Case Study: Water and Waste Water Plants

Water and Waste Water Plants Transform Using Web-Launched, Java-Based SCADA Software

Professionals in the water and waste water management field face a series of difficult challenges as they seek to stabilize and expand their service delivery capabilities, while at the same time meeting the regulatory reporting requirements of the state. As if that were not enough, they must accomplish this in the current economic environment facing local governments. Managers clearly need better ways of doing business and an economic model which will give them the functionality and scalability required at a price point that does not break the budget.
Presented here are the perspectives of three jurisdictions that have found a workable solution to address their needs. Brazeau County in the Province of Alberta Canada; the City of Lago Vista in Texas and the Helix Water District in California’s San Diego County.

How It All Began

Steve Hechtman, the President and Founder of Inductive Automation Software, brings over 20 years experience as a systems integrator to the problem of managing water and waste water treatment plants. He shares his perspective on why he got into the software business and why it should matter to you:
“We needed a solution that allowed for PLC data to be readily available in SQL databases, that would not become obsolete every few years and which would provide an affordable expansion model for both run time and development needs. That was not available in the marketplace so I was forced into the software business.
“The first hurdle we put behind us was making PLC data readily available in SQL databases. From there we naturally started making reports and user interfaces using web pages. But it quickly became apparent we needed a rapid, standardized way of making such applications and of course security was a concern so we started investigating the various technologies available to do this.
“Ultimately, we decided to use Java for our platform, when virtually every other SCADA vendor chose the Microsoft route.”

Why Choose Java?

“Proofing against obsolescence is one major consideration. Every five years Microsoft reinvents itself and in that act churns the very platform these other SCADA applications are built on. The cost to the water plant manager is often prohibitive with current traditional vendor licensing models.
“Cross-platform support is another consideration. Vista was having problems. Meanwhile Linux operating systems such as Ubuntu are free and are gaining ground fast around the world.
“Our Java application could care less what platform it runs on or what database it interacts with. It works comfortably with them all.
“So now, today, what do we have? We have the world’s only fully mature, cross-platform, web-launched, secure, reliable SCADA application server which can support any SQL database and which is very easy to use. A skilled integrator can set up an amazing SCADA application in about an hour and then proceed from there to launch five or fifty clients anywhere, totally securely.”
The benefits to the water and waste water plant manager or supervisor will be obvious as you read the case studies and thoughts of Rick Flikkema from Brazeau County, Alberta; M.J. Duke from the City of Lago Vista and Henry Palachek, the Information and Process Control Systems Supervisor from the Helix Water District in San Diego.

Brazeau County, Alberta, Canada

Clearly, every municipality has a water and waste water department. The people who work in these departments are responsible for maintaining water quality delivered to their constituents as well as the delivery system itself. Well pumps and HighLift pumps are typically employed to move the water from the inside the earth or from reservoirs to fill the miles of pipes that go to each home and business to supply fresh potable water. On the output end, the systems have to treat contaminated water and remove the waste.
Typically these departments rely on the expertise of a system integrator (SI) or a consultant to guide them in their technological quests.
The county of Brazeau is located north-west of Calgary, Alberta in the Canadian Rockies. They needed to upgrade their Texas Instruments PLCs and chose to go with KSB Industrial (KSBI) as the SI.
Ken Bannard, President of KSBI, used GE PLCs for the Brazeau county new technology platform. These two PLCs are connected to the main office by leased lines using 9600 baud modems. Along with the new platform, KSBI implemented new SCADA software as well.
FactoryPMI from Inductive Automation was selected as the ideal software for this implementation. Rick Flikkema operates the two water plants and the three lift stations for the county.
“FactoryPMI has eased up alot of my time,” Rick said. “I was skeptical at first, when Ken introduced me to FactoryPMI.”
Over time Ken showed Rick how it would save the county money and time. “FactoryPMI is very cost-effective solution. Our end users become very interested when they hear that they can have unlimited clients at no extra cost,” Ken said.
Most municipalities are on a reduced budget and have fewer resources available to them. FactoryPMI makes up for those ‘losses’.
“FactoryPMI is both the development system and runtime. My customer has the ability to have anyone make changes if needed,” said Bannard. “And with the VPN remote access ability, a web access license doesn’t need to be purchased, unlike most other SCADA products.”
For the county of Brazeau, the total cost of ownership is hugely attractive. They have one server for control, monitoring and data tracking of the two water plants and lift stations.
“FactoryPMI has been running for 24 months trouble-free. It has made my job easier because I can monitor all areas of operation efficiently,” said Rick.
For the county of Brazeau, when they move towards additional reporting and data logging as well as a third water plant, their upfront costs will be negligible. “The upgrade path is very easy and inexpensive,” remarked Bannard. “FactoryPMI is good for integrators since it empowers them on behalf of their customers. The no-limit tag count allows me to provide the best possible system for my customer with minimal capital outlay.”

Realtime Status and Control Overview

City of Lago Vista Water and Waste Water Facilities

Deep in the heart of Texas, there is a city of approximately 6,000 people called Lago Vista. Located just west of Austin, there are many qualified system integrators nearby.
Patrick Callaghan from MCS Integrations was selected as the SI to assist Lago Vista with their SCADA upgrade path. M.J. Duke, Superintendent of Plant Operations for the district explains why: “Pat does his homework and is very thorough. If Pat likes it, then I like it!”
And Pat likes FactoryPMI from Inductive Automation.
Lago Vista often had issues with their previous software; and the common answer to many questions was “We just can’t do that.” And if there was a way, it was often too costly to implement.
Like most integrators, Callaghan mainly used one of the ‘big three’, and typically used Wonderware’s Intouch HMI software. “With what we have accomplished using the stock FactoryPMI software, I would have had to write custom code [with Wonderware],” indicated Callaghan.
Inductive Automation’s licensing model made the decision easy. “We were operating on stand-alone systems, and wanted to move towards a centralized system,” said Duke. “Runtime licensing with our former supplier was an issue. The upfront license costs for the new system were one-fifth what it would have cost using Wonderware,” stated Callaghan.
Duke oversees the operation of two water plants and the waste water facilities. There are six distribution pump stations remote to the main plants, as well as two intake stations all having Automation Direct PLC technology. There are also four holding ponds which require monitoring. And soon, Lago Vista will add an irrigation system for a city-owned golf course which will also need control and monitoring.
MCS Integrations began the migration by consolidating the existing applications into one FactoryPMI server-based application. After adding all the functionality available before the migration, the city was able to add additional functionality which wasn’t previously possible. “There were no holes in the conversion,” Callaghan said. “There was a learning curve in the beginning – my database experience was small. But Inductive Automation’s new SQLTags technology was a blessing.”

Graph Screen Showing History of Turbidity, Tank Level, Flows, etc.
The former HMI/SCADA system had stand-alone applications running in each different location. In order to monitor the operations, the operators needed to drive to individual locations. While the efficiency of the department wasn’t ideal, it was rapidly deteriorating as the cost of operator travel increased.
Callaghan installed a FactoryPMI server at the primary water plant (WP1). Plant-to-plant communications were established with fiber optics. VHF communications connect the remote
PLCs to the system network. As well, there are client workstations in each plant. The router at WP1 connects to the Internet to allow for remote VPN access. Each plant also has a Wi-Fi access point.
Lago Vista wanted to be able to access all systems from each plant, as well as from mobile tablets, which they can now do. “When the operators are in their trucks, they can use the tablet PCs to access the network,” Duke said. They use a Bluetooth-enabled cell phone for internet connectivity and then create a VPN connection through the Internet to the router located at WP1.
All forms the operators need are embedded into the FactoryPMI system. The operators can input data in real-time, speeding up some compliance requirements. “No more driving to get data. They used to enter data on paper on a clipboard,” said Duke. “We looked into using Palm Pilot type devices before, but we wouldn’t be able to get the amount of data onto the screen that we needed. Without the tablets and system coverage, our response to issues would be way too slow.”
The department has to provide 24/7 service, so the mobile tablets and the ability to access the systems from any location means very fast response. “The FactoryPMI server will send an email alarm-notification to the cell phone of the person on call,” says Callaghan. The operator can then log-on to the FactoryPMI server and figure out what the issues might be. “This has increased our efficiencies,” stated Duke.
The operators can also do process checks at night, which can catch problems before they escalate. “Equipment failure can be circumvented,” says Callaghan.
Compliance regulations require city water departments to log and track data on all aspects of water plants and waste water facilities. This is done to ensure municipal compliance with the law, and ensure required levels are maintained (such as of chlorine).
Callaghan says, “Data logging with FactoryPMI is really easy. Logging this much data with Wonderware would have been much more difficult and costly. We have over 3,000 tags. Every day there is something different to add – with direct data entry and SQL—voila!”
There was some hand-holding at the beginning of the project due to Callaghan’s lack of database experience. “The support from Inductive Automation was immediate when required,” Callaghan said. He observes that what the project now entails could not be easily replicated using another HMI product. In fact, he wonders if it would be possible at all without a lot of custom code. There is no doubt that—regardless of which product it might be—it would cost more and take longer.
Callaghan concludes “FactoryPMI is a non-proprietary solution and uses standard platforms. The scripting language is very powerful (Python for Java). It’s a fabulous product!”

A Year’s Worth of Data in a PDF Document

An interview with Helix Water District’s Henry Palachek

Information and Process Control Systems Supervisor

Henry Palachek has been with the Helix Water District for the past fifteen years. He serves as the Information and Process Control Systems Supervisor. Inductive Automation (IA) caught up with him to get his views on the value of implementing web-launched and database centric SCADA software in meeting the challenges he faces supervising the water and waste water systems for the Helix Water District.

What is the biggest challenge you face with your job?

The way in which SCADA systems age and how it is related to the operating system they work on is a big challenge for us particularly right now.
With the current SCADA system and how traditional SCADA software products work, you are not certified to run on Vista. You are then forced to upgrade your system because you are only certified to work on Windows 2000 or XP II and if those are going away then the cost of upgrading the SCADA system becomes too much.
This means that obsolescence becomes a big problem with traditional SCADA software products.
When software is created based on working directly with the DB, which is what Inductive Automation has done with FactorySQL, you get a longer life span for the system. The life span goes to 10-13 years. Obsolescence and cost prohibitive upgrade cycles then are not a problem.

How does Inductive Automation’s FactorySQL assist you with California state reporting requirements?

The Surface Water Treatment Rule for California requires monitoring filters’ turbidity and reporting that to the state on set intervals. So having a software package that allows for talking directly to the field controller is a great advantage.
Helix has 50 sq. mile distribution system and 260,000 customers. The Distribution Manager logs the data to the database on 5 minute intervals. We have then set up stored procedures that create hourly and daily summary data.
This then gives us the ability to create reports which we can mail directly to the state for complying easily with the Surface Water Treatment Rule.
We have had InTouch for over 10 years. Classic SCADA packages don’t have an easy way to do that. The drag and drop ease of use of FactorySQL is great for these reporting requirements.

Ease of use, learning curve and set up time are important factors. Has IA software measured up in that area?

Absolutely, I had it set up on my notebook in about half an hour. With a classical Wonderware package it is cumbersome if you do DB. It requires multiple steps to configure. With FactorySQL it is like one step configuration. You put in a tag name and drag the tag name and drop to the bottom to create a table and start logging. It is like night and day difference.

How did you make a decision to go with Inductive Automation software?

I went out and looked at all the leading vendors; none of them had the same ease of use with the drag and drop feature.
We have had no issues with reliability or uptime.
Plus there is a big advantage if a computer fails. With traditional systems you have to rebuild the computer and then get SCADA system back on it with whatever patches or upgrades you may have. It can cost time and money and lost data. With FactorySQL you can take any PC almost out of the box and get it easily up and running. This will help you solve hardware problems a lot faster.
It is a nice feature to have unlimited tags and to not have to buy a license for unlimited tags and not to worry about how many tags I do have.

Is there a cost advantage?

We’re running 16 SCADA clients in our treatment plant. When you start adding up 16 licenses just so our operators can view and acknowledge alarms, it starts getting pretty expensive.
The cost of just a single license for development or runtime with traditional software vendors can be about $5,000 to $12,000. So you certainly do have a cost advantage with FactorySQL and FactoryPMI, as the license is sold by the server and provides unlimited tags and unlimited clients to us as the customer.
If you are doing a SCADA change out with a large number of clients price does become an issue.

Any final thoughts for our readers?

In the water utility field there is a lot more pressure than there used to be in three areas:
1. Regulation requirements—Working with a database-centric product helps with regulatory issues.
2. Economic issues—It is not just business as usual. You really have to look at the cost of the system and FactoryPMI and FactorySQL have a definite advantage there.
3. Managers need better ways of doing business—Web technology with SQL databases is really a better way of doing business.

An Introduction to RSLogix5000 Tags

Tags are the method for assigning and referencing memory locations in Allen Bradley Logix5000 controllers. No longer are there any physical addresses such as N7:0 or F8:7 which use symbols to describe them. These have been replaced with tags which are a pure text based addressing scheme. This is a departure from the more conventional ways of programming PLC’s, which includes Allen Bradley’s earlier line of PLC5 and SLC 500 controllers.
One of the hardest transitions from the older systems is realizing how the tag database works. The person with experience in Allen Bradley systems will recognize many of the instructions and be at home with the editor in RSLogix 5000. Understanding the tag database is the first major hurdle in becoming comfortable with the ControlLogix and CompactLogix systems. So let’s dig in and get started.

The Way We Used To Be

Earlier Allen Bradley PLCs programmed with RSLogix 5 and RSLogix 500 software had data files to store I/O and other internal values. These different data files could only hold one data type. A data type defines the format and the size of the stored value.
Default Data Files

Data File Descriptions

File #	Type	Description
O0	Output	This file stores the state of output terminals for the controller.
I1	Input	This file stores the state of input terminals for the controller.
S2	Status	This file stores controller operation information useful for troubleshooting controller and program operation.
B3	Bit	This file stores internal relay logic.
T4	Timer	This file stores the timer accumulator and preset values and status bits.
C5	Counter	This file stores the counter accumulator and preset values and status bits.
R6	Control	This file stores the length, pointer position, and status bits for control instructions such as shift registers and sequencers.
N7	Integer	This file is used to store bit information or numeric values with a range of -32767 to 32768.
F8	Floating Point	This file stores a # with a range of 1.1754944e-38 to 3.40282347e+38.

While this method made it easy for using instructions, it provided a challenge for logically grouping different data types together according to function. For instance, in machine control, a motor may have a start, stop, speed and alarm code each with its own data type. Thus, the data was “scattered” throughout the data files.

File #	Name	Data Type
I1	Start	Input
I1	Stop	Input
F8	Speed Setpoint	Floating Point
N7	Alarm Code	Integer

Comparing the Old and New

The Logix5000 controllers have done away with data files and in its place is the tag database. The tag database organizes memory locations in one place. Each tag is assigned its own data type. The table below shows the association between the current data types and the older systems with data files.

RSLogix 5 / 500			RSLogix 5000
File #	Type
O0	Output		Input and output modules, when configured, automatically create their own tags like Local:0:I.Data.0
I1	Input
S2	Status		Use the GSV and SSV instructions to get status information such as the CPU time, module states and scan times.
B3	Bit		Assign the Boolean (BOOL) data type to the tag.
T4	Timer		Assign the TIMER data type to the tag.
C5	Counter		Assign the COUNTER data type to the tag.
R6	Control		Assign the CONTROL data type to the tag.
N7	Integer		Assign the double integer (DINT) data type to the tag.
F8	Floating Point		Assign the REAL data type to the tag.

Creating a Tag

One way to create a new tag is right click on the Controller Tags in the Controller Organizer and select New Tag. Even faster is the Ctrl+W hot key.



The following dialog box pops up.



The Name given to the tag has the following rules:

• only alphabetic characters (A-Z or a-z), numeric characters (0-9), and underscores (_)
• must start with an alphabetic character or an underscore
• no more than 40 characters
• no consecutive or trailing underscore characters (_)
• not case sensitive

While tags are not case sensitive, it is good practice to mix cases for readability. It is much easier to read Line1_Start then LINE1START or line1start.
In addition, the tag database list sorts alphabetically. Therefore, it is best to use similar starting characters when you want tags to be together in the monitor list.

Tags Named for Grouping		Tags Not Named for Grouping
Level_High		High_Level
Level_Low		Insert_Nut
Insert_Nut		Knife_Stop
Knife_Stop		Low_Level

Use the Description field for a longer description of the tag. It is best to keep names short yet not cryptic. Tag names are downloaded and stored in the controller but the description is not as it is part of the documentation of the project.
The tag Type defines how the tag operates in the project

Base	A tag that actually defines the memory where the data is stored
Alias	A tag that represents another tag
Produced	Send data to another controller
Consumed	Receive data from another controller

Alias tags mirror the base tag to which they refer. When the base tag value changes so does the alias tag. Use aliases in the following situations:

• program logic in advance of wiring diagrams
• assign a descriptive name to an I/O device
• provide a more simple name for a complex tag
• use a descriptive name for an element of an array

Produced and consumed tags make it possible to share tags between controllers in the same rack or over a network. This article does not cover this aspect.
Select a Data Type for the tag by typing it in or by clicking on the ellipsis button and selecting it from the list. A data type is a definition of the size and layout of memory allocated for the created tag. Data types define how many bits, bytes, or words of data a tag will use.
The term Atomic Data Type refers to the most basic data types. They form the building blocks for all other data types.

Data Type	Abbreviation	Memory bits	Range
Boolean	BOOL	1	0-1
Short Integer	SINT	8	-128 to 127
Integer	INT	16	-32,768 to 32,767
Double Integer	DINT	32	-2,147,483,648 to 2,147,483,647
Real Number	REAL	32	+/-3.402823E38 to +/-1.1754944E-38

Logix5000 controllers are true 32-bit controllers, meaning the memory words are 32-bits wide. No matter what, a tag always reserves 32 bits of memory even if it is a Boolean or integer data type. For this reason, it is best to use a DINT when dealing with integers. Furthermore, a Logix5000 controller typically compares or manipulates values as 32-bit values (DINTs or REALs).
A Logix5000 controller lets you divide your application into multiple programs, each with its own data. The Scope of the tag defines if a tag is global (controller tags) and therefore available to all programs or local (program tags) to a select program group. Pay careful attention to this field as creating it in the wrong area may lead to some confusion later on as to its location.



Controller Tags are available to all programs. You cannot go wrong using controller scoped tags unless you easily want to copy and paste programs. A tag must be controller scoped when used in a Message (MSG) instruction, to produce or consume data and to communicate with a PanelView terminal.
Program Tags are isolated from other programs. Routines cannot access data that is at the program scope of another program. Having program tags make it easy to copy/paste programs and not have to worry about conflicting tag names. Make sure though that no controller tags are named the same as program tags.
Style is the form in which to display the tag by default. The following table provides you with information on the base and notation used for each style.

Style	Base	Notation
Binary	2	2#
Decimal	10
Hexadecimal	16	16#
Octal	8	8#
Exponential		0.0000000e+000
Float		0.0

Edit and Monitor Tags

To edit existing tags select the Logic > Edit Tags menu item. A spread sheet like view lets you create and edit tags.



Clicking the + sign next to a tag reveals its structure. For a DINT tag this is the 32 individual bits that make up the tag which will not be of interest if you are using the tag as a number rather then individual bits. If you do wish to use the individual bits then you can address them in this way with the tag name followed by a period and then the bit position (e.g. MyTag.5). Shown below is the expanded structure for a TIMER. Notice it is made of two DINTs and three BOOLs. In this case, the Booleans are packed into one DINT and therefore a timer uses three DINTs of memory.

An Easier Way to Create Tags

The easiest way to create tags is on the fly while programming. When an instruction is first used a “?” will indicated the need for a tag. There are three options at this point:

1. Double click on the “?” and select an existing tag from the drop down box.
2. Right click on the “?” and select new tag.
3. Double click on the “?” and type in the tag name. If it does not all ready exist, then right click on the tag name and select Create “NewTagName”. Be careful with this method not to use spaces or special characters.

The nice thing about all these methods is that RSLogix5000 will automatically fill in the correct data type according to the instruction used.
Another quick method is to drag and drop an existing tag to a new instruction. Make sure to click on the tag name rather then the instruction.

Conclusion

These are the basics of tags. The advantages are:

1. Tags, if done right, create a level of documentation that is stored in the PLC.
2. The software does an automatic housekeeping of memory locations. There’s no more worrying about physical addressing and memory conflicts.
3. Structures can be more easily put together based on function rather then data type.

Advance subjects include arrays, user defined data types (UDT) and Add-On Instructions. Hopefully, you will continue to learn more about the power of tags. There is no doubt that if you grasp the principles presented here you will be well on your way to using and troubleshooting any Logix5000 controller.

An Introduction to RSLogix5000 Tags

Tags are the method for assigning and referencing memory locations in Allen Bradley Logix5000 controllers. No longer are there any physical addresses such as N7:0 or F8:7 which use symbols to describe them. These have been replaced with tags which are a pure text based addressing scheme. This is a departure from the more conventional ways of programming PLC’s, which includes Allen Bradley’s earlier line of PLC5 and SLC 500 controllers.
One of the hardest transitions from the older systems is realizing how the tag database works. The person with experience in Allen Bradley systems will recognize many of the instructions and be at home with the editor in RSLogix 5000. Understanding the tag database is the first major hurdle in becoming comfortable with the ControlLogix and CompactLogix systems. So let’s dig in and get started.

The Way We Used To Be

Earlier Allen Bradley PLCs programmed with RSLogix 5 and RSLogix 500 software had data files to store I/O and other internal values. These different data files could only hold one data type. A data type defines the format and the size of the stored value.
Default Data Files

Data File Descriptions

File #	Type	Description
O0	Output	This file stores the state of output terminals for the controller.
I1	Input	This file stores the state of input terminals for the controller.
S2	Status	This file stores controller operation information useful for troubleshooting controller and program operation.
B3	Bit	This file stores internal relay logic.
T4	Timer	This file stores the timer accumulator and preset values and status bits.
C5	Counter	This file stores the counter accumulator and preset values and status bits.
R6	Control	This file stores the length, pointer position, and status bits for control instructions such as shift registers and sequencers.
N7	Integer	This file is used to store bit information or numeric values with a range of -32767 to 32768.
F8	Floating Point	This file stores a # with a range of 1.1754944e-38 to 3.40282347e+38.

While this method made it easy for using instructions, it provided a challenge for logically grouping different data types together according to function. For instance, in machine control, a motor may have a start, stop, speed and alarm code each with its own data type. Thus, the data was “scattered” throughout the data files.

File #	Name	Data Type
I1	Start	Input
I1	Stop	Input
F8	Speed Setpoint	Floating Point
N7	Alarm Code	Integer

Comparing the Old and New

The Logix5000 controllers have done away with data files and in its place is the tag database. The tag database organizes memory locations in one place. Each tag is assigned its own data type. The table below shows the association between the current data types and the older systems with data files.

RSLogix 5 / 500			RSLogix 5000
File #	Type
O0	Output		Input and output modules, when configured, automatically create their own tags like Local:0:I.Data.0
I1	Input
S2	Status		Use the GSV and SSV instructions to get status information such as the CPU time, module states and scan times.
B3	Bit		Assign the Boolean (BOOL) data type to the tag.
T4	Timer		Assign the TIMER data type to the tag.
C5	Counter		Assign the COUNTER data type to the tag.
R6	Control		Assign the CONTROL data type to the tag.
N7	Integer		Assign the double integer (DINT) data type to the tag.
F8	Floating Point		Assign the REAL data type to the tag.

Creating a Tag

One way to create a new tag is right click on the Controller Tags in the Controller Organizer and select New Tag. Even faster is the Ctrl+W hot key.



The following dialog box pops up.



The Name given to the tag has the following rules:

• only alphabetic characters (A-Z or a-z), numeric characters (0-9), and underscores (_)
• must start with an alphabetic character or an underscore
• no more than 40 characters
• no consecutive or trailing underscore characters (_)
• not case sensitive

While tags are not case sensitive, it is good practice to mix cases for readability. It is much easier to read Line1_Start then LINE1START or line1start.
In addition, the tag database list sorts alphabetically. Therefore, it is best to use similar starting characters when you want tags to be together in the monitor list.

Tags Named for Grouping		Tags Not Named for Grouping
Level_High		High_Level
Level_Low		Insert_Nut
Insert_Nut		Knife_Stop
Knife_Stop		Low_Level

Use the Description field for a longer description of the tag. It is best to keep names short yet not cryptic. Tag names are downloaded and stored in the controller but the description is not as it is part of the documentation of the project.
The tag Type defines how the tag operates in the project

Base	A tag that actually defines the memory where the data is stored
Alias	A tag that represents another tag
Produced	Send data to another controller
Consumed	Receive data from another controller

Alias tags mirror the base tag to which they refer. When the base tag value changes so does the alias tag. Use aliases in the following situations:

• program logic in advance of wiring diagrams
• assign a descriptive name to an I/O device
• provide a more simple name for a complex tag
• use a descriptive name for an element of an array

Produced and consumed tags make it possible to share tags between controllers in the same rack or over a network. This article does not cover this aspect.
Select a Data Type for the tag by typing it in or by clicking on the ellipsis button and selecting it from the list. A data type is a definition of the size and layout of memory allocated for the created tag. Data types define how many bits, bytes, or words of data a tag will use.
The term Atomic Data Type refers to the most basic data types. They form the building blocks for all other data types.

Data Type	Abbreviation	Memory bits	Range
Boolean	BOOL	1	0-1
Short Integer	SINT	8	-128 to 127
Integer	INT	16	-32,768 to 32,767
Double Integer	DINT	32	-2,147,483,648 to 2,147,483,647
Real Number	REAL	32	+/-3.402823E38 to +/-1.1754944E-38

Logix5000 controllers are true 32-bit controllers, meaning the memory words are 32-bits wide. No matter what, a tag always reserves 32 bits of memory even if it is a Boolean or integer data type. For this reason, it is best to use a DINT when dealing with integers. Furthermore, a Logix5000 controller typically compares or manipulates values as 32-bit values (DINTs or REALs).
A Logix5000 controller lets you divide your application into multiple programs, each with its own data. The Scope of the tag defines if a tag is global (controller tags) and therefore available to all programs or local (program tags) to a select program group. Pay careful attention to this field as creating it in the wrong area may lead to some confusion later on as to its location.



Controller Tags are available to all programs. You cannot go wrong using controller scoped tags unless you easily want to copy and paste programs. A tag must be controller scoped when used in a Message (MSG) instruction, to produce or consume data and to communicate with a PanelView terminal.
Program Tags are isolated from other programs. Routines cannot access data that is at the program scope of another program. Having program tags make it easy to copy/paste programs and not have to worry about conflicting tag names. Make sure though that no controller tags are named the same as program tags.
Style is the form in which to display the tag by default. The following table provides you with information on the base and notation used for each style.

Style	Base	Notation
Binary	2	2#
Decimal	10
Hexadecimal	16	16#
Octal	8	8#
Exponential		0.0000000e+000
Float		0.0

Edit and Monitor Tags

To edit existing tags select the Logic > Edit Tags menu item. A spread sheet like view lets you create and edit tags.



Clicking the + sign next to a tag reveals its structure. For a DINT tag this is the 32 individual bits that make up the tag which will not be of interest if you are using the tag as a number rather then individual bits. If you do wish to use the individual bits then you can address them in this way with the tag name followed by a period and then the bit position (e.g. MyTag.5). Shown below is the expanded structure for a TIMER. Notice it is made of two DINTs and three BOOLs. In this case, the Booleans are packed into one DINT and therefore a timer uses three DINTs of memory.

An Easier Way to Create Tags

The easiest way to create tags is on the fly while programming. When an instruction is first used a “?” will indicated the need for a tag. There are three options at this point:

1. Double click on the “?” and select an existing tag from the drop down box.
2. Right click on the “?” and select new tag.
3. Double click on the “?” and type in the tag name. If it does not all ready exist, then right click on the tag name and select Create “NewTagName”. Be careful with this method not to use spaces or special characters.

The nice thing about all these methods is that RSLogix5000 will automatically fill in the correct data type according to the instruction used.
Another quick method is to drag and drop an existing tag to a new instruction. Make sure to click on the tag name rather then the instruction.

Conclusion

These are the basics of tags. The advantages are:

1. Tags, if done right, create a level of documentation that is stored in the PLC.
2. The software does an automatic housekeeping of memory locations. There’s no more worrying about physical addressing and memory conflicts.
3. Structures can be more easily put together based on function rather then data type.

Advance subjects include arrays, user defined data types (UDT) and Add-On Instructions. Hopefully, you will continue to learn more about the power of tags. There is no doubt that if you grasp the principles presented here you will be well on your way to using and troubleshooting any Logix5000 controller.

Factory Tours

Factory Tours

I love factory tours especially if they're personal ones. There's just something about seeing automation in action that's just cool.

I got started on a little factory tour information internet romp after watching this cool flash video about the Lego factory. I love Legos so seeing it in automation is a bit of double your pleasure. If you're a Lego fanatic and in Denmark then you might actually get an inside tour. I have no plans so you'll have to tell me about it.
There's a book called Watch It Made in the USA which is a guide to visit nearly 300 factories and company museums across the U.S.A. So you could plan your whole family vacation around factory tours. Yeah right, if you could just get the kids to agree to that. The book is very well done but if you just want a quick run down of some local factories you can try the Factory Tours USA website.
Here's a list of one's that sound fun and interesting to me.

• Boeing (Everett, WA) - I've actually been on this tour and would love to go again. Absolutely worth it.
• Jelly Belly (Fairfield, CA) - Oh these jelly beans have amazing different flavors. It'd be great to be up to your armpits in them.
• Ben and Jerrys (Waterbury, VT) - Another one of my favorites: Ice Cream!
• Taylor Guitars (El Cajon, CA) - I play guitar so this would be awesome.
• Toyota (Georgetown, KY) - Any automobile manufacturing is cool.
• Crayola (Easton, PA) - Now here's one the kids could get into especially if they are Sesame Street age.
• Celestial Seasonings (Boulder, CO) - I dunno, it just sounds so comforting.

Factory Tours

Factory Tours

I love factory tours especially if they're personal ones. There's just something about seeing automation in action that's just cool.

I got started on a little factory tour information internet romp after watching this cool flash video about the Lego factory. I love Legos so seeing it in automation is a bit of double your pleasure. If you're a Lego fanatic and in Denmark then you might actually get an inside tour. I have no plans so you'll have to tell me about it.
There's a book called Watch It Made in the USA which is a guide to visit nearly 300 factories and company museums across the U.S.A. So you could plan your whole family vacation around factory tours. Yeah right, if you could just get the kids to agree to that. The book is very well done but if you just want a quick run down of some local factories you can try the Factory Tours USA website.
Here's a list of one's that sound fun and interesting to me.

• Boeing (Everett, WA) - I've actually been on this tour and would love to go again. Absolutely worth it.
• Jelly Belly (Fairfield, CA) - Oh these jelly beans have amazing different flavors. It'd be great to be up to your armpits in them.
• Ben and Jerrys (Waterbury, VT) - Another one of my favorites: Ice Cream!
• Taylor Guitars (El Cajon, CA) - I play guitar so this would be awesome.
• Toyota (Georgetown, KY) - Any automobile manufacturing is cool.
• Crayola (Easton, PA) - Now here's one the kids could get into especially if they are Sesame Street age.
• Celestial Seasonings (Boulder, CO) - I dunno, it just sounds so comforting.

Case Study: Water and Waste Water Plants

Water and Waste Water Plants Transform Using Web-Launched, Java-Based SCADA Software

Professionals in the water and waste water management field face a series of difficult challenges as they seek to stabilize and expand their service delivery capabilities, while at the same time meeting the regulatory reporting requirements of the state. As if that were not enough, they must accomplish this in the current economic environment facing local governments. Managers clearly need better ways of doing business and an economic model which will give them the functionality and scalability required at a price point that does not break the budget.
Presented here are the perspectives of three jurisdictions that have found a workable solution to address their needs. Brazeau County in the Province of Alberta Canada; the City of Lago Vista in Texas and the Helix Water District in California’s San Diego County.

How It All Began

Steve Hechtman, the President and Founder of Inductive Automation Software, brings over 20 years experience as a systems integrator to the problem of managing water and waste water treatment plants. He shares his perspective on why he got into the software business and why it should matter to you:
“We needed a solution that allowed for PLC data to be readily available in SQL databases, that would not become obsolete every few years and which would provide an affordable expansion model for both run time and development needs. That was not available in the marketplace so I was forced into the software business.
“The first hurdle we put behind us was making PLC data readily available in SQL databases. From there we naturally started making reports and user interfaces using web pages. But it quickly became apparent we needed a rapid, standardized way of making such applications and of course security was a concern so we started investigating the various technologies available to do this.
“Ultimately, we decided to use Java for our platform, when virtually every other SCADA vendor chose the Microsoft route.”

Why Choose Java?

“Proofing against obsolescence is one major consideration. Every five years Microsoft reinvents itself and in that act churns the very platform these other SCADA applications are built on. The cost to the water plant manager is often prohibitive with current traditional vendor licensing models.
“Cross-platform support is another consideration. Vista was having problems. Meanwhile Linux operating systems such as Ubuntu are free and are gaining ground fast around the world.
“Our Java application could care less what platform it runs on or what database it interacts with. It works comfortably with them all.
“So now, today, what do we have? We have the world’s only fully mature, cross-platform, web-launched, secure, reliable SCADA application server which can support any SQL database and which is very easy to use. A skilled integrator can set up an amazing SCADA application in about an hour and then proceed from there to launch five or fifty clients anywhere, totally securely.”
The benefits to the water and waste water plant manager or supervisor will be obvious as you read the case studies and thoughts of Rick Flikkema from Brazeau County, Alberta; M.J. Duke from the City of Lago Vista and Henry Palachek, the Information and Process Control Systems Supervisor from the Helix Water District in San Diego.

Brazeau County, Alberta, Canada

Clearly, every municipality has a water and waste water department. The people who work in these departments are responsible for maintaining water quality delivered to their constituents as well as the delivery system itself. Well pumps and HighLift pumps are typically employed to move the water from the inside the earth or from reservoirs to fill the miles of pipes that go to each home and business to supply fresh potable water. On the output end, the systems have to treat contaminated water and remove the waste.
Typically these departments rely on the expertise of a system integrator (SI) or a consultant to guide them in their technological quests.
The county of Brazeau is located north-west of Calgary, Alberta in the Canadian Rockies. They needed to upgrade their Texas Instruments PLCs and chose to go with KSB Industrial (KSBI) as the SI.
Ken Bannard, President of KSBI, used GE PLCs for the Brazeau county new technology platform. These two PLCs are connected to the main office by leased lines using 9600 baud modems. Along with the new platform, KSBI implemented new SCADA software as well.
FactoryPMI from Inductive Automation was selected as the ideal software for this implementation. Rick Flikkema operates the two water plants and the three lift stations for the county.
“FactoryPMI has eased up alot of my time,” Rick said. “I was skeptical at first, when Ken introduced me to FactoryPMI.”
Over time Ken showed Rick how it would save the county money and time. “FactoryPMI is very cost-effective solution. Our end users become very interested when they hear that they can have unlimited clients at no extra cost,” Ken said.
Most municipalities are on a reduced budget and have fewer resources available to them. FactoryPMI makes up for those ‘losses’.
“FactoryPMI is both the development system and runtime. My customer has the ability to have anyone make changes if needed,” said Bannard. “And with the VPN remote access ability, a web access license doesn’t need to be purchased, unlike most other SCADA products.”
For the county of Brazeau, the total cost of ownership is hugely attractive. They have one server for control, monitoring and data tracking of the two water plants and lift stations.
“FactoryPMI has been running for 24 months trouble-free. It has made my job easier because I can monitor all areas of operation efficiently,” said Rick.
For the county of Brazeau, when they move towards additional reporting and data logging as well as a third water plant, their upfront costs will be negligible. “The upgrade path is very easy and inexpensive,” remarked Bannard. “FactoryPMI is good for integrators since it empowers them on behalf of their customers. The no-limit tag count allows me to provide the best possible system for my customer with minimal capital outlay.”

Realtime Status and Control Overview

City of Lago Vista Water and Waste Water Facilities

Deep in the heart of Texas, there is a city of approximately 6,000 people called Lago Vista. Located just west of Austin, there are many qualified system integrators nearby.
Patrick Callaghan from MCS Integrations was selected as the SI to assist Lago Vista with their SCADA upgrade path. M.J. Duke, Superintendent of Plant Operations for the district explains why: “Pat does his homework and is very thorough. If Pat likes it, then I like it!”
And Pat likes FactoryPMI from Inductive Automation.
Lago Vista often had issues with their previous software; and the common answer to many questions was “We just can’t do that.” And if there was a way, it was often too costly to implement.
Like most integrators, Callaghan mainly used one of the ‘big three’, and typically used Wonderware’s Intouch HMI software. “With what we have accomplished using the stock FactoryPMI software, I would have had to write custom code [with Wonderware],” indicated Callaghan.
Inductive Automation’s licensing model made the decision easy. “We were operating on stand-alone systems, and wanted to move towards a centralized system,” said Duke. “Runtime licensing with our former supplier was an issue. The upfront license costs for the new system were one-fifth what it would have cost using Wonderware,” stated Callaghan.
Duke oversees the operation of two water plants and the waste water facilities. There are six distribution pump stations remote to the main plants, as well as two intake stations all having Automation Direct PLC technology. There are also four holding ponds which require monitoring. And soon, Lago Vista will add an irrigation system for a city-owned golf course which will also need control and monitoring.
MCS Integrations began the migration by consolidating the existing applications into one FactoryPMI server-based application. After adding all the functionality available before the migration, the city was able to add additional functionality which wasn’t previously possible. “There were no holes in the conversion,” Callaghan said. “There was a learning curve in the beginning – my database experience was small. But Inductive Automation’s new SQLTags technology was a blessing.”

Graph Screen Showing History of Turbidity, Tank Level, Flows, etc.
The former HMI/SCADA system had stand-alone applications running in each different location. In order to monitor the operations, the operators needed to drive to individual locations. While the efficiency of the department wasn’t ideal, it was rapidly deteriorating as the cost of operator travel increased.
Callaghan installed a FactoryPMI server at the primary water plant (WP1). Plant-to-plant communications were established with fiber optics. VHF communications connect the remote
PLCs to the system network. As well, there are client workstations in each plant. The router at WP1 connects to the Internet to allow for remote VPN access. Each plant also has a Wi-Fi access point.
Lago Vista wanted to be able to access all systems from each plant, as well as from mobile tablets, which they can now do. “When the operators are in their trucks, they can use the tablet PCs to access the network,” Duke said. They use a Bluetooth-enabled cell phone for internet connectivity and then create a VPN connection through the Internet to the router located at WP1.
All forms the operators need are embedded into the FactoryPMI system. The operators can input data in real-time, speeding up some compliance requirements. “No more driving to get data. They used to enter data on paper on a clipboard,” said Duke. “We looked into using Palm Pilot type devices before, but we wouldn’t be able to get the amount of data onto the screen that we needed. Without the tablets and system coverage, our response to issues would be way too slow.”
The department has to provide 24/7 service, so the mobile tablets and the ability to access the systems from any location means very fast response. “The FactoryPMI server will send an email alarm-notification to the cell phone of the person on call,” says Callaghan. The operator can then log-on to the FactoryPMI server and figure out what the issues might be. “This has increased our efficiencies,” stated Duke.
The operators can also do process checks at night, which can catch problems before they escalate. “Equipment failure can be circumvented,” says Callaghan.
Compliance regulations require city water departments to log and track data on all aspects of water plants and waste water facilities. This is done to ensure municipal compliance with the law, and ensure required levels are maintained (such as of chlorine).
Callaghan says, “Data logging with FactoryPMI is really easy. Logging this much data with Wonderware would have been much more difficult and costly. We have over 3,000 tags. Every day there is something different to add – with direct data entry and SQL—voila!”
There was some hand-holding at the beginning of the project due to Callaghan’s lack of database experience. “The support from Inductive Automation was immediate when required,” Callaghan said. He observes that what the project now entails could not be easily replicated using another HMI product. In fact, he wonders if it would be possible at all without a lot of custom code. There is no doubt that—regardless of which product it might be—it would cost more and take longer.
Callaghan concludes “FactoryPMI is a non-proprietary solution and uses standard platforms. The scripting language is very powerful (Python for Java). It’s a fabulous product!”

A Year’s Worth of Data in a PDF Document

An interview with Helix Water District’s Henry Palachek

Information and Process Control Systems Supervisor

Henry Palachek has been with the Helix Water District for the past fifteen years. He serves as the Information and Process Control Systems Supervisor. Inductive Automation (IA) caught up with him to get his views on the value of implementing web-launched and database centric SCADA software in meeting the challenges he faces supervising the water and waste water systems for the Helix Water District.

What is the biggest challenge you face with your job?

The way in which SCADA systems age and how it is related to the operating system they work on is a big challenge for us particularly right now.
With the current SCADA system and how traditional SCADA software products work, you are not certified to run on Vista. You are then forced to upgrade your system because you are only certified to work on Windows 2000 or XP II and if those are going away then the cost of upgrading the SCADA system becomes too much.
This means that obsolescence becomes a big problem with traditional SCADA software products.
When software is created based on working directly with the DB, which is what Inductive Automation has done with FactorySQL, you get a longer life span for the system. The life span goes to 10-13 years. Obsolescence and cost prohibitive upgrade cycles then are not a problem.

How does Inductive Automation’s FactorySQL assist you with California state reporting requirements?

The Surface Water Treatment Rule for California requires monitoring filters’ turbidity and reporting that to the state on set intervals. So having a software package that allows for talking directly to the field controller is a great advantage.
Helix has 50 sq. mile distribution system and 260,000 customers. The Distribution Manager logs the data to the database on 5 minute intervals. We have then set up stored procedures that create hourly and daily summary data.
This then gives us the ability to create reports which we can mail directly to the state for complying easily with the Surface Water Treatment Rule.
We have had InTouch for over 10 years. Classic SCADA packages don’t have an easy way to do that. The drag and drop ease of use of FactorySQL is great for these reporting requirements.

Ease of use, learning curve and set up time are important factors. Has IA software measured up in that area?

Absolutely, I had it set up on my notebook in about half an hour. With a classical Wonderware package it is cumbersome if you do DB. It requires multiple steps to configure. With FactorySQL it is like one step configuration. You put in a tag name and drag the tag name and drop to the bottom to create a table and start logging. It is like night and day difference.

How did you make a decision to go with Inductive Automation software?

I went out and looked at all the leading vendors; none of them had the same ease of use with the drag and drop feature.
We have had no issues with reliability or uptime.
Plus there is a big advantage if a computer fails. With traditional systems you have to rebuild the computer and then get SCADA system back on it with whatever patches or upgrades you may have. It can cost time and money and lost data. With FactorySQL you can take any PC almost out of the box and get it easily up and running. This will help you solve hardware problems a lot faster.
It is a nice feature to have unlimited tags and to not have to buy a license for unlimited tags and not to worry about how many tags I do have.

Is there a cost advantage?

We’re running 16 SCADA clients in our treatment plant. When you start adding up 16 licenses just so our operators can view and acknowledge alarms, it starts getting pretty expensive.
The cost of just a single license for development or runtime with traditional software vendors can be about $5,000 to $12,000. So you certainly do have a cost advantage with FactorySQL and FactoryPMI, as the license is sold by the server and provides unlimited tags and unlimited clients to us as the customer.
If you are doing a SCADA change out with a large number of clients price does become an issue.

Any final thoughts for our readers?

In the water utility field there is a lot more pressure than there used to be in three areas:
1. Regulation requirements—Working with a database-centric product helps with regulatory issues.
2. Economic issues—It is not just business as usual. You really have to look at the cost of the system and FactoryPMI and FactorySQL have a definite advantage there.
3. Managers need better ways of doing business—Web technology with SQL databases is really a better way of doing business.