Reading Flow Meters With Revenue-Grade Accuracy Through Your SCADA, Telemetry, Or Building Automation System

Jim Mimlitz
SCADAmetrics
Reading Flow Meters
With Revenue-Grade Accuracy
Through Your SCADA, Telemetry,
Or Building Automation System
© 1995-2013 COPYRIGHT
SCADAMETRICS
ALL RIGHTS RESERVED.

SCADAMETRICS
Flow Meter Reading
Technology Background…
Flow Meter Industry Serves 2 Traditional Applications
RESIDENTIAL METERS
PURPOSE: Billing
MONITORING: Monthly Reads (AMR)
COMMERCIAL/INDUSTRIAL METERS:
PURPOSE: Process Monitoring, Control, Alarming
MONITORING: Continuous Reads
(SCADA, Telemetry, Building Automation)
SCADAmetrics

Residential
1980‟s –
Digital Encoders
Touchread
1990‟s, 2000‟s –
Improved Reliability Digital Encoders
Radio Read
Phone Read
Revenue-Grade Accuracy
SCADA/Telemetry,
Bldg Automation
SCADAMETRICS
Electronic Meter Reading
Technology Timeline…
Low Volume Automation
Meter Reading
Stalled In 1970’s-Era
Technology
High Volume Residential
Meter Reading Technology
Advancing Rapidly
SCADAmetrics
1970‟s –
Pulse Generator
1st Generation Remote Reading
4-20mA Signaling

Good Flow Rate Info
Moderate/Severe Totalization Errors
High-Speed Pulse (eg 1 Pulse Per Gallon)
Flow Rate Info Takes Long To Develop (eg. 10+ minutes)
Better Totalization
Low-Speed Pulse (eg 1 Pulse Per 1000 Gallons)
Excellent Flow Rate Info
Poor Totalization
4-20mA Signal (eg 4mA=0 gpm, 20mA=800 gpm)
SCADAMETRICS
Pulse & 4-20mA
Signal Limitations…
SCADAmetrics

• Unable To Distinguish Between Forward And Reverse Flows
Generally Same Pulse or 4-20mA Signal Regardless Of Flow Direction
• Requires Continuous Power
Generally Not Compatible With Small Solar Panels
• Requires Manual Synchronization
Must Regularly Re-Adjust Start Count Within Host Telemetry/SCADA System
• Pulse Methods Provide No Meter Fault Information
Example: Cannot distinguish between „no flow‟ and a cut signal cable.
High-Speed Pulse, Low-Speed Pulse,
4-20mA Signaling
SCADAMETRICS
More Pulse & 4-20mA
Signal Limitations…
SCADAmetrics

Automation
System
Combine State-of-the-Art Encoder Meter Technology
With Automation System Communication Protocols.
ABB, Actaris, Badger, Elster-AMCO,
Hersey, Invensys, Itron, Kent, Master-Meter,
Metron-Farnier, Neptune, Rockwell,
Schlumberger, Sensus, Siemens, Sitrans,
and Others…
Request
Response
SCADAMETRICS
Request
Response
Bi-Directional
Industrial Communication Protocols:
MODBUS®,
Allen Bradley DF1,
Allen Bradley EtherNet/IP™
The Metering Solution For
Automation Systems…
EtherMeter™
Flow Meter Gateway For
SCADA, Telemetry,
& Building Automation Systems
Sensus ICE
Register
SCADAmetrics
Bi-Directional
Meter Protocols:
Sensus, Neptune, Elster

Latest Technology Solves The Common Problems Involved With
Connecting Flow Meters To SCADA, Telemetry, & Building Automation Systems.
• Revenue-Grade Total/Flow Using Standard AMR Protocols.
Sensus, Neptune, Elster Protocols w/ Auto-Detect
• Comm To Automation System Using Standard Protocols
MODBUS® Via Serial and Ethernet Ports, Allen Bradley DF1, Allen Bradley EtherNet/IP™.
• Integrated Networking
Industrial Networking Protocols: MODBUS®/TCP/UDP and Allen Bradley EtherNet/IP™.
Web Server, Remote Configuration/Management Via Telnet
• Auxiliary I/O Provides Basic Control
Eliminates PLC/RTU Costs For Simple Monitoring/Control Applications
• No Manual Synchronizations Required
Even After Power Outage Or Cut Cable
• Reverse Flows Detected
Example – Check Valve Failure
• Solar-Power Compatible
1.5 Watt, Meter Only Powered During Read
• Meter Communication Faults Alarmed
SCADAMETRICS
Features… SCADAmetrics

SCADAMETRICS
Same Meters, Upgraded Registers…
Original (Pulse) Influent Meter: ABB T3000
Retrofit Elster-AMCO “InVision” Encoder
Register Installed on ABB T3000
Effluent Meter: Sensus W1000 with “ICE” Encoder Register.
EtherMeter Collecting and Transmitting Total and Flow
From Both Meters Back to Water District Office.
SCADAmetrics

Control Valve Station
4” Sensus Compound Meter
With “ICE” Encoder Register.
Water Purchaser:
RTU and Radio.
(Collects Meter Total and
Flow From EtherMeter.
Collects Seller‟s Pressure.
Provides Control and
Monitoring For Valve.)
SCADAMETRICS
Metering At Pump Stations, Plants,
Master Meters, and Valve Stations…
Where the EtherMeter™ Can Serve As Either An
“Input Module” Or As A Basic RTU.
Water Seller:
EtherMeter and Radio.
(Collects Meter Total,
Flow, and Seller‟s
Pressure)
SCADAmetrics

SCADAMETRICS
Application Photos…
Sensus 10” Propeller Meter
With “ICE” Encoder Register
• Gateway Regional Water District
(Sandoval, IL).
• Treatment Plant Influent and
Effluent Meters.
• Master (Custody-Transfer) Meters
In Distribution System.
• EtherMeters Integrated Into PC-Based
SCADA System.
• Daily Production And Process Monitoring.
• Satellite District Realtime Consumption
Monitoring.
SCADAmetrics

SCADAMETRICS
Neptune HPT Turbine With
“E-Coder” Encoder Register
• Calhoun County (IL) Water District.
• Treatment Plant High Service Meter.
• Legacy Meter With Upgraded Register.
• EtherMeter Integrated Into Existing PC-Based
SCADA System.
• Revenue-Grade Daily Water Production Reporting.
• Reverse-Flow Detection (Check Valve Fail) Alarming
SCADAmetrics

SCADAMETRICS
Itron (Actaris) FloStar Single-Jet Meter
With “Cyble-Coder” Encoder Register
• Mill Creek Water District (Quincy, IL).
• Disinfection Treatment Station.
• EtherMeter Integrated Into Existing
PC-Based SCADA System.
• SCADA System Collects Production Totals
And Controls Chlorine Pump Speed
Proportional To Measured Flow Rate.
SCADAmetrics

SCADAMETRICS
16” Sensus Turbo Meters (4)
With “ICE” Encoder Registers
• St. Louis County (Missouri American)
Water District.
• Hog Hollow Pump Station (50 MGD).
• Custody-Transfer Point Between
St. Louis City and St. Louis County.
• EtherMeters Integrated Into Existing
Allen Bradley-Based SCADA System
Network.
• SCADA System Uses Revenue-Grade
Totalization From EtherMeters To Manage
Water Purchase Agreement.
Communicates To SCADA OPC Server Using
MODBUS®/TCP, And To PLC Using
EtherNet/IP™ Simultaneously.
• Installation And Setup By Missouri American.
• Payback Within A Few Months.
SCADAmetrics

• Real-Time “Water Usage” Data Is Possible When All Major
Flows Can Be Accounted For Within The SCADA System
(Requires Flows At Pump Stations, Master Meters, and
Water Towers).
• Solar-Powered Master Meters Enable Low-Cost “Leak Detection
RTU‟s” To Be Staged Throughout A Water District (Many
Master Meter Locations Do Not Have Power).
• Encoder Registers Are Generally The Most Accurate and
Least Expensive Of All Electronic Meter Register Types Due
To Economies Of Scale.
SCADAMETRICS
Master Metering Benefits… SCADAmetrics

Master Metering Pilot Project…
SCADAMETRICS
ABS Water Cooperative (Clayton, IL)
Adams, Brown, and Schuyler Counties
• Collect Data From 34 Master Meters
Using SCADA System.
• 4 Readings Per Day (More Possible).
• Emphasis On Revenue-Grade Accuracy
Of Meter Readings.
• Accelerated Leak Detection.
• Emphasis On Minimizing Recurring Costs:
Low Energy Footprint (Solar Solution)
Eliminate Manual Read Payroll
Reduce Fuel and Vehicle Wear/Tear
Reduce Data Entry and Reporting Time
• Increased Employee Safety.
• 3 Year Investment Payback.
0 105
miles
SCADAmetrics

SCADAMETRICS
Solar-Power Intensive Project
Reduced Energy Costs For Water District
Several Meter Brands Mixed
Throughout System
Solar-Power Eliminates Electric Service
Hookup Fee And Recurring Monthly Charges.
Lexan Window
“Visual Read”
Sensus
Badger
Master Metering Pilot Project… SCADAmetrics

SCADAMETRICS
Manual Data-Entry Eliminated.
History Data Permanently Stored On SCADA Server.
Automatic Generation Of Regulatory Compliance Reports (EPA).
EPA Reports: Automatically-Generated Excel Spreadsheets
Master Metering Pilot Project… SCADAmetrics

SCADAMETRICS
Operators Have Remote Access To Data Via Smart Phones.
Ability To Share Data With Bulk Water Customers And Suppliers.
Master Metering Pilot Project…
Web Browser-Based Monitoring
SCADAmetrics

SCADAMETRICS
Military Base SCADA Flow Metering…
Metron-Farnier Meters Retrofitted w/
Encoder Registers by AFB Personnel
The US Air Force “Bone Yard”
EtherMeter Installed In
Well Pump Station And
Programmed By AFB Personnel.
Modicon PLC-Based
SCADA Panel.
(MODBUS®/TCP)
Davis-Monthan AFB
Tucson, AZ
SCADAmetrics

SCADAMETRICS
Metro Airport SCADA Flow Metering…
• NY-Based Utility/Property Management Firm
Manages All Port Authority Utility Metering.
• Collect Data From NY Area Airport Sub-Meters
Using Centrally-Managed SCADA System.
(Potable Water, Hot Water, Electricity, Gas)
• EtherMeters Collect Potable & Hot Water
Meter Totalizations And Flows.
• Emphasis On Revenue-Grade Accuracy Of Meter
Readings And Unified Interface To Many
Different Water Meter Brands.
• Emphasis On Use Of Standard SCADA
Communication Protocols (MODBUS®/TCP).
• Safety Recognition Required For All Electronics
(UL 508A Control Panels).
Phoenix Contact-Based
SCADA Panel.
(MODBUS®/TCP)
JFK International Airport
New York, NY
SCADAmetrics

Summary
For Telemetry, SCADA, & Building Automation Applications…
Pulse & 4-20mA Meters = Old And Limited Technology.
Encoder-Based Meters = Newest and Highest Performing Technology.
Encoder-Based Metering Benefits…
• Error-Free, Revenue-Grade Totalization
• Accurate Flow
• Regular Synchronization (Maintenance) Is Eliminated
• Reverse Flows Are Detectable/Alarmable
• Many Meter Failures Are Detectable/Alarmable
• Low-Power Requirements
• Lower Cost
• Most Major Meter Brands Are Compatible
• Low-Cost Retrofits Are Generally Possible.
• Low-Power and Low-Cost Make Simple SCADA Master-Metering Affordable
SCADAMETRICS
SCADAmetrics

Jim Mimlitz
SCADAmetrics
St. Louis, Missouri
636.405.7101
scadametrics.com
SCADAMETRICS
SCADAmetrics

Reading Flow Meters With Revenue-Grade Accuracy Through Your SCADA, Telemetry, Or Building Automation System

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Reading Flow Meters With Revenue-Grade Accuracy Through Your SCADA, Telemetry, Or Building Automation System