Transcript Ute Water Conservancy District

The Challenges in Upgrading Plant
Automation for an Existing
Wastewater Treatment Plant
By Gary Parker, PE
Burns & McDonnell
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
Agenda
Background
Data Gathering
Control system documentation
Interviewing operator and maintenance
personnel
Design Phase
Construction Phase
Control system startup
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
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
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
Data Gathering
Site survey
Collect control system documentation
Review O&M manuals
Review plans
Interview operations and maintenance
staff for changes to plant controls
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
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
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
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
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
Rear view of main graphic
panel CP-01
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
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
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
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
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
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
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
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
Grit Unit Automation
Alarm annunciator
Pilots lights
Pushbuttons
Methane gas detection
Screening equipment monitoring
Grit equipment monitoring
Primary clarifiers monitoring
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
Blower System Automation
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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
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
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
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
Digester Automation
Tight area to replace control panel
Alarm annunciator
Methane gas detection
Pilot lights
Single loop controller
Process indicators
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
Energy Unit Automation
Temperature single loop controllers
Manual pump control through switches
Boiler monitoring
Digester gas for boilers
Remote alarms to CP-01
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
In Plant Pump Station Automation
Pump control
Wetwell level monitoring through bubbler
Grinder monitoring
Sump pump monitoring
Remote alarms to CP-01
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
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
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
New Dewatering Building
New centrifuge equipment
Integrate packaged controls into plant
control system
Owner prepurchased centrifuge equipment
Soilds pump control over control system
network in Digester building
Solids loadout conveyor system
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference
Thank You
Questions?
Gary Parker, PE
Burns & McDonnell
[email protected]
303-474-2241
March 31st and April 1st, 2009
Mile High Industrial and Automation Conference