Bollman Water Treatment Plant Distributed Control System Replacement

Contra Costa Water District, 
California

Bollman Water Treatment Plant Distributed Control System Replacement

Service Type: 
Carollo was the prime contractor for a $1.7 million turnkey (hardware and software) replacement of the distributed control system at the 75-mgd Bollman Water Treatment Plant for the Contra Costa Water District in Concord, California. The project included replacement of the plant’s obsolete, proprietary Bailey Infi-90 DCS with a modern, open standards based distributed PC/PLC system. The new system utilizes four Modicon Quantum Unity hot-failover CPU pairs connected to I/O modules in eight area control cabinets. The PLC control network is configured in a redundant Ethernet/fiber ring. The remote I/O communications are also redundant. The operator interface is provided by 12 thin-client terminals connected to redundant SCADA terminal servers running Wonderware InTouch for Terminal Services version 9.5. Carollo provided hardware, software, programming, and complete systems integration services. Carollo was the prime contractor and directed the work of subcontractors for electrical installation, fiber optic cable testing, panel fabrication, and design assistance. The Bollman Plant is the main source of water for several communities, and allowable shut down times were very short, considering the magnitude of the project. Our team worked closely with District staff to develop a comprehensive cutover plan, including fallback options to ensure continuous water deliveries. Carollo completed the project on time, within budget, and with minimal disruptions to staff and operations.