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Case Studies

Case Studies

Water - Treatment Works/ BS1

Key Features:   

  • Control Engineering
  • Design Consultancy
  • Fibre Ethernet Ring using Hirschmann  MICE Switches
  • Ethernet Communications
  • Allen Bradley
  • 5 off ControlLogix PLCs
  • 4 off CompactLogix PLCs
  • 6 off PanelView + HMI’s
  • 4 intelligent MCCs
  • Replacement and expansion of the existing site wide SCADA system
  • Replacement of 4 HMIs

Project Overview


This is a key treatment works for a major regional Water Company.


Saftronics was selected to implement the project in 2006. This project set out to overhaul, repair and extend the whole of the plant control systems in order to address significant weaknesses in the plant operation and to achieve the design through put of the works that was being restricted by the M&E infrastructure.


Scope of Works


The existing SCADA system had to be replaced and expanded to accommodate a large scale process automation scheme and to integrate several remote sites into the scope of monitoring. Numerous PLCs were upgraded to enable Ethernet PLC communications and the pre-existing DH485 ntwork was to be gracefully retired.


Technology Platform


The site SCADA system utilises a FTViewSE Client / Server architecture with VPN access for support. The SCADA servers were duty / standby units with RAID 1 configured hard disks hosting a MS Windows XP Pro SP2 O/S.


The existing Allen Bradley PLCs were upgraded to accommodate Ethernet communications and the site communications networks were re-engineered to increase the speed and bandwidth and to enable a view anywhere approach. These PLCs were then equipped with new 10” colour HMIs.


The new process areas were equipped with ControLogix PLCs or Compact Logix PLCs. The site was equipped with multiple DeviceNet Fieldbus networks to collect data from intelligent starters and local junction boxes.


Throughout this scheme the treatment process had to be maintained fully operational and so careful planning of the change over process was necessary.


As PLCs were upgraded interim software had to be created to enable the upgrade prior to new mechanical plant being installed and commissioned.


The project was a significant success and all of Saftronics scope of works was completed ahead of schedule.

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