A time-critical upgrade for a rural WTP’s control systems.

SGA’s client required a seamless migration from an outdated SLC (PLC) to a new Omron NX102 PLC to improve efficiency and meet budget deadlines.

SGA’s expertise in automation and project management ensured a smooth transition with minimal disruption, enhancing the plant’s efficiency and reliability.

About the Site

The rural WTP serves a small town of approximately 15,000 people by treating and supplying drinking water.

It uses two DAFF filters as the primary treatment method, supported by the dosing of chemicals like soda ash, chlorine, alum, PAC, and fluoride.

The plant typically processes around 115 litres per second of raw water, capable of producing nearly 10 million litres per day. The treated water is stored in a 10 ML tank before being gravity-fed into the town.

  • Upgraded SLC (PLC) to a new Omron NX102 PLC.
  • Upgraded the existing SCADA system to the Aveva Plant SCADA platform.
  • Integrated the client’s existing libraries and function blocks into the new SCADA project.
  • Delivered a succinct and comprehensive SCADA Operator manual.

An 11-Week Turnaround

To ensure minimal disruption during the upgrade, a 2 stage migration approach was implemented.

  • Stage 1 involved cutting over the I/O, where all field
    devices were rewired from the old SLC to the new Omron
    PLC. This allowed the old PLC to continue controlling the
    site while the new system was set up.
  • Stage 2 was the full migration, where the new PLC and
    SCADA system were brought online, ensuring a seamless
    transition with minimal downtime.

The project was completed in 11 weeks

  • Design – 3 weeks
  • Development – 4 weeks
  • Testing – 2 weeks
  • Implementation – 2 weeks
  • Upgraded SLC (PLC) to a new Omron NX102 PLC.
  • Upgraded the existing SCADA system to the Aveva Plant SCADA platform.
  • Integrated the client’s existing libraries and function blocks into the new SCADA project.
  • Setup a Red Lion protocol converter to allow communication between the old and new PLCs during the transition.
  • Implemented a two-stage migration process.
  • Acted as the principal contractor, overseeing the entire upgrade project, including managing the electrical subcontractor.
  • Ensured the safety and compliance of all site activities.
  • Conducted thorough testing and commissioning of the new PLC and SCADA systems.
  • Provided remote support post-commissioning to address any issues and ensure smooth operation.
  • Delivered a succinct and comprehensive SCADA Operator manual.
  • Provided all necessary documentation for the new systems, ensuring the client’s team could effectively operate and maintain the upgraded systems.