PLC Upgrade Project for a Municipal Wastewater Treatment facility

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Summary

ITG completed a Central East Florida wastewater treatment facility critical infrastructure upgrade. As the city transitions from Wonderware to VT SCADA, ITG spearheaded the conversion of 6 processors from Siemens to AB Controllogix. This project encompasses the full spectrum of engineering services—from design to startup and commissioning—providing a seamless and turnkey operational system upgrade.

Project included design-build solution for a Siemens to Allen-Bradley PLC conversion. Discovery and documentation of existing instrumentation and control systems (control, network and instrumentation). New application included technologies such as: Allen-Bradley Control Logix series PLC, Rockwell Automation PlantPAX library, VTSCADA, Cisco switches, Corning fiber optics, Siemens HydroRanger 200 level transmitters, Endress+Hauser Promag W500flowmeters, Rosemount 3051 series pressure transmitter, EtherNet/IP messaging, among others.

Solution and Deliverables

Detailed Onsite Discovery

Our experts conducted a thorough onsite inspection to understand the existing system's architecture and challenges. This step ensures a flawless migration to the new system.

PLC Migration & Update

ITG converted the existing Siemens PLC program to be compatible with the new AB 1756 Controllogix PLCs.

Factory Acceptance Test (FAT)

Before shipping the hardware, a Factory Acceptance Test was completed to make sure the system meets all specifications and requirements.

Installation & Commissioning

Our field engineers installed and commissioned the AB 1756 Controllogix PLCs at the central east wastewater facility.

Site Acceptance Test (SAT)

Post-installation, a Site Acceptance Test was performed to ensure the system is operating as intended in its actual working environment.

Updated Drawings

All electrical and control drawings were updated to reflect all the changes and modifications made during the upgrade.

Services

PLC Coding & Backup

• Our software engineers handled all required PLC coding.
• We backuped the final PLC program for future reference and maintenance.

I/O Checkout

• ITG was responsible for the checkout of each Input/Output point.
• This includes scaling of analogs to ensure accurate data representation.

Siemens Panel Cleanup

• Our team identified and marked any obsolete or unused wiring in the existing Siemens panels.

Turnkey Solutions for Filter Upgrade

We provided a full turnkey solution for the filter upgrade to Controllogix, which includes:

• Merging the two existing Siemens PLC Programs for each panel

• Integrating the new PLCs into the current Profibus network
• Validating the Profibus connection
• Setting up and configuring a redundant PLC for each filter (panel)

Training and Turnover

• ITG conducted training to ensure smooth handover and operational knowledge for the city's personnel.

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