Existing AC70 CPUs for each pump have been replaced with the next-generation AC800M PM856 series DCS controllers. The parts previously seen as remote I/O in the existing architecture continue to be used as remote I/O. TB825 fiber optic cards were provided to facilitate communication between the DCS controllers and remote I/O panels and were installed accordingly. Additionally, multimode fiber optic cables were pulled between two points, with terminations and tests completed.
To cancel the existing AF100 communication infrastructure and establish a new redundant Ethernet communication infrastructure, a network cabinet was installed next to the MAIN DCS panel. This cabinet provides the necessary Ethernet cabling infrastructure between the motor pump DCS controllers, operator workstations, MAIN DCS controller, and Modbus communication devices, and is ready for commissioning.
The existing Advant 450 DCS system has been replaced with the next-generation AC800M PM862 DCS controllers. The newly installed DCS controllers have been configured redundantly.
Tests were conducted on the fiber optic cable pulled between the output water tank Wago PLC and the Wago PLC in the mimic panel to ensure the communication infrastructure is operational. It was determined that the communication ports of the Wago PLCs were faulty. As a solution, the Siemens PLC on the air compressor panel to be dismantled was tested and, if deemed suitable, used for this purpose.
The existing UNIX-based operator stations have been completely removed and replaced with the latest Windows OS-based 800xA v6 SCADA system.
Since there are two operator stations in the system, their connection to the servers is provided via remote access terminals. Two screens were installed at the first operator station, and three screens at the second operator station.
The third screen at the second operator station is a minimum of 55 inches, enabling effective monitoring of parameters determined by the business. Additionally, the SCADA system will operate with a client-server architecture, with redundant servers installed.
The communication architecture between the client, server, and controllers is Ethernet-based and designed and implemented redundantly.
A UPS with the same specifications as the existing UPS system was procured and transported to the site. A suitable area was created next to the existing UPS, and it was made ready for operation in case of a power outage.
A communication infrastructure was established between the Siemens RTU and the newly installed DCS system. Despite the request for wired acquisition of flowmeter signals, this infrastructure was prepared using 6-core copper cables. Panel-to-panel and panel-to-external communications were provided through Ethernet, fiber optic, and Profibus cables.
