March 31st and April 1st, 2009Mile High Industrial and Automation Conference The Challenges in Upgrading Plant Automation for an Existing Wastewater Treatment Plant By Gary Parker, PE Burns & McDonnell

March 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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

Rear view of main graphic panel CP-01

March 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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

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

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 31 st and April 1 st, 2009Mile High Industrial and Automation Conference 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 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile 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 31 st and April 1 st, 2009Mile High Industrial and Automation Conference Thank You Questions? Gary Parker, PE Burns & McDonnell