Waste Water Automation

This waste-water system consists of three geographically separate operations. Peak flow is around 500 gpm, but average flow was only half of that due to mismatched flows. The system was manually operated, requiring a full-time operator. Regulatory reports were manually compiled from daily records, and assembled with the help of a consultant.

By modifying the process flow, I was able to eliminate one tank, improve the screening of solids from the waste stream, and remove bottle-necks from the system. One 75 hp pump was replaced by a 10 hp pump, at considerable energy and maintenance savings.

A PLC with remote I/O was added to tie the three centers together. This allowed system parameters at one point to control valves and pump speeds at others. It also improved backup and alternative operations.

Improving control and removing flow bottle-necks allowed the entire system to operate at its peak flow, raising average throughput to around 500 gpm.

The PLC also allowed us to gather regulatory data. By adding a MMI (man-machine-interface) software, a database, and appropriate SQL commands, I was able to gather and analyze the twelve regulated values on a continuous, real-time basis. I created queries and reports that duplicated the submission documents, eliminating the need for consulting, while improving the regulatory report generation from 21 days to 21 seconds (no that isn't a typo).

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	This waste-water system consists of three geographically separate operations. Peak flow is around 500 gpm, but average flow was only half of that due to mismatched flows. The system was manually operated, requiring a full-time operator. Regulatory reports were manually compiled from daily records, and assembled with the help of a consultant. By modifying the process flow, I was able to eliminate one tank, improve the screening of solids from the waste stream, and remove bottle-necks from the system. One 75 hp pump was replaced by a 10 hp pump, at considerable energy and maintenance savings. A PLC with remote I/O was added to tie the three centers together. This allowed system parameters at one point to control valves and pump speeds at others. It also improved backup and alternative operations. Improving control and removing flow bottle-necks allowed the entire system to operate at its peak flow, raising average throughput to around 500 gpm. The PLC also allowed us to gather regulatory data. By adding a MMI (man-machine-interface) software, a database, and appropriate SQL commands, I was able to gather and analyze the twelve regulated values on a continuous, real-time basis. I created queries and reports that duplicated the submission documents, eliminating the need for consulting, while improving the regulatory report generation from 21 days to 21 seconds (no that isn't a typo). Home t Feedback