Client Goal

Technical Goals:

• Develop a SCADA system built on non-proprietary technology
• Cover the 30-mile span of the municipality
• Provide a cost-effective, dependable system with exceptional uptime
• Build in scalability to incorporate an additional 100 stations over a ten-year period
• Provide comprehensive paging capability in the event of critical alarms
• Provide an easy-to-use GUI (Graphical User Interface) that provides operations personnel with concise data
• Provide a comprehensive documentation package
• Train operations/maintenance personnel for self support
• Log critical plant data for DHEC (Department of Health and Environmental Concerns)
• Ensure uninterrupted operation during future additions

Project Overview

A growing southeastern municipality was ready to invest in a SCADA (Supervisory Control and Data Acquisition) system that would cover its existing 30-mile span, but wanted to ensure that the system would be built on non-proprietary technology and could be scaled up to incorporate anticipated growth. In addition the wastewater collection system must be dependable, cost effective, comprehensive in its functionality, and easy to use. After acceptable budgets and conceptual plans were developed, Tegron was enlisted and began work on the project according to PEM (Project Execution Methodology).

The system consisted of a master radio PLC unit, a master PC station, and an RTU (Remote Telemetry Unit) for each station. The initial system comprised five RTU units and the master.

A radio survey was provided to ensure that the required sites were within the range needed for proper communications, to establish antenna heights, and to determine possible frequency conflicts.

An Allen-Bradley 5/05 PLC was used for the master PLC communications station, with a Rockwell RSView32 station for the HMI station. Radio communications were established via licensed 450 MHz Esteem modems. Each RTU station included an Allen-Bradley MicroLogix1200 PLC, Esteem radio modem, appropriate lightning protection, and properly sized antenna masts to enable communication with the master station. Selected RTU stations were configured as repeaters to enable the longer distance communications from some of the remote units to the master station. The RSView32 master station was configured to provide a graphics overview of the entire system, individual graphics for each RTU, alarm management, logging of historical alarms and variables, and paging for critical alarms.

Upon completion of the commissioning phase, Tegron provided a comprehensive electrical documentation package, documented PLC and HMI configuration files, and a user’s manual on CD to ensure proper maintenance and service of the system. Tegron also provided comprehensive training for system operators and maintenance personnel to better familiarize them with the installed system.

Since the initial installation of the master station and five RTUs, the system has been expanded to over 40 RTUs and continues to expand geographically. In addition, existing lift stations are being retrofitted with new RTUs to enhance monitoring capability. As new stations have been added, the documentation has been updated and the software backed up to ensure the system is maintainable and serviceable.

Tegron has provided a service contract to support system additions, maintenance of the existing system, and any service calls that may be necessary.

Scope of Supply

• CAD Documentation
• Commissioning & Start-up
• Control Panel Fabrication
• Electrical Control Design
• Human Machine Interface Development
• PLC Software Development
• System Training
• Emergency Support
• Support Agreements

The Outcome

Production Benefits:

• Maintainable system with reduced downtime due to system documentation, spare parts, system training, and program familiarity
• Reduced manpower requirements due to remote monitoring capabilities
• Reduced cost due to fewer trips required to lift stations
• Enhanced data management