Wastewater Treatment Control

The Challenge

Faced with aging equipment, a lack of documentation and more, a pair of wastewater facilities wanted modern systems to help data and results flow more freely. Vertech was tapped to help calm troubled waters by replacing equipment and software without shutting down the plant.

The Plot Thickens

With the challenge of maintaining operations, upgrades were meticulously planned and executed at night.

We accurately field documented all panels wire-by-wire, including all field wiring out to the instruments. Our team developed new drawings for each panel incorporating the upgraded controllers. We staged cutovers to new controllers one at a time. Our shop pre-wired I/O cards to reduce on-site time even further.

Vertech performed each cutover in a single night when inflow to the plant was at a minimum. The second integrator loaded converted, pre-tested PLC code and performed I/O checkout simultaneously on the same night. Communication between all parties was handled in a weekly meeting to keep the project on track, and when required, more frequent meetings kept the project running smoothly.

The Happy Ending

The successful integration resulted in a modernized control system, ensuring operational efficiency and reliability for the client. Nightly upgrades minimized disruptions, allowing continuous treatment processes.

The integration of modern Rockwell ControlLogix PLCs and precision instruments marked a pivotal transition toward enhanced control and monitoring. And the 10 upgraded panels and one new remote I/O panel we provided were accurately documented, which will be a huge benefit to maintenance and operations moving forward.

In the end, Vertech finished the project on time, and the resulting upgrade will see our wastewater treatment client through the next 20 years.