Carollo Engineers and another firm designed a new 7.7-mgd water recycling facility for the City of Watsonville, California. The $50 million treatment plant includes coagulation, flocculation, and sedimentation as pretreatment, followed by filtration and UV disinfection. The project included a new SCADA process control system for the plant, programmed by Carollo Systems.

The new SCADA system consists of redundant SCADA servers running Wonderware InTouch 9.5 for Terminal Services, plus a dedicated History Server. The system also includes control room operator stations and four remote operator terminals, all running thin client sessions of Wonderware InTouch.

The plant PLCs are all Allen-Bradley, mostly ControlLogix models. The PLC system is connected over an Ethernet network, which uses fiber optic media for all runs between buildings.

Carollo Systems provided complete SCADA HMI and PLC programming and system integration services. The scope of work included meetings with the client prior to programming, coordination with the construction contractor and several vendors and subcontractors, programming, testing, startup, and training.

Carollo Systems worked as an integral part of the construction team. During startup, Carollo programmers worked in the field with the contractor and construction management personnel to integrate all of the various plant PLCs, including those provided by vendors as part of mechanical equipment packages.