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The Challenges in Upgrading Plant Automation for an Existing Wastewater Treatment Plant

The Challenges in Upgrading Plant Automation for an Existing Wastewater Treatment Plant. By Gary Parker, PE Burns & McDonnell. Agenda. Background Data Gathering Control system documentation Interviewing operator and maintenance personnel Design Phase Construction Phase

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The Challenges in Upgrading Plant Automation for an Existing Wastewater Treatment Plant

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  1. The Challenges in Upgrading Plant Automation for an Existing Wastewater Treatment Plant By Gary Parker, PE Burns & McDonnell Mile High Industrial and Automation Conference

  2. Agenda • Background • Data Gathering • Control system documentation • Interviewing operator and maintenance personnel • Design Phase • Construction Phase • Control system startup Mile High Industrial and Automation Conference

  3. Background • Existing WWTP built mid 1980’s • Present capacity 5 MGD, 15MGD future • Plant control system • Local control panels in each process area • Loop controllers, lights, pushbuttons • Remote monitoring of major plant alarms • Telephone dialers to call operators • Existing SCADA for remote sites Mile High Industrial and Automation Conference

  4. Data Gathering • Site survey • Collect control system documentation • Review O&M manuals • Review plans • Interview operations and maintenance staff for changes to plant controls Mile High Industrial and Automation Conference

  5. Existing Documentation • Shop drawings for each control panel • Notes from maintenance staff • Maintenance electrician with plant history left for another company • Memory test of operators • No P&IDs existed • Modifications not documented Mile High Industrial and Automation Conference

  6. Existing Plant Controls • Main Graphic Panel CP-01 • Local control panels for • Grit CP-03 • Blower/RAS CP-07 • Digester CP-11 • Energy CP-12 • In Plant pump station CP-14 Mile High Industrial and Automation Conference

  7. Rear view of main graphic panel CP-01

  8. New Plant Control System • Redundant operator workstations • New modem and software for alarm dialing • Ethernet TCP/IP control system network • New PLC panels replacing old CPs for • Operations PLC-01 • Grit PLC-03 • Blower/RAS PLC-07 • Digester PLC-11 • Energy PLC-12 Mile High Industrial and Automation Conference

  9. New Control System (cont.) • New PLC control panels for: • In Plant pump station PLC-14 • Dewatering System PLC-08 • UV System PLC-09 • Iron Salts PLC-16 • New RIO panels for: • Maintenance/Collections RIO-01 • Chlorine Unit RIO-10 Mile High Industrial and Automation Conference

  10. Construction Challenges • Constructing pathways for new control system network • Replacing old control panels • Tight space to remove and replace • Keep old system operational • Startup of new control system one point or one system at a time • Training operators during and after installation Mile High Industrial and Automation Conference

  11. Construction Coordination • Daily coordination meetings • Operator assigned to contractor daily • Transfer one system at a time • Test each system before moving to the next system • Functional test each area upon completion • Point by point test from field device to operator workstation Mile High Industrial and Automation Conference

  12. Grit Unit Automation • Alarm annunciator • Pilots lights • Pushbuttons • Methane gas detection • Screening equipment monitoring • Grit equipment monitoring • Primary clarifiers monitoring Mile High Industrial and Automation Conference

  13. Blower System Automation • Existing aeration blower system manual • New system fully automated • Blower current • New basin DO analyzers • New temperature & pressure transmitters • New flow meters • Retrofit bearing temperature and vibration sensors

  14. Original Blower Building Control Panel CP-07 Alarm Annunciator Hardwired alarms back to CP-01 Single Loop Controllers Methane Gas Detection Pilot lights Pushbuttons Years of modifications

  15. Blower Automation • Blower control options • Fixed pressure mode • Time adjusted fixed mode • DO control mode • Blower auto start sequence • Blower failure protection • Blower surge protection Mile High Industrial and Automation Conference

  16. Digester Automation • Tight area to replace control panel • Alarm annunciator • Methane gas detection • Pilot lights • Single loop controller • Process indicators Mile High Industrial and Automation Conference

  17. Energy Unit Automation • Temperature single loop controllers • Manual pump control through switches • Boiler monitoring • Digester gas for boilers • Remote alarms to CP-01 Mile High Industrial and Automation Conference

  18. In Plant Pump Station Automation • Pump control • Wetwell level monitoring through bubbler • Grinder monitoring • Sump pump monitoring • Remote alarms to CP-01 Mile High Industrial and Automation Conference

  19. New UV System • Retrofit UV system in existing effluent chlorine contact basin • Enclose outdoor basin • Interface packaged controls into plant control network • Demolish gaseous chlorine system • New sodium hypochlorite system Mile High Industrial and Automation Conference

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