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Migration management for the Reijerwaard water treatment facility
The Reijerwaard water treatment facility in Ridderkerk provides drinking water for roughly 50,000 inhabitants in Ridderkerk. To do so, it has to collect, purify and distribute 3.5 million m³ of water. The primary steps of the treatment process comprise collection, aeration, pre-filtration and follow-up filtration, water softening and CO filtration. Five pumps take care of distributing the purified water, and the facility also has its own backup power supply. At the request of the treatment facility, the Water division at Industrial Automation took care of migrating the existing process automation configuration to an IT System 800xA.
The process automation system for the Reijerwaard water facility migration project included nine SattCon35 PLCs, one AC800M PLC and the associated SCADA environment. Before the migration, reverse engineering was used to prepare a functional description, which served as a reference for the integration test and Factory Acceptance Test. The new hardware configuration consisted of three redundant AC800M controllers and a remote I/O. The Dox2CB conversion tool from ABB served as a basis for generating the application software. It was used to automatically convert part of the existing DOX10 application software to the 800xA format.
Benefits and opportunities
For this project, it was decided to implement the migration without any functional changes in order to minimize the risk of interpretation errors. The new configuration is built completely of modern components which will be supported by the suppliers for years to come. It will also be easier to maintain and service the new application software.