Process visualization and state-based maintenance at Warendorf wastewater treatment plant

• The Warendorf wastewater treatment plant consists of one central main wastewater treatment plant and several distributed external constructions.
• In order to achieve a high level of flexibility and effectiveness, standardized data exchange takes place between field devices and the control system via FDT technology.
• A modern visualization solution from Phoenix Contact enables fast alarm management as well as comprehensive documentation.
• Thanks to the intuitive user interface, the visualization can be changed with minimal effort and optimally tailored to the processes and the system.

The modernized Warendorf wastewater treatment plant consists of numerous systems and constructions. The main wastewater treatment plant is designed for approximately 80,000 people, while another smaller treatment plant is intended for 7000 residents.

Eleven pump stations and approximately 25 special constructions are interlinked. The channel and pipe network consists of a total length of over 250 kilometers.

Increasingly complex processes call for more intelligent and reliable field devices. The system operator must be able to call any operating data and diagnostic messages at a central location as well as to parameterize and diagnose the intelligent field devices during runtime. This is the only way to achieve such a high degree of flexibility and effectiveness in all areas of the system.

A core element here is FDT technology, which enables standardized data exchange between the field devices and the control system. A solution is required for visualization purposes, which offers the user simple handling and a high level of convenience during operation. In order to swiftly respond to unscheduled events, the operator must be able to navigate between the various areas in complex systems. Furthermore, the visualization solution should feature various communication interfaces in order to connect the range of system parts, which has increased over the years, with numerous transmission protocols.

The FDT frame application consists of various device and communication drivers and provides the operator with an overview of all installed field devices. The device DTM can be used to call operating data, alarms, and key measured values from the intelligent field devices at any time from various locations. In doing so, the lower level bus system no longer plays a role, due to the standardized communication interface.

In the event of a fault, the error can be quickly localized via the FDT framework application. This means that the operator is able to respond to the fault in a targeted manner. Equally important is the simple and fast integration of new hardware into the existing application. All the user has to do is integrate a device DTM into the framework application. In the next step, the user can parameterize the field device either remotely or directly on site and adjust it to suit future tasks.

Fast localization and removal of faults

The local visualization system consists of one stationary computer and two connected monitors. The data are transmitted from a controller to the local Visu+ visualization solution from Phoenix Contact via the OPC protocol. Visu+ can be used by the operator to monitor the entire treatment process and, if required, quickly intervene. Measured values, switching cycles, and operating hours of the individual devices are displayed to the user in the form of an overview or trend graph.

The various processing variables make it difficult to perform an accurate comparison. This is why Visu+ creates numerous trend graphs which offer various adjustments and filters. As a result, they enable a detailed examination of the relevant information.

The local visualization system also manages alarm management. Should an error occur in a running process, Visu+ immediately forwards the error message to the relevant persons. This means that the operator is immediately informed of the system state and is able to take prompt action.

The demands placed on cost effectiveness are continually increasing. With this in mind, it is becoming increasingly important to bundle information and to forward it to the relevant persons in a targeted manner. The Visu+ visualization software implements these general conditions.

“The intuitive user interface empowers my colleagues to easily change the visualization to harmonize it with the processes and the plant as needed”, explains Tim Jungmann, Technical Manager at the Warendorf wastewater treatment plant. What is more, faults can be detected at an early stage and preventively eradicated.

“By using FDT technology, my team is able to conveniently operate the entire plant with all distributed substations from the control room in Warendorf and record all the data relevant for maintenance”, adds Jungmann. “The concept optimally supports our approach to control the plants as energy-efficiently and cost-effectively as possible”.