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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 - PowerPoint PPT Presentation
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March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
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
BackgroundData GatheringControl system documentationInterviewing operator and maintenance
personnelDesign PhaseConstruction PhaseControl system startup
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Background
Existing WWTP built mid 1980’sPresent capacity 5 MGD, 15MGD futurePlant control system
Local control panels in each process area Loop controllers, lights, pushbuttons
Remote monitoring of major plant alarmsTelephone dialers to call operatorsExisting SCADA for remote sites
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Data Gathering
Site surveyCollect control system documentationReview O&M manualsReview plansInterview 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 panelNotes from maintenance staffMaintenance electrician with plant history
left for another companyMemory test of operatorsNo P&IDs existedModifications not documented
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Existing Plant Controls
Main Graphic Panel CP-01Local control panels for
Grit CP-03 Blower/RAS CP-07 Digester CP-11 Energy CP-12 In Plant pump station CP-14
Rear view of main graphic panel CP-01
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
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 meetingsOperator assigned to contractor dailyTransfer one system at a timeTest each system before moving to the
next systemFunctional test each area upon completionPoint 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 annunciatorPilots lightsPushbuttonsMethane gas detectionScreening equipment monitoringGrit equipment monitoringPrimary clarifiers monitoring
Blower System AutomationBlower 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
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
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Blower Automation
Blower control options Fixed pressure mode Time adjusted fixed mode DO control mode
Blower auto start sequenceBlower failure protectionBlower surge protection
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Digester Automation
Tight area to replace control panelAlarm annunciatorMethane gas detectionPilot lightsSingle loop controllerProcess indicators
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Energy Unit Automation
Temperature single loop controllersManual pump control through switchesBoiler monitoringDigester gas for boilersRemote alarms to CP-01
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
In Plant Pump Station Automation
Pump controlWetwell level monitoring through bubblerGrinder monitoringSump pump monitoringRemote 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 basinInterface packaged controls into plant
control networkDemolish gaseous chlorine systemNew sodium hypochlorite system
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
New Dewatering Building
New centrifuge equipmentIntegrate packaged controls into plant
control systemOwner prepurchased centrifuge equipmentSoilds pump control over control system
network in Digester buildingSolids loadout conveyor system
March 31st and April 1st, 2009 Mile High Industrial and Automation Conference
Thank You
Questions?
Gary Parker, PE
Burns & McDonnell
303-474-2241
