Transducer Suffered From Water Ingress?
Freezing Weather Conditions?• Transducer Over-Pressurized From Sensing Line Freeze-Up?• If Freeze-Up… Insufficient Insulation? Heat Tape Failure? Oil-Seal Failure?
ISAWWATraining
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Common Issues –Pressure Transducer Failed.
What Is Nature Of Fault?• Transmitting “Zero” Reading?... Or Reading Not Changing?
Did failure occur during a storm?• Transducer Electronics Lightning-Damaged?
Transducer Submerged In Below-Grade Pit?• Transducer Suffered From Water Ingress?
Freezing Weather Conditions?• Transducer Over-Pressurized From Sensing Line Freeze-Up?• If Freeze-Up… Insufficient Insulation? Heat Tape Failure? Oil-Seal Failure?
ISAWWATraining
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Common Issues –Variable Frequency Drive Failed.
VFD Fault Code Displayed On LCD Display?• Record the Fault Code. VFD Manual Or Supplier Can Help Decipher.
(eg Over-Voltage, Over-Current)
Did failure occur during a storm?• VFD Electronics Lightning-Damaged?
VFD Faults Can Often Be Reset• Depress Reset Button.
Recurrent VFD Faults?• Underlying Problem Should Be Discovered And Addressed.
ISAWWATraining
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Common Issues –Communication Fault.
Triangulate, If Possible, The Location Of The Problem.
ISAWWATraining
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Common Issues –Communication Fault.
Triangulate, If Possible, The Location Of The Problem.
ISAWWATraining
CheckHereFirst
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Common Issues –RTU/Computer Fault.
Usually No LEDs ON.Sometimes, LEDs ON – But Not Blinking.
ISAWWATraining
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Common Issues –Radio Fault.
Power LED ON?• If NO, Possible Power Supply Failure (Not Radio Failure).• If NO, Possible Radio Internet Fuse Blown (Repair Possible).• If YES, Possible Electronic Circuit Failure.
‘RECEIVE’ LED Steady?• If YES, Interference From Within Or Wihout (Usually Within).
‘TRANSMIT’ LED Steady?• If YES, Transmitter Locked ON. Could be caused by faulty radio, modem, RTU/Computer.
ISAWWATraining
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Common Issues –Pump (or Valve) Short-Cycling ON/OFF Too Quickly.
Setpoint Problem?• Water Tower ON/OFF Setpoints Too Close Together?• Or Pressure ON/OFF Setpoints Too Close Together?
Pressure Transducer Problem?• Transducer Malfunctioning.• Electrical Noise Causing Readings To Jump High/Low.
ISAWWATraining
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Common Issues –Pump Speed Oscillating Up And Down Too Rapidly.
Gain Setpoint Problem?• Gain Is Set Too High
Explanation Of “Feedback Gain”• Automobile Cruise Control Example
ISAWWATraining
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Common Issues –Throttling Valve Oscillating Open and Closed Too Rapidly.
Gain Setpoint Problem?• Gain Is Set Too High
ISAWWATraining
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Common Issues –Pump Speed Not Ramping Up and Down Quickly Enough.Telemetry Not Properly Maintaining Pressure (or Flow) Setting.
Gain Setpoint Problem?• Gain Is Set Too Low
ISAWWATraining
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Common Issues –Valve Position Not Adjusting Quickly Enough.Telemetry Not Properly Maintaining Pressure (or Flow) Setting.
Gain Setpoint Problem?• Gain Is Set Too Low
ISAWWATraining
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Common Issues –Battery Backup (UPS Fault).
Does Not Keep RTU/Computer Up And RunningDuring Power Outage?• If NO, Possible Internal Battery Failure (Replace Battery)• If NO, Possible UPS Unit Failure (Replace Entire Unit)NOTE! – Batteries Require Special Disposal/Recycling.
How To Test For UPS Fault?• Simulate Outage By “Pulling The Plug”.
ISAWWATraining
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Remote Access Help, Reduce Travel Expenses –
Via Internet Or Telephone Modem
Telemetry Vendor, Consultant, Engineer
Share Historical Trending Charts
Troubleshooting Advice
Install Updates/Upgrades
Modify Programming
ISAWWATraining
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ISAWWATrainingConclusion
Thank You!
Jim MimlitzNavionics Research Inc.wireless-telemetry.com
Telemetry Educational Blog:wireless-telemetry.com/blog
Telemetry Educational Newsletter:wireless-telemetry.com/signup/signup.htm
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