PROJECT: CRS Industrial Water – Barrow Island Sewage Treatment Plant
CUSTOMER: CRS Industrial Water
DESCRIPTION: CRS Industrial Water Treatment Systems is an Australian-owned engineering company specialising in the field of water and wastewater treatment.
REQUIREMENTS: KAPP Engineering was contracted by CRS to design and develop the PLC control system for the Barrow Island Sewage Treatment Plant as part of the multi-billion dollar Gorgon Project.

The overall process comprises of the following sub-processes:

  • Raw sewage pumping, Balance Tank & Inlet Screening
  • Main Bioreactor
  • Ultra-filtration Plant
  • Sludge Handling & Digestion
  • Treated Effluent Storage
  • Chemical Dosing
SOLUTION: The control system comprised of a Modicon M340 PLC, which included 128 digital I/O and 36 analogue I/O. A Magelis 15” colour touch screen provided the operator interface, while an Ethernet communications network allowed for the monitoring and control of 8 x ABB variable speed drives (VSDs).

KAPP Engineering designed and developed a flexible and user-friendly control system, including P&ID style graphic screens which allow the operator to view the status of the entire plant at a glance. Intuitive system settings and maintenance mode controls ensure that the system is highly flexible and simple to maintain and troubleshoot.

The final product was a fully-automated control system which included control and monitoring of the following equipment:

  • 14 x Motorised/Solenoid Valves
  • 21 x Pumps (including 8 x Chemical Dosing Pumps)
  • 3 x Blowers / Mixers
  • 1 x Screw Conveyor
  • 6 x Ultrasonic Level Transmitters
  • 8 x MagFlow Meters
  • 2 x pH / Temperature Probes
  • 2 x Pressure Transmitters
  • 1 x Dissolved Oxygen Probe
  • 1 x MLSS Suspended Solids Probe
  • 1 x Turbidity Probe
  • 1 x Chlorine Residual Probe