Articles & Case Studies

SCADA for Portsmouth

Posted: Friday 7th February 2014

Trant Systems Electrical (TSE) awarded £1m SCADA upgrade project at wastewater pumping station in Portsmouth, Hampshire; collaboration of excellence with Tata Consultancy Services Ltd, a Tata group company.

TSE, a division of the Southampton-based Trant Group, is a control systems specialist in the design and custom-build of high-quality control panels, motor control centres and automation systems. It has a challenging brief - the refurbishment and upgrade of the site-wide SCADA at Eastney WPS, Portsmouth, Hampshire, on behalf of BTU, a Southern Water Tier 1 contractor.

Southern Water’s wastewater headworks and pumping station at Eastney has been in operation since 1868, the year of three Prime Ministers – the Earl of Derby, Disraeli and Gladstone. The James Watt & Co. beam engine pumps of 1887, housed in the original Victorian engine house, were replaced with diesel engine-powered pumps in 1954 and preserved as museum pieces. In 2011 TSE replaced the 6 nr diesel engine control panels as part of the on-going asset improvements on site.

Refurbishment of 6 nr diesel engine control panels at Eastney WPS

A standard asset provider to Southern Water, TSE chose to utilise the expertise of Tata Consultancy Services (TCS) to assist with the upgrade and enhanced serviceability of this highly complex project.

TCS is an IT services, consulting and business solutions organisation which delivers real results to global business, ensuring a level of certainty no other firm can match. TCS offers a consulting-led, integrated portfolio of IT, BPO, infrastructure, engineering and assurance services.

This is delivered through its unique Global Network Delivery Model™, recognised as the benchmark of excellence in software development. A part of the Tata group, India’s largest industrial conglomerate, TCS has more than 276,000 of the world’s best-trained consultants in 44 countries.

Tim Bullen, the divisional manager of TSE, said: “We are again delighted to be collaborating with TCS on this project and we are totally committed to ensuring a successful outcome for this very challenging brief. We are striving to help our client achieve the required efficiencies within the AMP5 works programme by embracing the proven and effective onsite and offshore model of delivery with the help of TCS.”

Eastney WPS – as it stands

Eastney WPS had a new control system installed in the early 1980s, of which this project automated the site and its automatic plant. The system employed at the time was the Alstom Gem80 platform which was extensively used in industrial automation.

Around 2001, three new SLC PLCs were installed on the LSO MCC, High Lift Storm MCC and Fort Cumberland to further automate the plant and additional processes associated with them.

These MCCs were added in conjunction with a larger project name PortseaClean, designed to send storm flows to Budds Farm WTW from Eastney WPS for treatment and to return treated wastewater from Budds Farm to Eastney to be released out to sea.

At the Eastney site the PLC hardware is now predominately of two variant types, these being:

1. GEM80/131 and GEM80/400s

2. Allen Bradley SLC 5/05s

Each of the Gem80s is connected to one other to form a communications network via an existing GEMLAN-T Ethernet network. The existing SCADA visualization system Imagem is connected locally to the site master PLC via RGB cable. The existing SLCs are connected via a more recent (circa 2000) fibre-optic, Ethernet-based system.

The site processes were controlled by 17 individual PLCs.

Eastney WPS –improvements

Following a detailed study of the existing systems at Eastney, the following upgrades and refurbishments were identified:

The upgrade to a modern serviceable system that is easily maintained, ensures reliability and easily allows future expansion, additions and modification in the future.

The control philosophy contained within existing GEM80 PLC code was reverse-engineered and re-implemented in Rockwell Allen-Bradley Control Logix PLCs. A new integrated Wonderware InTouch SCADA system replaced all existing SCADA/HMI components to provide a single site-wide SCADA system.

The proposal re-engineered like-for-like functionality of the existing GEM80/Imagem control system in modern PLCs and SCADA and was MEDs-compliant as far as practicable.

Commissioning comprised a rolling programme over a period of 12 months, phased by process area in order to manage risk.

Barhale Trant Utilities (BTU) itself is a Tier 1 service partner of Southern Water.

Led by highly experienced management and operational teams, backed with quality assurance accreditations and a recipient of RoSPA gold awards for four consecutive years,

BTU works closely with Southern Water in providing design, construction and asset optimisation services in reactive and planned maintenance and capital projects region-wide in both water and wastewater non-infrastructure and infrastructure.

BTU, with 250 staff, is headquartered at Havant, near Portsmouth, and was established as a joint venture between civil engineering contractors Barhale and Trant in July 2009.

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