Big Creek WRF

How We Transformed and Modernized SCADA, PLC Controls, and Networked Smart MCC for the Big Creek WRF Phase 2B Project

The Big Creek Water Reclamation Facility (WRF) Phase 2B project in Roswell, Georgia, represents one of the largest wastewater infrastructure modernization efforts in the region. As system integrators, we were entrusted with the critical task of transforming legacy systems, enhancing process control efficiency, and ensuring long-term scalability through cutting-edge technology. Here’s how we delivered an advanced, interconnected solution that aligned with the ambitious objectives of this landmark project.

Project Overview: Enhancing Big Creek’s Capacity and Efficiency

The Big Creek WRF serves the City of Roswell and surrounding areas, processing millions of gallons of wastewater daily. The Phase 2B upgrade aimed to increase treatment capacity from 24 million gallons per day (MGD) to 38 MGD while meeting stricter environmental standards. To achieve this, a complete modernization of SCADA, PLC controls, smart MCCs, and field instrumentation was essential for efficient operations, compliance, and future-proofing the facility.

Our Approach to System Integration

The scope of the project involved integrating legacy systems with new technology to ensure a seamless transition. We focused on four key areas:

1. SCADA Modernization
2. PLC Controls Upgrade
3. Smart MCC Networking
4. Field Instrumentation Deployment

Each component required careful planning, design, implementation, and testing to deliver a unified, highly reliable, and scalable system.

1. SCADA Modernization: Driving Centralized Control

Supervisory Control and Data Acquisition (SCADA) systems form the backbone of wastewater treatment plant operations. For the Big Creek WRF, we replaced the aging SCADA infrastructure with a modern, intuitive system designed for advanced monitoring and control.

• Intuitive User Interface: Operators now benefit from a streamlined, graphical user interface that provides real-time data visualization, trends, and historical reporting.
• Centralized Command: The new SCADA system consolidates control of all plant processes, reducing manual intervention and improving operational efficiency.
• Cybersecurity Enhancements: Robust firewalls, encryption, and multi-factor authentication were implemented to secure the system against evolving threats.
• Remote Accessibility: Plant operators can monitor and manage systems remotely via secure connections, enhancing responsiveness to critical issues.

2. PLC Controls Upgrade: Enhancing Automation

Programmable Logic Controllers (PLCs) are vital for precise process control. Our team deployed advanced PLC hardware and software to automate complex workflows at Big Creek.

• Standardized Programming: Using IEC 61131-3-compliant programming standards, we ensured consistency across the plant’s diverse systems.
• Improved Reliability: Redundant controllers were installed for critical processes to minimize downtime.
• Seamless Integration: The new PLCs were integrated with the SCADA system, enabling real-time data exchange and tighter control loops.
• Scalable Design: The PLC architecture was designed to accommodate future expansion as plant demands grow.

3. Smart MCC Networking: Optimizing Motor Control

The implementation of networked smart Motor Control Centers (MCCs) was a game-changer for Big Creek’s electrical infrastructure.

• Enhanced Diagnostics: Smart MCCs provide real-time data on motor performance, energy consumption, and fault conditions, empowering operators to take proactive action.
• Reduced Maintenance Costs: Advanced predictive analytics allow for condition-based maintenance, minimizing costly downtime and unplanned repairs.
• Ethernet Connectivity: Smart MCCs were fully networked, enabling seamless communication with SCADA and PLC systems for unified control and monitoring.
• Energy Efficiency: Optimized motor management improved energy utilization, aligning with the project’s sustainability goals.

4. Field Instrumentation Deployment: Improving Process Accuracy

Precise measurement and control are critical in wastewater treatment. We deployed a suite of advanced field instrumentation to enhance Big Creek’s operational precision.

• State-of-the-Art Sensors: Flow meters, level transmitters, pressure gauges, and analyzers were installed for real-time monitoring of key parameters.
• Data Integration: Field devices were networked to PLCs and SCADA, enabling comprehensive data collection and process optimization.
• Harsh Environment Durability: Instruments were selected for their robustness, ensuring reliable operation in the demanding wastewater treatment environment.

The Outcome: A Future-Ready Wastewater Facility

The modernization of SCADA, PLCs, smart MCCs, and field instrumentation at the Big Creek WRF has transformed the facility into a model of efficiency, reliability, and scalability.

• Increased Capacity: The plant now handles 38 MGD, meeting the growing needs of Roswell’s population.
• Operational Efficiency: Automated workflows, centralized control, and predictive maintenance have significantly reduced operational costs.
• Regulatory Compliance: Enhanced monitoring and control ensure compliance with stringent environmental standards.
• Future Scalability: The modular design of the integrated systems allows for seamless expansion as demand grows.

Lessons Learned and Key Takeaways

This project highlighted the importance of collaboration, meticulous planning, and leveraging cutting-edge technology to address complex infrastructure challenges. By modernizing Big Creek’s systems, we delivered a solution that not only meets today’s needs but positions the facility for long-term success.

If your organization is considering a similar modernization effort, our expertise as a system integrator can help you navigate the complexities of integrating SCADA, PLCs, smart MCCs, and field instrumentation. Contact us today to learn more about how we can transform your operations.

About Us
We specialize in designing and implementing advanced control and automation solutions for industrial facilities. With a proven track record of successful integrations, we are committed to driving efficiency, reliability, and innovation for our clients.

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