Client Challenge
A wastewater treatment plant in North Florida was seeking an upgrade to its aging control systems. The existing setup used an Automation Direct PLC system and an outdated iFix SCADA platform, both of which lacked modern functionality and ease of use. Additionally, the client needed to convert a “black box” OEM-provided Sequential Batch Reactor (SBR) system to a more transparent and manageable control system.
The project’s goals included:
- Replacing the Automation Direct PLC with a Siemens S7-315 platform.
- Upgrading the SCADA system from iFix to WinCC with an improved user interface.
- Recreating the SBR controls on the Siemens platform, despite limited documentation from the OEM.
- Minimizing operational downtime during the transition.
Our Solution
Our team successfully executed a comprehensive PLC and SCADA system upgrade tailored to the client’s needs. Key deliverables included:
- SCADA Upgrade:
- We migrated the SCADA system from iFix to Siemens WinCC, providing a modern, user-friendly interface for operators.
- SCADA functionality was enhanced to streamline monitoring and control of plant operations.
- PLC Upgrade:
- We replaced the legacy Automation Direct PLC with Siemens S7-315 components, including remote I/O racks.
- We converted all existing software to run seamlessly on the new Siemens platform.
- SBR System Conversion:
- We translated the functionality of the OEM-provided “black box” SBR system into the Siemens S7 platform.
- SBR controls were recreated based on the control narrative provided by the OEM and insights from plant personnel.
- On-Site Installation and Support:
- Our team provided hands-on installation of the new PLC components and remote I/O racks.
- We were able to minimize plant downtime during installation and transition to the new system efficiently.
The Results
The PLC and SCADA system upgrade delivered significant improvements for the wastewater treatment plant:
- Enhanced Control and Visibility:
- The new Siemens S7-315 PLC and WinCC SCADA platform provided operators with modern tools for monitoring and managing plant processes.
- SBR System Transparency:
- The recreated SBR controls eliminated reliance on the opaque OEM system, giving the plant full control and understanding of this critical process.
- Improved User Experience:
- The upgraded SCADA interface offered intuitive navigation and streamlined workflows, improving operator efficiency.
- Minimal Downtime:
- DSI’s careful planning and execution ensured the plant continued operations with minimal disruption during the transition.
- Cost Management:
- Despite a single change order, the project stayed close to its original budget, reflecting effective scope management and client collaboration.
This project demonstrated DSI Innovations’ ability to modernize wastewater treatment control systems, providing the client with a reliable, transparent, and user-friendly solution to support their operational needs.
