Plant Utilities SCADA System Upgrade

Project

Provide services and hardware for a phased upgrade from an obsolete DCS control system based on Siemens APACS and Wonderware InTouch to Allen-Bradley ControlLogix PLCs with Wonderware System Platform.

Architecture
  • Two VMWare Hypervisor Virtual Machine Servers
    • Two Object Servers
    • Two Domain Controllers
    • One Galaxy Server
    • One Historian
    • One Engineering Workstation
  • Five ACP Thin Client Terminals (ACP Thinmanager)
  • Four Allen-Bradley ControlLogix PLCs
  • Moxa modular managed switches
Implementation

The upgrade for this SCADA system is being performed in three phases. In the first phase a managed network made up of a fault tolerant chain of switches will be configured, installed, and commissioned.

In the second phase a SCADA system is being configured and installed to replace the existing InTouch HMI stations as well as two of the APACS control systems, Wastewater Treatment and Tank Farm. The system servers will be virtualized and two virtual terminal servers will serve client sessions out to the five areas utilizing thin client technology and ACP’s ThinManager software.

The new Wonderware System Platform will feature an updated look and feel with ArchestrA graphics and include a Wonderware Historian for trend display and reporting and a centralized security structure with two domain controllers. The System Platform will also provide for the visualization of the two remaining APACS control systems. The existing graphics are being upgraded to ArchestrA graphics, extending the updated look and feel to the legacy systems.

In the last phase of the project the remaining APACS control systems will be migrated to the ControlLogix platform and the affected ArchestrA graphics will be reworked to include the new objects.

Status

ACE has completed the design and staging for the networking phase with installation scheduled for the end of May. The second phase of the upgrade is underway with commissioning scheduled for later in the summer. The design of the new Wastewater Treatment Plant and Tank Farm PLC control systems is complete and fabrication and programming have begun. The design of static graphics for the system is complete and object templates are in development. The final phase, including the upgrade of the Hydrogen and Ammonia control systems, is scheduled for commissioning in the fall.