Fairwinds Automation designed and programmed the control system for a major nutrient removal process upgrade at this 3 million gallon per day (MGD) regional wastewater treatment plant located near Broadway, VA. 

Central to this project was replacement of the legacy supervisory control and data acquisition (SCADA) system with a state-of-the-art SCADA system built on the Inductive Automation Ignition platform. This innovative system will provide many years of reliable process monitoring and control to the plant operations staff.

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We designed the process control algorithms and programmed a programmable logic controller (PLC) to perform sophisticated closed-loop control of dissolved oxygen levels throughout the treatment basin.

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The new control system is integrated with a network of legacy PLCs that will continue to provide data from existing equipment to the new control system. Integration with existing plant equipment helped keep the budget under control and minimize the plant downtime necessary to install and cut over to the new control system. 

We provided detailed specifications for the new process instrumentation at the plant, to include digital flow meters, automatic flow control valves, motor current sensors, and temperature sensors.  Additionally, we provided detailed design of the industrial communication network, tying together equipment from about a dozen manufacturers in a plant-wide data network. 

Fairwinds Automation developed a process simulator that allowed for sophisticated and through testing of the plant control strategies and control logic in the development lab. This helped to minimize on-site integration and troubleshooting time, ensuring that the project remained on schedule. 

This project was completed in 2017 and was on time and on budget. Fairwinds Automation was proud to be part of this project that will assist in providing safe and reliable wastewater treatment for the Broadway region for years to come.