A wastewater plant has seen reduced energy costs and optimisation thanks to a much needed SCADA upgrade...
Industry

Utilities: Water

Outcome

Upgraded major waste water treatment plant's aging SCADA system including HMI, PLC, project managment, engineering design, strategy and key risk assessments. 

Capability
Networks, SCADA integration, HMI, PLC, Telemetry, Project Management
Region

Bolivar, South Australia

Shan Bala, SA Water program manager 

“The upgraded SCADA system has made plant optimisation possible. Improving plant processes goes a long way in terms of energy saving and long term business improvements.”

Challenge

Bolivar Wastewater Treatment Plant (WWTP) treats approximately 70 percent of metropolitan Adelaide’s wastewater (approximately 150ML/d - 440ML/d during peak wet weather flows).

The original parts of the plant, such as the pumping and power stations and inlet works, were built approximately 45 years ago and much of the PLC/HMI/RTU equipment is either no longer supported by the manufacturer, or soon won't be.

As such, a comprehensive and staged upgrade of the SCADA, PLC and communication networks is ultimately required for the entire WWTP.

Solution

The WWTP upgrade required a staged approach which first began in November 2014.

SAGE Automation was contracted by SA Water to upgrade the site facilities based around a redundant ControlLogix platform for the Master PLC system, Hirschman RS40 switches for the networks and CompactLogix platform for the field PLCs.

Outcome

Key deliverables include:

  • Turnkey Solution within tight project time lines
  • Stakeholder and subcontractor management
  • Estimation and cost planning
  • Safety assessment and management
  • Risk mitigation planning and management
  • Environmental assessment
  • SCADA and PLC system design
  • CAD drafting
  • Low / medium voltage electrical design
  • SCADA integration
  • Control Panel manufacture / wiring
  • HMI
  • System Integration
  • PLC networking
  • Low / medium voltage electrical installation
  • FAT and SAT testing
  • Provision of final, as built, documentation, MAXIMO - Asset Management and maintenance

Technology used

  • SCADA - Citect merging to iFix
  • PLCs - Allen Bradley CompackLogix, Allen Bradley ControlLogix
  • Network Protocols - Ethernet
  • Prophecy Historian



Project Highlights

  • Collaborative project between SA Water and SAGE
  • No incidents of EPA reporting
  • Project delivered on time and on budget

“SAGE were a valued partner from the inception of the project - they did risk assessments of various sections of the plant and were involved in assisting with the delivery strategy which was fundamental to getting the necessary approvals for the project.” –Shan Bala, program manager, SA Water.

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