Item #04 Approval of Replacement of SCADA System and PLC for Wastewater Treatment Plant
AGENDA ITEM COVER SHEET
Contact Name:
Contact Number:
Charles K. Smith, P.E
407-905-3159
Meeting Date: October 20, 2009
Item # t.}
Reviewed By:
Department Director: Charles
City Manager: Robert Fran
Subject: Replacement of SCADA System and PLC for Wastewater Treatment Plant
Background Summary:
The City of Ocoee Wastewater Plant's treatment was substantially upgraded in 1993 to the I. Kruger Inc patented
biological treatment process during the reconstruction of the wastewater plant. The process employs a patented
nitro and de-nitro cycle that utilizes specially designed oxidation ditches and Kruger-proprietary automation
programming.
At the time of the reconstruction, both the PLC (Programmable Logic Controller) and SCADA (Supervisory Control
and Data Acquisition) computers were placed in service. Each of the computers has developed recurring failure
issues with some of the issues leading to significant treatment issues, Staff is recommending the replacement of
both the PLC and SCADA computers and to use Kruger as a best source vendor because of the implicit
relationship Kruger has with design, construction and processes of the plant. Attached is a more specific
discussion with diagrams and figures,
Issue:
Should City Commission authorize the City Manager to procure the replacement of the PLC and the SCADA
computers from I. Kruger Inc, as a best source vendor, in the amount of $243,600?
Recommendations
Motion to authorize the City Manager to procure the replacement of the Programmable Logic Controller computer
and Supervisory Control and Data Acquisition computer, and all associated equipment, material, manpower and
programming from I. Kruger Inc, in the amount of $243,600.
Attachments:
SCADA and PLC Upgrade proposal from Kruger, Memo to Mayor and City Commissioners
Financial Impact:
In the Fiscal Year 2009/2010 approved budget, Utilities Wastewater (407-535-00-6400) R&R funds provide
$300,000 for the funding of the PLC/SCADA replacement. The proposal from Kruger is $56,400 under budget.
Type of Item: (please mark with an "x'J
Public Hearing
Ordinance First Reading
Ordinance Second Reading
Resolution
~ Commission Approval
Discussion & Direction
For Clerk's Deat Use:
_ Consent Agenda
_ Public Hearing
_ Regular Agenda
Original DocumenUContract Attached for Execution by City Clerk
Original DocumenUContract Held by Department for Execution
Reviewed by City Attorney
Reviewed by Finance Dept.
Reviewed by ( )
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Mavor
S. Scott Vandergrift
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Commissioners
Gary Hood. District 1
Rosemary Wilsen. District 2
Rusty Johnson. District 3
Joel F. Keller. District 4
City Manager
Robert Frank
STAFF REPORT
FROM:
Charles K. Smith, P .E., Director of Utilities
TO:
DATE:
October 20, 2009
RE:
Replacement of SCADA System and PLC for Wastewater Treatment Plant
The City of Ocoee's Wastewater Treatment Plant's advanced operations are managed by the utilization of two
computer systems configured in a series layout.
I/O TO PLANT
D
00
110 FROM PLANT
ALARM NOTIFICATION
0 0 0 0 0
0 0 0 0
0 0 0 0
= = = = =
= = = = =
= = = = =
000
000
W'ASTE-
W'ATER
PLANT
OPERA TOR INPUT
TO/FROM SECONDARY PLC
POW'ER IN POW'ER OUT
SCADA COMPUTER
PLC COMPUTER
The first computer, a Programmable Logic Controller (PLC), directly administers the plant's processes and is
composed of a processing unit, input/output modules and power supply. It is very dependable and it tracks and
monitors the plant and is stackable with a secondary remotely located PLC; however, it has limited user interface.
To overcome the limited user interface of the PLC, a second computer, a Supervisory Control and Data
Acquisition Computer (SCADA), is used to monitor and modify the status of the plant by way of set-points in the
PLC status. The SCADA computer is a conventional desktop setup and is equipped with graphical user software
representing the plant.
PLC & SCADA COMPUTER 1
The effect of the PLC being inoperable is immediate and can be significant in terms of treatment. A SCADA
failure may not affect treatment for an extended interval, but it will lead to treatment issues and also disable parts
of the plant's alarm notification system.
The City of Ocoee Wastewater Plant's treatment process and associated unit operation was significantly upgraded
in 1993 to the I. KrUger Inc. patented method. At that time, both the PLC and SCADA computers were placed in
service by KrUger. A few years later, the SCADA computer and its associated software was updated by
replacement. The PLC has had elements replaced due to failures and has lost programming on numerous
occasions. The PLC uplink is serial port, which is no longer supported and must be done on-site by a KrUger
representati ve.
The Utilities Department is recommending the replacement/upgrade of both the PLC and the SCADA computers
by the plant's process designer/contractor I. KrUger Inc. Both PLC and SCADA computers shall be internet-ready
for easy and remote uplink and diagnostics. The upgrade will also include the necessary programming for the
PLC and SCADA computers, all computer equipment, power supply and a second remote laptop with SCADA
software for remote operation of the plant. Attached is the proposal from I. KrUger Inc. for the engineering design,
procurement of equipment, field services and installation of the system in the amount of $243,600. Because of the
necessary continued use of the KrUger Process, staff recommends the awarding of the computer upgrades to I.
KrUger Inc. as the best source vendor.
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KRUGER
September 9, 2009
Charles Smith
Director of Utilities, City of Ocoee, FL
1800 A.D. Mims Road
Ocoee, FL 34761
Re: SCADA and PLC Upgrade
Ocoee,FL
Kruger Project No: 42090913
Dear Mr. Smith:
Please find enclosed our revised proposal for the above referenced project. Based on the
previous phone conversations Kruger is proposing a plant-wide PLC and SCADA upgrade. As
you requested we have provided a larger screen laptop and accounted for the additional I/O
associated with the high service pump, sludge press and future magmeters.
Kruger appreciates the opportunity to further expand our involvement with the City of Ocoee. In
reviewing our proposal, we request you consider the following benefits offered by Kruger:
. I&C Staff In-house - Kruger's I&C Engineers work side by side with Plant Personnel on
each project, customizing PLC and SCADA operation to your needs.
. Site Familiarity - Being that the existing Oxidation Ditch, PLC and SCADA System
were supplied by Kruger we are intimately familiar with site details,
. Support - The work will be performed to Kruger's high standards under the direction of
a Project Manager. All matters related to the design, installation or performance of the
SCADA and controls system shall be communicated through Kruger's Project Manager,
giving the City of Ocoee ready access to our extensive capabilities.
. Veolia Family - Kruger is a subsidiary of Veolia Water Solutions and Technologies
(VWS), a world leader in engineering and technological solutions in water treatment for
industrial companies and municipal authorities, providing unsurpassed technical and
process support to Kruger and our clients.
If you have any questions or need further information in the meantime, please do not hesitate to
contact Todd Casey (todd.casey@veoliawater.com) or myself (garrett.howell@veoliawter.com)
at 919-677-8310.
Respectfully,
\. Kruger Inc.
Sent via email
Garrett Howell
Application Engineer
Biological Treatment Systems
ATT
cc: MCK, CWJ, ETC, project file (Kruger)
Kruger Inc.
401 Harrison Oaks Blvd, Suite 100
Cary. NC 27513 USA
Tel: 919-677-8310. Fax: 919-677-0082
Web site: www.krugerusa.com
G) VEOLIA
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KROGER
SCADA and PLC Upgrade for
Ocoee,FL
Kruger Project No.: 42090913
Charles Smith
Director of Utilities, City of Ocoee, FL
1800 A.D. Mims Road
Ocoee, FL 34761
September 9, 2009
I. Kruger Inc.
401 Harrison Oaks Blvd.
Suite 100
Cary, NC 27513
Kruger Inc.
401 Harrison Oaks Blvd. Suite 100
Cary, NC 27513 USA
Tel: 919-677-8310. Fax: 919-677-0082
Web site: www.krugerusa.com
KROGER
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Table of Contents
1. Company Introduction
2. Scope of Supply
3. Pricing, Terms of Payment, and Schedule
4. I. Kruger Inc. Standard Terms of Sale
roposa IS ory
Version Date Process Eng. Comments
0 6/24/09 GNH, CWJ Initial, budgetary proposal.
1 9/3/09 ETC, GNH Revised
2 9/9/09 GNH, ETC Revised
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1. Company Introduction
I. Kruger Inc. (Kruger) is a water and wastewater solutions provider specializing in advanced
and differentiating technologies. Kruger provides complete processes and systems ranging
from biological nutrient removal to mobile surface water treatment. The ACTIFLO@ Microsand
Ballasted Clarifier, AnoxKaldnes MBBR, BIOCON@ Dryer, BIOSTYR@ Biological Aerated Filter
(BAF), NEOSEpTM MBR and HYDROTECH Discfilters are just a few of the innovative
technologies offered by Kruger. Kruger is a subsidiary of Veolia Water Solutions and
Technologies (VWS), a world leader in engineering and technological solutions in water
treatment for industrial companies and municipal authorities.
VWS, present throughout the world, develops a global approach responding to specific needs of
customers at each of their production facilities. This has allowed VWS to become the world
leader in design, project management, and execution of projects for water and wastewater
treatment plants. The company also creates dedicated technology solutions to meet its
customer's needs. Its unique portfolio of differentiating technologies, developed by the group's
R&D centers, ensures unsurpassed innovation and control of each treatment line for public
organizations and industries. Furthermore, a whole range of associated services is offered on
each site to guarantee the technical efficiency and life expectancy of the installed solutions.
VWS continually extends and enriches its offer, to guarantee expertise and competence at
every step of the projects it undertakes.
Kruger prides itself for being a customer focused organization that provides solutions to
challenges faced by municipalities and not just another equipment supplier. To achieve this,
Kruger has gathered a force of process experts, trained sales staff, and project managers that
share our vision and priorities.
2. Scope of Supply
Kruger is pleased to present our scope of supply which includes engineering design, equipment
procurement, and field services required for the proposed SCADA and controls system, as
described herein for the Ocoee, FL project. Please note that Kruger intends to supply only the
software and equipment detailed in this scope of supply. The work will be performed to Kruger's
high standards under the direction of a Project Manager. All matters related to the design,
installation, or performance of the SCADA and controls system shall be communicated through
Kruger's Project Manager giving the Engineer and Owner ready access to Kruger's extensive
capabilities.
I&C and Desion Enqineerinq
Kruger shall provide I&C engineering and design support for the SCADA and controls system as
follows:
. Technical instructions for operation and start-up of the system
. Equipment drawings
. Project specific O&M manuals
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Field Services
Kruger will furnish an I&C Engineer as specified at the time of start-up to inspect the installation
of the completed system, place the system in initial operation, and to instruct operating
personnel on the proper use of the equipment. Specifically, Kruger will provide:
. On-site equipment checkup and start-up assistance, including advice during construction
and operator training, for a period not exceeding fifteen (15) man days and three (3) site
visits
Kruoer Scope of Supplv
Kruger will supply Instrumentation and SCADA services as described herein for the Ocoee, FL
WWTP.
Please note that Kruger intends to supply only the items and services specifically detailed in this
scope of supply. No other equipment or services will be supplied.
All SCADA programming is based on Kruger standards; any requests or requirements that
would deviate from this standard will result in additional costs.
The SCADA screens and the application developed by Kruger are for use at the Ocoee, FL site
and the application or its screens cannot be used, whole or any part for other systems.
The PLC programs developed by Kruger are for use at the Ocoee, FL site, and the PLC
programs cannot be used, whole or any part for other systems.
Kruger will not be supplying any computer hardware, network hardware, computer furniture,
printers, or network configuration other than what is specified herein. Software and its
installation/modification are for the Ocoee, FL site.
CONTROL PANELS:
Kruger will replace the PLC internals of the four (4) existing panels (transfer pump, 2 PLC room,
reuse building) on the site. All of the existing four PLCs onsite will be replaced with ControlLogix
equipment from Allen-Bradley. The equipment supplied will be comprised of the following:
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All PLC and Operator Interface/SCADA programming is based on Kruger standards, any
requests or requirements that would deviate from this standard will result in additional costs.
Kruger will be providing PLC programming only for the Kruger supplied PLC Control Panel.
The PLC Program and Operator Interface/SCADA Program and its associated Graphic screens
developed by Kruger, are for use on the Kruger supplied PLC and Operator Interface/SCADA
only. The Kruger supplied PLC Program and Operator Interface/SCADA Program and its
associated Graphic screens cannot be used, whole or any part for other uses.
Kruger will supply copies of the completed PLC and Operator Interface/SCADA programs at job
completion. Prior to supplying completed PLC and Operator Interface/SCADA programs, Kruger
requests that a non-disclosure agreement be signed and returned to Kruger.
This panel does not include an Operator Interface, per contact drawings and specifications. In
the event that an Operator Interface is required for this panel this will result in additional costs.
The Oxidation Control PLC program will be modified to include monitoring of Oxidation Ditch
Weirs and Levels to generate Alarms in the event of High Level, Weir Inactivity and Level High
Rate of Change. It will also be able to accommodate the sludge press alarms as currently
configured and operate the additional high service pump.
All installation of equipment outside of control panels is by others including but not
limited to Ethernet cabling, the magnetic flowmeter, and any new wires to be run to the
control panels.
INSTRUMENTATION:
Kruger shall supply the field instruments as described herein.
Field Instruments
Qty Description Manufacturer
2 Endress & Hauser FMX 167 Submersible Pressure Endress & Hauser
Transmitter (For Monitoring Oxidation Ditch Level)
2 Fluidwell Local Display Unit (For Local Display of Oxidation Fluidwell
Ditch Level)
2 Dissolved Oxygen Analyzer wlTransmitter LDO Analyzer Hach
SC100 Transmitter
Kruger will calibrate and start-up Instruments supplied by Kruger. Instruments supplied by
others will require calibration and start-up by others. No other instruments will be supplied by
Kruger unless specifically listed above. Any additional training or start-up time required will be
charged at Kruger's advertised rates.
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SCADA EQUIPMENT AND SOFTWARE:
Kruger will upgrade the existing SCADA system with the latest version of the Wonderware
software. Kruger will be supplying the following SCADA/Computer hardware or software.
Qty Description Manufacturer
1 Dell Optiplex PC SCADA Computer (Intel Dual Processor, Dell
Windows Vista, 4GB RAM, 300GB Hard Drive, Keyboard
and Mouse, 27" Ultrasharo Widescreen Monitor)
1 Dell Studio 17 Laptop (Intel Dual Processor, Windows Vista, Dell
4GB RAM, 250GB Hard Drive, Keyboard, 17" Screen)
1 Wonderware SCADA license for SCADA Computer Intouch
1 SCADA Database Configuration, Ethernet Configuration, Kruger
Driver Configuration, Conversion of Existing SCADA
Application
Any additional training or start-up time required will be charged at Kruger's advertised rates,
To facilitate remote access to the site SCADA system, the city will be required to supply
high speed internet access.
Contractor's Scope of Supply
The contractor's scope of supply for the Kruger system should include, but is not limited to, the
following items:
. Crane or other lifting and handling equipment including associated rigging
. Unloading and recommended storage of equipment
. Design, supply and installation of equipment foundations, pads and external supports
. Modifications to existing equipment or structures
. Wiring of motors, controls, or control panels
. Installation of all supplied process equipment, instrumentation, piping, etc.
. Design, supply, and installation of all utility services (instrument air, electrical service,
etc.) and their respective distribution systems
. Spare parts
. Installation supervisory services
. Process testing services and/or sample analyses
. Detail shop fabrication drawings
. Concrete erection/construction
. Junction or pull boxes or any other like device
. Field Motor Disconnects
. Interconnecting wiring and/or conduit
. Telephone service for leased lines or auto dialer
. Motor control equipment MCCs or VFDs, AFDs
. Power distribution equipment
. Motor starters, contactors, reversing contactors
. Local control panels
. Computer furniture or desks
. Fiber optic cable, terminations, splicing, mounting equipment or patch cords
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. Field Terminations
. Packaged control panels for other unit processes
. Field Termination or Barrier Cabinets
. Test equipment
. Programming Software (PLC, SCADA and Operator Interface), except as described herein
. Programming Interface Cables or Hardware
. Heat tape
. Power monitors
3. Pricing, Payment Terms, and Schedule
Pricina
The price for the SCADA and PLC upgrade, as defined herein, including process and design
engineering, field services, and equipment supply is
$243.600
Please note that the above pricing is expressly contingent upon the items in this
proposal and are subject to I. Kruger Inc. Standard Terms of Sale detailed herein.
This pricing is FOB shipping point, with freight allowed to the job site. This pricing does not
include any sales or use taxes. In addition, pricing is valid for ninety (90) days from the date of
issue and is subject to negotiation of a mutually acceptable contract.
Terms of Payment
The terms of payment are as follows:
. 10% on receipt of fully executed contract on invoice
. 15% on submittal of panel drawings
. 30% on the delivery of equipment to the site
. 45% on the commissioning of the system
Payment shall not be contingent upon receipt of funds by the Contractor from the Owner. There
shall be no retention in payments due to I. Kruger Inc. All other terms per our Standard Terms
of Sale are attached.
All payment terms are net 30 days from the date of invoice. Final payment not to exceed 120
days from delivery of equipment.
Schedule
. Panel drawings will be submitted within 4-6 weeks of receipt of an executed contract by
all parties.
. All equipment will be delivered within 6-8 weeks after receipt of written approval of the
panel drawings.
. Kruger anticipates a Start-up/Commissioning beginning in January of 2010 (date is
subject to change based on receipt of PO and approval of panel drawings).
. Installation manuals will be furnished upon delivery of equipment.
. Operation and Maintenance Manuals will be submitted within 90 days after receipt of
approved shop drawings.
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4. I. Kruger Inc. Standard Terms of Sale
1, Applicable Terms, These terms govern the purchase and sale of the equipment and related services, if any (collectively, "Equipment"),
referred to in Seller's purchase order, quotation, proposal or acknowledgment, as the case may be ("Seller's Documentation"). Whether
these terms are included in an offer or an acceptance by Seller, such offer or acceptance is conditioned on Buyer's assent to these terms,
Seller rejects all additional or different terms in any of Buyer's forms or documents.
2, Payment. Buyer shall pay Seller the full purchase price as set forth in Seller's Documentation, Unless Seller's Documentation
provides otherwise, freight, storage, insurance and all taxes, duties or other governmental charges relating to the Equipment shall be paid by
Buyer, If Seller is required to pay any such charges, Buyer shall immediately reimburse Seller. All payments are due within 30 days after
receipt of invoice, Buyer shall be charged the lower of 1 X% interest per month or the maximum legal rate on all amounts not received by
the due date and shall pay all of Seller's reasonable costs (including attorneys' fees) of collecting amounts due but unpaid, All orders are
subject to credit approval.
3, Deliverv, Delivery of the Equipment shall be in material compliance with the schedule in Seller's Documentation, Unless Seller's
Documentation provides otherwise, Delivery terms are F.O,B, Seller's facility,
4, Ownership of Materials, All devices, designs (including drawings, plans and specifications), estimates, prices, notes, electronic data
and other documents or information prepared or disclosed by Seller, and all related intellectual property rights, shall remain Seller's property.
Seller grants Buyer a non-exclusive, non-transferable license to use any such material solely for Buyer's use of the Equipment. Buyer shall
not disclose any such material to third parties without Seller's prior written consent.
5, Chanoes, Seller shall not implement any changes in the scope of work described in Seller's Documentation unless Buyer and Seller
agree in writing to the details of the change and any resulting price, schedule or other contractual modifications, This includes any changes
necessitated by a change in applicable law occurring after the effective date of any contract including these terms,
6, Warrantv, Subject to the following sentence, Seller warrants to Buyer that the Equipment shall materially conform to the description in
Seller's Documentation and shall be free from defects in material and workmanship, The foregoing warranty shall not apply to any
Equipment that is specified or otherwise demanded by Buyer and is not manufactured or selected by Seller, as to which (i) Seller hereby
assigns to Buyer, to the extent assignable, any warranties made to Seller and (Ii) Seller shall have no other liability to Buyer under warranty,
tort or any other legal theory, If Buyer gives Seller prompt written notice of breach of this warranty within 18 months from delivery or 1 year
from beneficial use, whichever occurs first (the 'Warranty Period"), Seller shall, at its sole option and as Buyer's sole remedy, repair or
replace the subject parts or refund the purchase price therefore, If Seller determines that any claimed breach is not, in fact, covered by this
warranty, Buyer shall pay Seller its then customary charges for any repair or replacement made by Seller, Seller's warranty is conditioned
on Buyer's (a) operating and maintaining the Equipment in accordance with Seller's instructions, (b) not making any unauthorized repairs or
alterations, and (c) not being in default of any payment obligation to Seller, Seller's warranty does not cover damage caused by chemical
action or abrasive material, misuse or improper installation (unless installed by Seller), THE WARRANTIES SET FORTH IN THIS SECTION
ARE SELLER'S SOLE AND EXCLUSIVE WARRANTIES AND ARE SUBJECT TO SECTION 10 BELOW. SELLER MAKES NO OTHER
WARRANTIES OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY
OR FITNESS FOR PURPOSE.
7, Indemnitv, Seller shall indemnify, defend and hold Buyer harmless from any claim, cause of action or liability incurred by Buyer as a
result of third party claims for personal injury, death or damage to tangible property, to the extent caused by Seller's negligence, Seller shall
have the sole authority to direct the defense of and settle any indemnified claim, Seller's indemnification is conditioned on Buyer (a)
promptly, within the Warranty Period, notifying Seller of any claim, and (b) providing reasonable cooperation in the defense of any claim,
8. Force Maieure, Neither Seller nor Buyer shall have any liability for any breach (except for breach of payment obligations) caused by
extreme weather or other act of God, strike or other labor shortage or disturbance, fire, accident, war or civil disturbance, delay of carriers,
failure of normal sources of supply, act of government or any other cause beyond such party's reasonable control.
9, Cancellation, If Buyer cancels or suspends its order for any reason other than Seller's breach, Buyer shall promptly pay Seller for work
performed prior to cancellation or suspension and any other direct costs incurred by Seller as a result of such cancellation or sus pension,
10, LIMITATION OF LIABILITY, NOlWlTHSTANDING ANYTHING ELSE TO THE CONTRARY, SELLER SHALL NOT BE LIABLE FOR
ANY CONSEQUENTIAL, INCIDENTAL, SPECIAL, PUNITIVE OR OTHER INDIRECT DAMAGES, AND SELLER'S TOTAL LIABILITY
ARISING AT ANY TIME FROM THE SALE OR USE OF THE EQUIPMENT SHALL NOT EXCEED THE PURCHASE PRICE PAID FOR
THE EQUIPMENT, THESE LIMITATIONS APPLY WHETHER THE LIABILITY IS BASED ON CONTRACT, TORT, STRICT LIABILITY OR
ANY OTHER THEORY,
11, Miscellaneous, If these terms are issued in connection with a governrnent contract, they shall be deemed to include those federal
acquisition regulations that are required by law to be included, These terms, together with any quotation, purchase order or
acknowledgement issued or signed by the Seller, comprise the complete and exclusive statement of the agreement between the parties (the
"Agreement") and supersede any terms contained in Buyer's documents, unless separately signed by Seller, No part of the Agreement may
be changed or cancelled except by a written document signed by Seller and Buyer, No course of dealing or performance, usage of trade or
failure to enforce any term shall be used to modify the Agreement. If any of these terms is unenforceable, such term shall be limited only to
the extent necessary to make it enforceable, and all other terms shall remain in full force and effect. Buyer may not assign or permit any
other transfer of the Agreement without Seller's prior written consent. The Agreement shall be governed by the laws of the State of North
Carolina without regard to its conflict of laws provisions,
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