Water Treatment Plant Automation

Initial situation

The entire plant is divided into 2 groups placed at a distance from around 300m. The “A” group is already automated, but lacking memory in the PLC in order to make the required changes. The “B” group equipment are in manual mode operation.

Objective

Automate “B” group, renew the “A” group control and interconnect both groups, supervising both through a Scada software in one place (control room).

Requirements

Both groups must have identical control philosophies. The entire new hardware must be the same among groups. Each group must be locally controlled by a Siemens 12’’ touch-screen console. The Scada software must be Wincc, installed in a single PC with 2 monitors. The interconnection between the control panels of both groups must be Ethernet through optical fiber. The carrying out of the work will have to be phased and fully in line with the production plant.

Work performed

“A” group – PLC substitution for an equivalent model with more memory. Touch screen console substitution for a Siemens model 12’’/Ethernet. The electrical drawings were fully carried out as well as the overall control software in accordance with the new operating principle.
Integration of the new equipment and water abstractions in the overall control. Deployment of communications with the other group and Ethernet supervision, using optical fiber.

“B” group – installation of a new stainless steel cabinet to control this area, which was mechanically adjusted by the client. The PLC and console were equal to the other group, as well. In this console it will be also possible to visualize the pages referring the remaining plant. This cabinet also exchanges signals with the plan upstream and downstream through Ethernet network.

Results obtained

The plant became operating as a whole which simplified operators’ tasks. The “false” manual operations were eliminated which translated itself into water saving. Some electric power consumption was obtained by the elimination of unnecessary pumping. All volumetric measures were brought online allowing to know any defective situation. The traceability is evident at the main supervision plant (Wincc). The control achieved brought higher rationalization of the available resources, less energy consumption, minor operating time and much higher security among all operations.

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