The headlines in the water industry are always dominated by the need for advanced water treatment technologies and efficient processes, and it is the behind-the-scenes work that often goes unnoticed.
Beneath the surface of the water industry’s pursuit of delivering clean water and efficient wastewater treatment lies a complex tapestry of technologies, equipment, control systems and computers. While we may take for granted the seamless operation of water treatment facilities, it is the skilled control system engineers who navigate the labyrinth of interfaces, algorithms, and coding, who keep the systems in balance.
From control panels to the intricate networks of sensors and actuators, these engineers ensure that the heart of water treatment beats; fine-tuning algorithms, calibrating instruments, and analysing data to optimise performance, minimise energy consumption, and guarantee compliance with stringent environmental standards.
Seamless System Integration
For example, increasingly the industry uses packaged process plants, with the advantages of off-site manufacture and testing prior to on-site installation but, despite the almost universal claim of “plug-and-play” for these units, life is rarely that simple.
Mismatches between programmable logic controllers (PLC), incompatible smart instrumentation and different network and communication protocols all combine to undermine supervisory control and data acquisition (SCADA) systems.
Sorting out these challenges is the job of systems integrators, such as Te-Tech’s Automation, Control and Technology (ACT) team, who specialise in creating bespoke essential software that allows process control systems to interact with plant hardware, all developed in-house, for both new builds and upgrades of legacy assets.
Case Study: Rapid Installation of Emergency UV Plant
When a water utility company needed an emergency Cryptosporidium inactivation treatment process at one of their water treatment works, they turned to Trant Engineering, to design, build, install and commission a suitable system and return the works to full operation within 13 weeks.
Trant set up a multidisciplinary client and contractor project team which identified ultraviolet disinfection as the preferred solution and portable containerised UV treatment unit was procured.
Integrating the additional treatment process into the existing works operation and within the limited site space was a significant challenge. Te-Tech Process Solutions, part of the Trant Group, have a specialist team of controls engineers, and it was their expertise that helped deliver the integration:
- The existing WwTW control system used an Allen Bradley PLC, providing overall control of the abstraction, treatment and water quality monitoring systems.
- The new containerised UV system had its own local Compact Logic PLC and motor control centre (MCC), controlling duty and standby UV reactor streams.
- The maximum works flow was too high for a single UV reactor, so the control system had to be changed from duty/standby to duty/assist configuration. This alteration enabled a single UV reactor to operate within a defined flow and water quality range.
- Integrating the signals from the UV treatment control system with that of the existing works. The integration of the network architecture of the two control systems could be designed, tested and proven. The solution integrated the two PLC control system via Ethernet/IP.
- The human machine interface (HMI) was modified to allow key parameter and asset performance to be monitored easily.
- The retransmission of key operational and performance data to the remote telemetry system by programming and configuring remote Telemetry outstation and user terminals, via a Schneider GeoSCADA platform.
Benefits of Using Control System & Integration Specialists
While operational staff are focusing on day-to-day issues, a well-versed system integrator from an external company can significantly mitigate potential points of failure, scrutinise operational MCCs, and check for possible utility power issues.
Because of the diversity of equipment involved in water works systems, it is essential that the system integrator takes a truly independent approach and has experience in the design, development and supply of software for all major PLC, HMI and SCADA suppliers such as Rockwell, Siemens, Mitsubishi and Schneider, and can deploy network solutions using communications protocols, such as Ethernet/IP, Profibus, Profinet, DF1, DH+, Modbus TCP/IP, Modbus RTU.
Te-Tech’s System Integration team has carried out a range of projects not only in water and wastewater works but also in marine applications, healthcare facilities and MoD installations. From FDS development to panel manufacture and FAT testing, everything is carried out in-house within a ISO 9001 quality management system.
Matt Head
Technical Services Manager
Te-Tech Process Solutions
Email: matthew.head@te-tech.co.uk
