Two belt dryers with a yearly capacity of 80.000 tons were installed at a plant of an energy provider to increase the capacity. Besides the two new belt dryers, the control technology comprised the corresponding air circulation system, the conveyance of the wet and dry sludge as well as the exhaust air treatment. The energy supply of the plant is monitored fully automatically.

If one power supply fails, the network is completely switched to the redundantly planned second supply. The central control system was connected to the existing control system via a bus system.
Therefore, the plant can be completely controlled from the remote control room of the energy provider.

With our certification at UL Germany, we can produce plants for the North American market according to standard UL508A. For the final application in the USA, this was a basic requirement of the project.

For the control of the pumps and the fuelling process we were responsible for the electrotechnical conception of the prototype, the production and further development to serial production.

With the continuous application of EPLAN Electric P8 and Pro Panel, the complete control panel technology, from the 3D design to the digital wiring via routing was perfectly designed in accordance with the customer’s requirements

Three control cabinets were equipped with a Siemens PLC S7-1500-PN, which is, for detailed data analysis and control, linked with the process control system of the sewage treatment plant Göppingen. Visualisation on the Siemens Touchscreen HMI TP1200 allows intuitive working directly at the plant.

The continuous operation mode of the control system of the pumps which are responsible for the outlet, the circulation or the heating water is ensured reliably, according to needs, by several frequency converters, which are linked via bus system to the PLC.

With the new development of the process control the focus was put on safety as the gaseous hydrogen is highly explosive. Therefore, the safety performance category Safety Integrity Level (SIL) 2 was realized. This aims at finding and minimising possible risks for customers, plants and operators in advance. The mobile application of the electrolysers at different wind power plants requires an intuitively designed operation so that the operators can quickly learn the operation at various locations.

The three control panels were equipped with an IPC Beckhoff C6920 Twin Cat 3 which visualizes the plant and serves as interface for higher-level control systems. The Flow Chief control system takes over control, monitoring and evaluation.