Case Study
City of Stayton
Water treatment facility expansion with PLC-5 to ControlLogix migration and fiber optic ring network.
Client
City of Stayton
Location
Stayton, OR
Industry
Water Treatment
Project Overview
The Challenge
The City of Stayton needed to expand their water treatment facility by approximately 50% while updating the aging Allen-Bradley PLC-5 control system. The original PLC-5 control system was a CH2M Hill design and included redundant processors but with a single serial communications system — a vulnerability that could cause a plant-wide communications failure from a single path interruption.
Our Approach
The Solution
Industrial Systems provided the control system design and programming. The redesigned control system replaced the serial architecture with a fiber optic Ethernet network configured in a ring topology, guarding against plant-wide communications failure due to a single path interruption.
The PLC and HMI programming were ported from the original CH2M programs and then modularized to the greatest extent possible. This included the creation of PLC ladder logic blocks for common control functions such as fixed-speed pump/blower control and variable-speed pump/blower control. Similar custom configurable blocks were created for common HMI objects such as tanks, pumps, blowers, and similar equipment.
Results
Project Outcomes
The upgraded facility runs on the ControlLogix platform with a Wonderware SCADA system that includes remote access and data logging. The modular programming approach ensures that future modifications can be made quickly and consistently using the reusable control and HMI blocks.
50% capacity increase
Expansion
Fiber optic ring topology for redundancy
Network
PLC-5 to ControlLogix migration
Platform
Project Team
Team Members
The people behind this project.
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