Client Challenge
A wastewater treatment plant in Central Florida required a significant upgrade to its aging control and power distribution systems. The facility relied on older PLCs, which lacked the capacity and efficiency needed for modern plant operations. Additionally, the plant’s fiber optic control network was outdated, using OM1 fiber that limited data transmission capabilities.
The plant’s new medium-voltage switchgear installation required seamless integration with their existing GE iFix SCADA system while minimizing disruption to ongoing wastewater treatment processes. To achieve this, the client needed a robust solution that combined modern control hardware, fiber optic upgrades, and comprehensive system testing and commissioning.
Our Solution
DSI Innovations delivered a complete system upgrade, modernizing the plant’s control and communication infrastructure while ensuring uninterrupted plant operations. Key aspects of the project included:
- PLC Upgrades:
- Upgraded outdated Rockwell MicroLogix and Siemens S7-300 PLCs to Siemens S7-1500 controllers, leveraging the TIA Portal environment for streamlined programming, diagnostics, and future scalability.
- Programmed the new PLCs for seamless control of the plant’s new medium-voltage switchgear and motor control centers (MCCs).
- SCADA Integration:
- Integrated the upgraded PLCs with the existing GE iFix SCADA system, ensuring operators had real-time visibility and control over plant operations.
- Modified alarms and trends to reflect the new system architecture and enhance usability.
- Fiber Optic Network Upgrade:
- Designed a new fiber optic network infrastructure, upgrading cables, connectors, and patch panels from OM1 to OM3/OM4 fiber.
- Control Panel Design and Build:
- Designed and built new control panels, including detailed electrical drawings and procurement of all necessary parts.
- Testing, Commissioning, and Documentation:
- Developed comprehensive system test plans and executed thorough testing to verify control system functionality.
- Provided detailed operator manuals and system documentation to meet the client’s compliance requirements.
- Conducted on-site commissioning and start-up services, coordinating closely with plant personnel and contractors to minimize disruption to ongoing operations.
The Results
The successful completion of the PLC, fiber optic, and power distribution system upgrade provided the wastewater plant with:
- Enhanced System Performance: The new Siemens S7-1500 PLCs delivered faster processing, improved diagnostics, and greater operational flexibility.
- Improved Network Reliability: Upgrading to OM3/OM4 fiber significantly increased data transmission capacity and network resilience.
- Seamless SCADA Integration: Operators gained real-time visibility and control through updated iFix SCADA graphics and alarms.
- Minimal Operational Disruption: DSI’s meticulous planning and coordination ensured continuous plant operations throughout the upgrade process.
- Comprehensive Documentation: Detailed system manuals and test plans facilitated ongoing maintenance and future system expansions.
This project demonstrated DSI Innovations’ ability to deliver complex infrastructure upgrades while maintaining plant continuity, enhancing efficiency, and future-proofing critical control systems.
