PLC & SCADA Replacement

16 November 2017 - 16:02, by , in Case Studies, No comments

Adsyst successfully delivered a major PLC and SCADA Upgrade project for one of the UK’s Largest Clean Water Treatment Plants.


Our client is one of the UK’s largest water and waste water Services Company’s and as part of a major site refurbishment of a clean water treatment works, there was a requirement to upgrade the site SCADA and PLC equipment.

The Challenge:

Adsyst were initially engaged by our customer to undertake a detailed ‘reverse engineering’ on-site study/survey & generate a detailed recommendation report to refurbish and improve the existing ICA assets. Our client wanted to eliminate risk of process failure and consent due to legacy unsupportable networks, PLC & SCADA equipment.

The Solution:

The site surveys were commenced with a view to proposing the best strategy to replace unsupportable BBL RTU’s with Rockwell PLCs integrating to a new site wide fibre optic network. The scope also required surveying 30 additional remote sites, which link to this major water treatment site via a variety of leased lines, PSTN, ADSL and SDSL connections. Our survey extended to include the complete replacement of the existing RTAP SCADA solution on-site and resulted in detailed recommendations on how to replace the SCADA system whilst keeping the plant fully operational.

The Results:

In summary, Adsyst replaced the site BBL Remote Telemetry Units (RTU’s) with approximately 100 Allen Bradley PLCs and upgraded the SCADA system, including 8 dual screen workstations, to a current Wonderware System Platform system. Also, extensive mechanical and ICA modifications were required to existing assets.

To support the Ethernet capabilities of the new PLCs, we undertook detailed design for the new site-wide network. This included the installation and configuration of network monitoring software and the installation of multiple Hirschmann switches. Adsyst provided additional value to the customer in the areas of CPNI conforming security, VLAN set-up, port locking, MAC address recognition, rate limiting, broadcast storm protection, up-link failure detection and many more network specific innovation ideas to ensure a safe, secure, highly robust network was established.

Site Optimisation included new power metering across site, installed and displayed on SCADA and on-site and off-site Historians for data analysis. Service optimisation was to support replacement of 90 RTU’s across the site we created modular code which makes maintenance and training much easier and faster to fault find to reduce service disruption of any failures.

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