Design, installation and commissioning of PLC- Based control Systems for Water Treatment Plant of New Capital Power Plant.
Veolia Water Technologies was tasked with the automation of a critical Water Treatment Plant for the New Capital Power Plant in Egypt. Partnering with MISC, they required a highly reliable and fault-tolerant control system to ensure uninterrupted water purification processes, which are vital for the power plant’s operation.
• High-Availability Control System: Design and supply of a complete automation system based on a redundant Siemens S7-400H PLC controller with hot-swappable CPUs, power supplies, and communication modules.
• Distributed I/O Architecture: Implementation of ET200M distributed I/O stations with redundant Profibus networks, marshalled with fuses and interposing relays for over 1,000 I/O points (including 20% spares).
• Centralized Operations & Engineering: Supply of an Operator Workstation with dual 24-inch monitors running SIMATIC WINCC SCADA and a separate Engineering Station for system configuration and maintenance.
• Full System Integration: Provision of ancillary systems including redundant industrial network switches, a GPS-based plant time synchronization clock, alarm/report printers, and comprehensive on-site commissioning support.
• Maximum Process Uptime: The fault-tolerant S7-400H architecture ensured continuous operation of the water treatment plant, critical for supporting the power generation cycle without interruption.
• Enhanced Operational Insight: The WINCC SCADA system provided advanced visualization, process archiving, and reporting, giving operators full control and historical data analysis capabilities.
• Robust and Protected Design: The use of marshalling panels with fused terminals and interposing relays protected the controller from field-side faults, enhancing overall system longevity and safety.
• Seamless System-Wide Integration: The included networking and time synchronization components ensured reliable data exchange and unified timing across the control system and with other plant subsystems.
MISC delivered a turnkey, high-availability control system that provided Veolia with a robust and reliable automation platform for the New Capital Power Plant’s water treatment facility. This solution guaranteed the consistent and efficient production of treated water, directly supporting the power plant’s operational reliability and efficiency.
Redundant Siemens S7-400H PLC + ET200M Distributed I/O + WINCC SCADA
