Control architecture providing automatic as
well as manual control for all irrigation, fertilization and pumping functions
at a 36-square-mile Potlatch Corporation tree farm near Boardman, Oregon has
produced benefits exceeding original goals. The automated control system
designed and provided by Programmable Control Services, Inc. provides
operational data for analysis and diagnosis that competitors using largely
manual control systems do not have.
System information has allowed pump stations to run 10-20 psi lower than
originally thought necessary. Irrigation cycles have been modified to reduce
silt loading of emitters, and filtration improvements have been made based on
the data that would otherwise not have been available.
The
project began when Potlatch Corporation
needed to convert a huge farmland acquisition near Boardman on the Columbia
Riv
er from a rotating pivot-sprinkler irrigation to a drip irrigation system
in six phases. The rapid-growth hybrid poplar trees grown in each phase would
supply Potlatch's nearby Lewiston, Idaho, paper mill with 25 percent of its
annual pulpwood requirements.
The project required standardized control architecture for 109 manifolds
and 12 pump stations fielded incrementally over six years. Communications
between the manifolds, pump stations and master stations use fixed frequency
radios. All control hardware used is Allen-Bradley, with Windows graphical
user interface software.
PCS developed a common hardware configuration for the manifolds and a
general configuration for the pump stations utilizing the Allen-Bradley
SLC-5/03 and its related I/O. This yielded a simpler control architecture that
reduces spare parts, drawings and training. During phase four, the single SCADA (supervisory control and data acquisition) master functions running on
an Allen-Bradley PLC-5/40E were divided between a pump SCADA master and a
manifold SCADA master. This allowed each to control separate dedicated radio
networks with their slave units, thus increasing system expansion
capabilities.
Numerous add-on interfaces for the SCADA operator interface were developed
by PCS as needed to assist in generating both two-week irrigation schedules
for each manifold and fertilization schedules for each age-class of tree. The
controls allow farm managers to minimize peak power excess demand charges,
balance water usage, and efficiently operate the hydraulic and mechanical
systems.