Success Story: Water

I. CUSTOMER ENVIRONMENT / PROJECT CONTEXT

Customer profile:

Customer objective and constraints:

The reconstruction of the Benešov's municipal wastewater treatment plant was carried out by the joint stock company K&H Kinetic from Klatovy, with focus on sludge and gas system and on the automation of technological process of the whole plant.  The objective of the reconstruction was efficient sludge treatment by anaerobic stabilization system, improvement of output parameters of digested sludge, and reduction of odour load in the WTP neighbourhood. At the same time, it should bring savings of operating cost of energy and, thanks to process automation, also reduction of the scope and laboriousness of the WTP attendance.
Schneider Electric's Transparent Ready solution was selected for the control of the whole plant.

In addition to the process control itself, the installed control system enables also remote supervision and servicing.

II. SOLUTION IMPLEMENTATION

Implementation methodology (main phases):

The reconstruction of the biological line included modification of the inlet pumping station and the system of detritus tank cleaning, installation of the new gravel trap. The operation of this equipment is fully automated including air supply to activated sludge process and run of the bridges on the secondary settling tanks.

In sludge system, a separate mechanical thickening of excess sludge and independent pumping of primary sludge into the digestion tank were implemented. The digestion and storage tanks have been fully adapted to new conditions. Both the tanks have been fitted with new equipment.

In gas system, a new diaphragm gas tank was installed on the digestion tank. At the same time new biogas piping routes were installed between the gas tank and gas consumers. Boiler house equipment and cogeneration unit were installed for power utilization of biogas in the wastewater treatment plant.
The reconstruction also included turnkey supply of the control system for full automation of the whole WTP.

Duration:

Solution overview (services, products, systems, architectures...):

Process control description
Transparent Ready solution based on Modicon automation products was used for process control of the WTP in Benešov.

Overall conception is divided into five basic functional units controlled by Modicon Premium system. All control systems are equipped by local operator panels for Unitelway communication, a Modbus communication line for connection of a portable terminal for maintenance purposes. Individual control systems of the functional units are interconnected between each other and connected to the operator dispatching via Ethernet TCP/IP  100Mbps.

The main idea of the Transparent Factory solution is an integrated web server which is part of the system of every functional unit. The web server contains graphic interpretation of the controlled process and other available data.
Such solution substantially improves the comfort and capacity of transfer of possible data, thanks to the following advantages:

-  accessibility of process and statistical values, variables in the control system memory, physical inputs and outputs and equipment diagnostics,

-  monitoring the values in the environment of any internet viewer without necessity of any other program,

-  possible access from any place, via fixed network, telephone network, GSM network etc.

-  possibility of remote programming and parameterization via development environment.

III. RESULTS / ACHIEVEMENT

Customer benefits:

1. Optimalized tasks for treatment plant staff

2. Data transfer to VHS dispatching - reporting deviations from normal state; this is useful, when WTP unattended on weekends.

3. Securing the WTP premises by direct connection to the Central Security System of the city.

4. Remote supervision by K&H Kinetic of both the plant and control system enabling:

-   fast reaction to requested change in the control system program,

-   possible intervention in the plant and control system diagnostics bring a benefit to VHS Benešov in form of saving of maintenance costs¨
Technical and economical benefits:
-  uniform access to control and data without necessity of special programs,

-  simplification of service, easy preventive maintenance and diagnostics,

-  higher reliability and smooth production,

-  reduction of repair costs with the same manufacturing costs.

IV. ADDITIONAL INFORMATION

Other information