Source: AUTOMATION OF WASTEWATER TREATMENT FACILITIES

Chapter 1

Introduction

What Is Complete Automation

Design?

Motivation for Updating

This Manual

What This Manual Does and Does

Not Include
4

Technology Now a Strategy, Not a

Limitation
3

Intended Audience

Manual of Practice Chapter

Contents

References

WHAT IS COMPLETE AUTOMATION DESIGN?

This relatively simple question requires this entire manual of practice (MOP) to
answer fully. Basically, this manual specifies the information required to make the
decisions needed to build an effective automation system. It also introduces the types
of documentsboth text and drawingsthat constitute a complete design and provides guidance on what data these documents should contain.
Automation system design requires tremendous attention to detailseemingly
more so than other engineering disciplines. The design documents discussed in this
manual reflect that attention to detail. Does every project need every document discussed in this manual? No, but each project typically will require decisions on every
detail before the automation system can be installed. Someone will decide what to
install, where to install it, where to put the wires, and how to program it. Whether
that person is a design engineer, a general contractor, an electrical subcontractor, a
1
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Introduction

Automation of Wastewater Treatment Facilities

systems integrator, a programmer, a computer-aided design (CAD) specialist, an

installing electrician, or a trench digger depends on how complete the design documents are, which in turn depend on the owners design budget and the designers
technical competence.

MOTIVATION FOR UPDATING THIS MANUAL

This is the third edition of Instrumentation in Wastewater Treatment Facilities (MOP
No. 21), and the title was changed to Automation of Wastewater Treatment Facilities.
The first edition was published in 1978, and the second was published in 1993.
Although the automation field has matured considerably, it is still changing
rapidly. Since the last edition was published,
Researchers and practitioners have improved our understanding of physical,
chemical, and biological treatment processes and the best strategies to control them;
Manufacturers have begun creating field instruments specifically for the
wastewater treatment industry (rather than adapting ones made for other
industries);
Field instruments typically have become less expensive, more accurate,
easier to calibrate, and sometimes self-diagnosing because of digital electronics, better human interfaces, and other new technologies;
Networking and wireless (radio) communications have become less expensive, provide more capabilities, and are widely available (e.g., fiber-optic
cabling is now common);
Programmable logic controllers (PLCs) and distributed control systems
(DCSs) are smaller, perform better, have more capabilities, and are less
expensive;
Standardized PLC-programming tools based on the 1993 International
Electrotechnical Commission (IEC) 1131-3 standards are now used extensively;
Personal computers (PCs) operate even faster, have more capacity, are less
expensive, andalong with their related softwaredominate the automation market;

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Introduction

Introduction

Shrink-wrapped, PC-based, supervisory control and data acquisition

(SCADA) software is now readily available and relatively inexpensive (but
requires extensive configuration);
SCADA systems now typically include the monitoring, control, trend, and
data features that most users need, and many also include historical data
archiving, reporting, fuzzy control (a formal methodology for representing,
manipulating, and implementing a humans heuristic knowledge about how
to control a system), artificial neural networks, and model predictive control
(a class of controllers that use a model of the process to compute a sequence
of manipulated variable adjustments to optimize the future behavior of the
process);
The Internet now plays an important role in dispersing information and is
evolving into a platform for wide-area control systems;
Physical and cyber security have become important issues.
Twenty-eight years ago, the authors of the first edition noted that because
automation is a rapidly changing field, the manual would need frequent updates.
This is still true today.

TECHNOLOGY NOW A STRATEGY, NOT A

LIMITATION
Automation technology has largely matured. Today, instruments, control elements,
and strategies can handle most processes and problems, and wastewater treatment
facility owners, managers, and operators simply expect every part of an automation system to work and work well. Now, most of the keys to a successful project
are organizational and management issues rather than technical ones (Chapter 2).
Admittedly, some challenges, such as automation of solids treatment and
dewatering processes, remain. However, researchers, manufacturers, and practitioners have recently made tremendous progress in addressing them. For example,
a 2001 Water Environment Research Foundation project, Thickening and Dewatering
Processes: How to Evaluate and Implement an Automation Package, describes how to
evaluate and implement an automation system for thickening and dewatering
processes. Further research is being conducted in Europe.

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Introduction

Automation of Wastewater Treatment Facilities

WHAT THIS MANUAL DOES AND DOES NOT INCLUDE

When the Water Environment Federations (WEFs) Automation of Wastewater Treatment Facilities Task Force first defined the scope of this update, they estimated that
the manual would be about 500 pagesconsiderably longer than the 1978 edition
(108 pages) and 1993 edition (332 pages)to accommodate new developments in the
field.
After considerable discussion on what to keep, add, and leave out, the task force
decided to update much of the material in the previous editions, except for obsolete
technologies, such as pneumatic transmission systems. The task force also incorporated much of the content of the 1984 edition of WEFs MOP No. OM-6, Process
Instrumentation and Control Systems. However, the task force decided not to duplicate
WEFs 1997 Special Publication, Automated Process Control Strategies, which is currently the latest on specific process-control strategies for wastewater treatment systems. The task force also decided not to debate the relative merits of traditional
design-bid-build and design-build contracts or address construction management
issues. Nor did the task force address collection system controls in this edition,
because that topic deserves its own publication.

INTENDED AUDIENCE
This manual primarily focuses on the automation system designer and the design
process. However, this manual also will show wastewater treatment facility owners,
managers, and operators what types of design documents to expect when undertaking an automation project and the standards used to evaluate them.

MANUAL OF PRACTICE CHAPTER CONTENTS

Each chapter is written to stand alone, so the manual does not need to be read from
cover to cover. Readers looking for specific information should simply turn to the
appropriate chapter. For more information on a particular topic, see the references or
general bibliography included in each chapter.
In Chapter 2, a business case for automation is made, stressing that control systems can help utilities be more effective and efficient. Investments in automation can
and should reduce labor, chemical, and power needs while improving performance
and reliability. Ten Keys to Success are introduced.

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Introduction

Introduction

In Chapter 3, the elements of a complete automation design project are introduced. Each type of document is discussed briefly, and standards and references are
delineated.
In Chapter 4, the process and instrumentation diagram (P&ID)typically one of
the first design documents developed for a projectis introduced, its elements are
described, and its interactions with other design documents are discussed. Recent
developments in smart P&IDs also are introduced.
In Chapter 5, general instrumentation characteristics, including properties and
measures of accuracy, are introduced. Design considerations, such as temperature,
moisture, corrosion, and grounding, are discussed.
In Chapter 6, major types of instrumentation used at wastewater treatment
plants are discussed. This section has been revised to account for recent improvements, as well as new instruments specifically developed for solids treatment.
In Chapter 7, final control elements are discussed. Topics include valves, valve
actuators, pumps, pumping characteristics, blowers, blower characteristics,
motors, and variable frequency drives.
In Chapter 8, the characteristics of local control panels are discussed. Special
consideration is given to environmental requirements, thermal management, and
panel instrumentation.
In Chapter 9, signal transmission and data communications are discussed. This
section has been revised to include material on networking and new wireless communication technologies.
Chapter 10 is a tutorial on process-control basicsfrom feedback controllers to
advanced model-based controls.
In Chapter 11, process-control system functionality is discussed. The humanmachine interface (HMI) is addressed.
In Chapter 12, the design of control system hardware, including programmable
logic controllers (PLCs) and distributed control systems (DCSs), is discussed.
In Chapter 13, the process-control narrativea text-based method of
describing a process-control strategyis discussed. Several sample narratives for
common processes are developed.
In Chapter 14, advanced applications and tools, including energy management, decision support, modeling and simulation, artificial intelligence, and control strategies for biological nutrient removal (BNR) plants, are introduced.
Chapter 15 is an introduction to writing specifications. It describes the Construction Specifications Institute (CSI) format and provides an example of a spec-

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Introduction

Automation of Wastewater Treatment Facilities

ification, as well as a list of potential specifications for a typical automation

project.
Chapter 16 is an introduction to instrumentation maintenance. The difference
between instrumentation and rotating-equipment maintenance is discussed.
Chapter 17 is a brief introduction to troubleshooting instrumentation systems.
Finally, in Chapter 18, instrumentation documentation and training are
discussed.

REFERENCES
Water Pollution Control Federation (1984) Process Instrumentation and Control Systems, Manual of Practice No. OM-6; Water Pollution Control Federation: Washington, D.C.
Water Environment Federation (1993) Instrumentation in Wastewater Treatment
Plants, 2nd Ed.; Manual of Practice No. 21, Water Environment Federation:
Alexandria, Virginia.
Water Environment Federation (1997) Automated Process Control Strategies, Special Publication; Water Environment Federation: Alexandria, Virginia.
Water Environment Research Foundation (2001) Thickening and Dewatering
Processes: How to Evaluate and Implement an Automation Package, Project 03REM-3; Water Environment Research Foundation: Alexandria, Virginia.

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