In 2013, Danville, Kentucky elected to increase the capacity of its water treatment plant from 8 MGD to 12 MGD and add a Granular Activated Carbon (GAC) supplementary filtration system. During the complex expansion, the plant needed to remain 100% operational. This $30 million, multiple-year project was not an ordinary undertaking.
Prior to construction, each phase – filter building, settling tanks, raw water, GAC and chemical –had to be completed and tested to verify that system would be functional and able to achieve its target objective.
Prior to construction, the complete SCADA system had to be completed – panels made and tested to verify that the it would be functional and able to achieve its target objective.
As the systems integrator for this five-phase project – filter building, settling tanks, raw water, GAC and chemical – Rawdon Myers’ first step – a most critical one – was to create a strategy that addressed the intricate, multifaceted components. Each individual facet was like a puzzle piece and all of them needed to fit together perfectly. Layout of the entire system was done off site and the owner, engineers and plant operators all witnessed the Factory Acceptance Test (FAT). The added challenge of keeping the plant running at full capacity required meticulous planning to align with the construction schedule.
In addition to the fundamental determinations for a systems integration – scope, number of computers needed, panel layout, panel PCs and more – the project involved a considerable number of components: coordination of other manufacturers’ equipment to be integrated into the system, programming unique to each element and precise scheduling to avoid interference with plant operation.
At completion of the project in July 2017, The Danville Water Treatment Plant has a control system with the functionality to run the plant in fully automatic mode, from beginning to end. Capacity has increased by 50% and filtration is augmented by a GAC system. Wireless access enables the use of tablets throughout the plant. The HMI can be viewed from multiple sources – two servers, five workstations, three panel PCs and two tablets.
“We’ve worked with Rawdon Myers since the 1990s because of their technical ability to solve problems and their responsive service. They know our system inside out and are always willing to be on-site any time of day or day of the week. They are easy to talk to and better than other companies at working through problems. Rawdon Myers is definitely an asset for anybody that runs the type of SCADA system that we run. I absolutely would recommend them.”
— Andy Tompkins, Water Plant Superintendent, Danville, Kentucky Water Department