PLC Automation Upgrade — Chemical Plant ETP
Upgrading PLC automation program logic and pneumatic valve controls for a chemical manufacturer's Effluent Treatment Plant (ETP) to improve stability and reliability.
Project Overview
A chemical manufacturing company engaged SMRS Infra to redesign and upgrade the PLC automation system for their existing Effluent Treatment Plant (ETP), which had been experiencing frequent manual interventions, inconsistent chemical dosing, and valve sequencing faults. SMRS Infra reviewed the existing PLC logic (Siemens S7 series), identified control gaps, and developed a revised logic structure covering automatic start/stop sequences, pH dosing control loops, flow-proportional chemical dosing, and pneumatic valve sequencing for the filter press operation. The upgraded logic was documented with full function block descriptions and I/O mapping, ready for upload to the client's Siemens S7 PLC. SCADA integration points were also specified to enable remote monitoring.
Deliverables
- Revised PLC logic documentation (function blocks, sequence descriptions)
- Updated I/O list and instrument tag register
- Pneumatic control valve schematic
- SCADA integration point list
- Control system description document
The upgraded PLC logic eliminated the recurring valve sequencing faults and reduced manual operator interventions by approximately 60%, improving ETP uptime and effluent quality consistency.
Project Details
- Category
- Automation & ETP
- Location
- Remote Support / Automation Design
- Technologies
- Siemens S7 PLCSCADA IntegrationPneumatic Control Valves
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