As the pump stations cannot be controlled every day,
a warning and data transfer system was required. We have retrofitted every pump station with a Siemens S7 1214C control system and a remote maintenance modem for data transfer and connected it to the implemented control system.

All measured values and data, like levels, operating hours of the plants or fault messages are transferred to the central PC of the sewage treatment plant, registered and shown, clearly arranged and intuitively operable, via our visualisation. In addition to that, a power monitoring of the pumps provides information about power consumption and the mechanical state of the pump wheels.

In several steps the controls of the main and adjoining buildings were replaced and the communication to the process control system was completely changed to
ethernet.
To create the base to build up the ethernet network, we used fiber optic cables that are especially suitable for long transmission paths.

Before the final transition to ethernet could be completed, we firstly split up the existing Profibus system into segments. To connect such a segment then to the new network we first renewed the respective control and subsequently all associated peripheries.

We have connected 136 CPUs in a way that an efficient parametrisation and control of every single machine is possible so that the process with 128 sludge turners, 224 screw conveyors and 1152 ventilators work smoothly. The control technology consists of 192 control cabinets and 64 sub-distribution boxes. In addition, the network has a WLAN access, so that the machine can be controlled on site with a tablet.

A virtual simulation of the automatic drying tasks as well as the failure management enabled us to recognize
possible failures in advance and resolve them. This enabled a smooth start-up in Egypt.

Stadtentwässerung Mannheim (urban drainage)
modernized and expanded its sewage sludgy drying plant with three new belt dryer plants. We programmed and produced the switch and control system, inlcluding the conveyor system and exhaust air treatment.

The main control, a Siemens PLC S7-400, is also redundantly designed as the process control system Siemens SIMATIC PCS7, with which the plants are
operated per HMI.

A generously dimensioned power supply buffers as much electrical energy that all required PCs can continue their operation without any interruption in case of voltage breakdown.

The redundant system is a highly available equipment and provides in connection with the bus system a very high safety level.

The supply area of the Jachenhausen special-purpose water association comprises eight municipalities in the three administrative districts. Water is obtained from six wells and a spring. It is treated in two water plants and stored in three elevated tanks.

We have rebuilt the complete control technology – from planning of the system, to manufacturing the control cabinets, through to programming of the control. Two independent process control systems, which are established at different locations, provide an overview of the entire system and enable complete control, as well as an overview of all technical information. In addition, data is still being exchanged with a neighbouring special-purpose association which creates an emergency stand-by.

We carried out all renovation and rehabilitation work during operation to always guarantee water supply.

The plant treats around 60 percent of the wastewater of 20 million inhabitants of the state capital.

The wastewater treatment plant is consistently designed for safety and consists of two redundantly configured clarifying strands that run in parallel during normal operation. The same redundancy is found in the PLC hardware for the mechanical pre-treatment, so the system can continue to operate even if technical problems arise.

We planned and configured the 16 control cabinet fields that are needed for this using EPLAN Electric P8. The plant is divided into three area substations, each of which we have clearly displayed on a touch panel.

An integrated motor management connects the higher-level automation system and the motor feeder. In this way, the operator always has an overview of the current operating status of the drives. The corrosion-resistant construction protects the control hardware against aggressive substances.