Water

Solutions in water industry

Water
is the gold
of the
st
21 century

It is a planetary resource that concerns all countries.

Strong global players are present but it is still a local market.
Schneider Electric has all the solutions this market needs and
will allow you to face your challenges.

Schneider Electric is present in all

countries both with its international
project capabilities and its network
of partners: distributors, system
integrators, panel builders, electrical
contractors.
Schneider Electric boosts
your productivity with services and
solutions that cut operating costs:
reduced energy bills thanks to both
power quality and power savings,
improved process management for
treatment plants and pumping station
networks,
increased service life of hydraulic
equipment.
Schneider Electric reduces the design
cost of your installations:
preferred architectures for both Power
and Control,
design tools ranging from automation
object libraries to electrical network
calculation,
repetitive solutions,
reduced cabling and size of equipment.

Schneider Electric systems are
compliant with international regulations
and standards, they are safe and can be
depended on to supply water everyday
and to help save the environment.

Schneider Electrics sustainable

development approach
Schneider Electrics commitment can be
summed up in one phrase:
Sustainable development is good
for Schneider Electric and Schneider
Electric is good for Sustainable
development.
Indeed, for Schneider Electric, in a world
where energy efficiency has become
a major problem, the principles of
sustainable development represent a
tremendous opportunity for growth and
differentiation.
By helping its customers to have greater
respect for the environment, Schneider
Electric is positioning itself in new markets
(energy efficiency, building automation and
backup power supplies), all of which will
drive growth in the coming years.
Environmental responsibility
Monitoring sites, innovative production
processes, reducing consumption
In addition to applying international
directives and regulations, Schneider
Electric initiates concrete actions
with its partners in favour of the
environment.
Monitoring and managing hazardous
substances is a priority for Schneider
Electric in Europe and worldwide. We are
committed to complying with regulations
such as the EUs Restriction of Hazardous
Substances (RoHS) and Registration,
Evaluation, and Authorisation of Chemicals
(REACH) Directives.

A worldwide company
17.3 billion revenue
in 190 countries
local presence
in 106 countries
more than 200 factories

Power & Control

offer complies
with international
standards
we devote more than
4% of sales to Research
and Development.
Our 7,300 R&D
team members
around the world
are fully focused
on always adding
more value for users.

Water
Solution Guide
Desalination

Lifting station

Drinking water
Wastewater
Boosting station

The right answer

throughout the life cycle
of your water process

You want
to optimize design and construction costs

You need
to reduce your operating costs

You are
looking for high availability water treatment

14

You are
looking for a comprehensive Power and Control
solution
18
You have
to distribute water 24/7

22

You have
to manage a network of pumping stations

24

You have
to adapt the process to regulation changes

26

Architecture overview

30

You need services in all countries

34

photo

You want to
optimize design
and construction
costs . . .
6

Financing the investments to provide water on a long term basis

at a reasonable price for the population.
How to get the maximum number of efficient infrastructures
from the money allocated?
We need to achieve our objectives at the lowest cost.
Schneider Electric has solutions to reduce both design and operating costs.
Methodological tools are necessary for both power and control.
Optimizing costs requires structured design. Schneider Electric offers proven power
and automation architectures to simplify design. To adopt such architectures,
we provide customers with design, calculation and checking tools.
From design
Design tools enable the power rating to be easily and quickly sized and the electrical
distribution equipment to be chosen. As a consequence, design and installation costs
are reduced and the different solutions are easily compared.
Schneider Electric offers a range of variable speed drives with an integrated automation
controller. Using preloaded and user configurable applications, up to five pumps can be
controlled to ensure a constant water supply.
to operating tools
Collaborative tools allow design, engineering and commissioning, from the sensor up
to the SCADA (Supervisory Control And Data Acquisition) system. These tools provide
support throughout the projects lifecycle, including operation and maintenance,
as well as during extensions and process changes. The savings made by using these
tools are based on proven methodologies and the reuse of predefined application
know-how. The unique design and user interface reduce the effort needed for operator
and maintenance training.
Communication
Motor Control Centres (MCC) also reduce design costs. They use the latest
communication technologies (intelligent Motor Control Centres, iMCC): smaller
components and reduced cabling optimize hardware and labour costs.

Design software

You need
to reduce your
operating costs . . .

+
Electrical Energy represents
1/3 of the total operating costs
for water networks and
infrastructures

Our
Energy Efficiency expertise

Up to a 30%
saving in energy
You must reduce your operating costs through load shifting,
high efficiency motors & drives, process optimization.
Our solutions for Power Management and Control can reduce
your energy consumption by up to 30%

10

Electrical energy may account for as much as 30% of your

operating costs. 3 aspects of Energy Efficiency should be
considered for a high level of power quality:
> Energy Savings:
reduced consumption for all types of operations,
> Energy Cost Optimization:
reduced costs of the energy used by the different operations,
> Availability & Reliability:
minimize outage risks through design and strategy, and sustain
energy gains through reliable and efficient equipment operation.

Solutions for energy savings

The latest generation of low-loss
transformers and high performance
motors allows global efficiency to be
improved by up to 5%.

Variable Speed Drives are used to great

advantage in pumping applications.
By adjusting the speed of rotation,
the absorbed electrical power may be
reduced by 50% at 80% of nominal flow.

When high power motors are requested

(> 500kW), the use of an Medium Voltage
supply reduces line currents, thus
reducing the Joule losses in transformers,
cables and motors. A Low Voltage supply
may become cost-prohibitive because
equipment sizes get very large, limited or
unavailable, and multiple sets of cables
are needed.

In water installations, harmonics are mainly

generated by Variable Speed Drives,
Ozone generators and UV lamps, which
should all be carefully managed
to avoid resonance, particularly when
Power Factor Correction capacitors are
present.
Increased current demands and nuisance
tripping are the most frequent adverse
consequences of harmonics.
Schneider Electric can provide assistance
and solutions for Harmonic management
in compliance with Utility regulations.
Global
efficiency
improved
by up to

>>>
5%

Cost saving evaluation software

11

12

Solutions for energy cost optimization

The cost for a given energy consumption
may be reduced in different ways.

Process diagnostics and optimization

Detecting problems as early as possible
avoids process downtime and also
reduces operating costs. Schneider
Power Factor Correction provides several Electric offers diagnostic tools that are
advantages that add together:
easy to use and which give efficient
avoids invoicing of reactive energy
access to relevant information, such as
by the Utility,
the root cause and process values
reduces the current demand,
needed to fix the problem.
eliminates transformer over-sizing and
At the Supervision Control And Data
allows the full system capacity to be used. Acquisition (SCADA) level, tools such as
Power Factor Correction is generally
Process Analyst are available to create
achieved through the use of capacitor
reports and analyze process data, which
banks.
can then be used to optimize the process
in order to reduce electricity consumption.
Power monitoring devices are used for
2 main reasons:
to know which sectors consume the
most power,
to monitor Energy Efficiency
improvements.
Three types of technologies are available:
stand alone measurement unit,
LV and MV protection relays,
High performance metering units.
Various resources are used to send data
from metering and protection devices
installed in the users electrical panels,
via Schneider Electric Transparent
Ready.

Soft starters
are available in a wide
range of power ratings,
and are particularly
suitable for water
applications such as
pumping. Multiplexing
is commonly used for
cascading start-ups and
decelerations of multiple
motors.
The following is a list of
the main advantages
this provides:
less mechanical stress
at motor start-up, thus
improving mechanical
reliability,
controlled torque
at motor stopping, thus
avoiding water-hammer
and damage to pipes,
power peak shaving,
thus avoiding penalties,
reduced losses
at motor start-up.

13

You are looking

for high availability
water treatment . . .

14

The raw material needed to produce drinking

water may come from different sources
(springs, aquifers, rivers, oceans), and
appropriate technologies have to be used.
The available space and the volume of water
to be treated also determine the technical
choices. In all cases, the required water quality
has to be reached and proved in accordance
with regulations and the authorities contracts.
Both the automation system and the electrical
network must be studied to provide high
performance and a high level of availability.
The solution includes software and hardware
architecture with redundancy at all levels:
A high level of availability affects power as well as
automation:
A high level of availability is requested for all parts
of an application identified as being critical, and may include
redundancy for:
power architecture, stand-by generators,
UPS (Uninterruptible Power Supply),
motor control, PLCs (Programmable Logic Controller),
communication and SCADA (Supervision Control
And Data Acquisition).
Power solutions
Different Circuit Configurations can be selected, as listed here
in increasing order of power availability:
radial single feeder,
two-pole configuration (secondary selective),
double-ended power supply (primary selective).
The implementation of back-up generators is very common
in water treatment plants where water distribution cannot be
interrupted for periods longer than a few minutes.
No instantaneous take-over is necessary, as buffer tanks
are generally present. Automatic transfer switches are naturally
associated with generators for rapid take-over and smooth
switch-back to normal supply.
Protection coordination is a key aspect for improving supply
continuity. Two examples are mentioned here:
discrimination between functional units such that a problem
on a grid doesnt stop biological treatment for instance,
coordination of motor protection and control minimizes
downtime.

Uninterruptible Power
Supplies are essential
for the continuous
operation of water
treatment facilities,
by protecting process
controllers and
monitoring and control
rooms from power
outages.
Schneider Electric
provides high power
UPS for control rooms
and small units for field
automation devices.
For a large critical
application, a fully
secure power solution
would be engineered,
with relevant
redundancies: UPS,
switchgear

>>>
15

Automation solutions in water treatment

Programmable logical Controllers

Speed drive

Redundant PLC, the

heart of a process with
a high level of availability
Schneider Electrics
Hot Standby PLC offer
is designed for your
sensitive applications
that require high control
system availability, and for
which interruptions are
unacceptable.
Remarkable performance,
transparent switchover
and communication ensure
your 24/7 services.

Raw water

Coagulation / Flocculation

16

Settling

Availibility is mainly focuses on the following three levels

SCADA
On the SCADA side, Schneider Electric offers seamless, integrated and scalable
redundancy. This flexible redundancy can be enlarged to avoid not only network errors,
but also PC hardware errors the result is a highly optimized and available solution.
Network
Ethernet, which has proved itself over the years as being the reliable industrial
standard, provides the solution for communication architectures requiring high levels
of availability. Communication can easily be adjusted to the required level of availability,
such as redundant media and/or network interfaces, self-healing fiber optic rings and
communication backups.
Control
Doubling the PLC gives a highly optimized solution that avoids the negative effects
and process downtime caused by problems at the control level. In the event of an error,
there is an automatic bumpless switchover between the Primary and the Standby PLC both are connected by a dedicated high speed Ethernet link. The availability level of the
control system can be increased by duplicating the I/O level, along with
the corresponding sensors and actuators.
Automation components for harsh environments
In water applications, the environment is sometimes polluted and may have negative
impacts on the ageing of the electronic components used. This results in unexpected
downtime and higher maintenance costs. Based on extensive field experience,
Schneider Electric has developed a special protection process (conformal coating)
to improve service life in such aggressive chemical and corrosive environments.

Drinking water

Disinfection
Chlorination
Ozonation
UV radiation

Filtration
Sand
Activated carbon

17

You are looking for

a comprehensive
power and control
solution . . .

18

In a complex process like desalination, integrated solutions

for power and control are required to reach the expected
performance level. Based on the size of such applications,
a large amount of process information has to be treated
and exchanged between the different parts of the plant.
For such applications we provide dedicated water solution
architectures and tools covering the complete project lifecycle,
from design to operation and modernization.

Intelligent Motor Control Centres (iMCC)

Overall performance for motor control could be increased by using type tested
equipment that offers:
seamless integration into the control system,
prevention of malfunction,
type tested equipment,
reduction of space, installation time and maintenance,
easy addition or modification of feeders whilst energized.
Collaborative Control System (CCS)
Filtration process applications are based on various different components:
controllers,
SCADA systems (Supervisory Control And Data Acquisition),
instrumentation,
drives,
sensors and I/Os.
All these devices must be integrated, configured and optimized during commissioning
and operation.
Schneider Electric collaborative tools cover all the different aspects and reduce
integration costs. Proven application knowledge has been integrated into libraries,
thus offering a high level of quality and standardization. The level of standardization
provides consistent user interfaces, operating modes and diagnostic capabilities,
thus reducing the amount of training and maintenance needed.

>>>
Third-parties
Instruments

intelligent
Motor
Control
Centre

19

20

Membrane filtration
Reverse osmosis is the most common
technique used for desalination, and is as
an alternative to distillation. It may also be
used to recycle water to produce drinking
water from wastewater. Nano filtration
is another example used for instance
to produce drinking water from surface
water.
Membrane filtration is an up and coming
water treatment technology, for both
industrial and public use. The reduced
space needed for the plant and its ability
to treat all types of raw water are key
drivers.
Membrane technology has meant that
water treatment has changed from being
a batch process to a continuous process,
which has led to higher performance
constraints. High pressure is the key
to membrane filtration. This requires a
high quantity of electrical energy and
the use of high power motors. Electrical
Distribution and Motor Control are thus
a comprehensive part of the process.

Link to the Instrumentation

An instrumentation link based on
standardized protocols enables
significantly improved mastery of
complex filtration processes. Extensive
process feedback and access to device
parameters increases performance and
diagnostic capabilities.
Asset management tools with
standardized interfaces give access
to devices and provide benefits by
having access to a large range of
parameters and diagnostic information.
Hence preventive maintenance can be
used to reduce unexpected downtime.
Availability and operating costs are
greatly improved.

The cost and efficiency of membranes

have greatly improved, but membranes
remain fragile. Strict water pre-treatment
is necessary because of the sensitivity to
some pollutants. In addition, membranes
may deteriorate unless they are maintained
under high pressure.
Consequently, power interruptions should
be avoided as much as possible. Power
and control are highly interconnected.

Evolving technologies
1 Hair, mould
2 Bacteria, suspended
matter, grease
3 Organic matter, proteins,
viruses

Sand filters 10 m

4 Divalent ions, sugars,

colouring agents
5 Monovalent ions, salts

Microfiltration 0.1 m

Ultrafiltration 0.01 m
Nanofiltration 0.001 m
Reverse osmosis 0.0001m
1
2

Water
3
4

Enterprise
manager

Facility
portal

Corporate Bus
Computer
Room
Manager

Process
Manager

Power
Manager

Building
Manager

Private Bus

Devices
controllers

Actuators
sensors

Service Oriented Architectures and open protocols

guarantee an efficient solution.

21

You have to
distribute water
24/7. . .
Increase pumping station availability and performance levels

Desalination
plant

Storage or
overpressure station
Consumption

Treatment
plant

Wastewater
lift station
Pumping station and
containment reservoir
Discharge into
the natural
environment

22

Wastewater
treatment

In drinking water networks, constant distribution pressure

is required to reach all floors in urban zones and to overcome
physical barriers in rural zones. Boosting stations are placed
along the network, and both constant availability and real time
adaptation to the users water demands are required.
Different technologies are used: from fixed to variable speed,
from switchboards to stand alone devices, from medium voltage
to low voltage. In all cases, perfect integration into the electrical
and automation networks is necessary.

Schneider Electric offers additional advantages through

a set of innovative solutions for pumping stations:
Increased availability and performance with multi-drive
solutions for boosting stations
Using several variable speed drives is a way of increasing
system availability. Embedded programmable cards provide
a specific advantage.
Each pump is controlled using a variable speed drive, with
a controller inside the card. The various drives and their cards
are connected via a communication network. Only one pump
(the duty pump) is under variable speed control during normal
operation. The duty is passed from one pump to another
on a time basis.
This solution provides additional benefits such as smooth
and bumpless control, together with potential cost savings.
Small pumping stations and reservoirs
A cost effective and ready to use solution
- management of two pumps, control by direct-on-line
or soft starters,
- an all-in-one controller, with pre-programmed software and
integrated Remote Terminal Unit (RTU) capabilities, provides
a solution for pumping stations, recovery stations, reservoirs,
etc.

Medium Voltage Room

Ethernet TCP/IP redundant

Control
Pump 2

Control
Pump 1

Control
Pump N

Machine Room

Large Medium voltage pumping station

RTU

Variable speed drive

Direct online or soft starters
Pressure
Transducer
Optional
Pressure
Transducer

Optional
Flow
Transducer

Wastewater sewage treatement

23

You have to
manage a network
of pumping
stations . . .
Most of the time water sources are far from consumption points.
In addition, wastewater collection is required and coordination
between pumping stations is required to manage water flow.
This results in extensive networks and creates specific water
needs: remote locations, poor communication networks, difficult
and expensive maintenance, availability of electrical energy.

24

A telemetry system is the answer

All links between remote sites are periodic and characterized by exchanges
triggered by cyclical polling from the central system, upon operator request
or upon the occurrence of an event:
data transmission between remote sites and the central supervisory system
(Scada),
communication protocols (IEC 870, DNP3, Modbus),
media (cable, radio, GSM. Modem, Internet, ),
handling of time stamped events, measurements and buffering of data
in case of interrupted links.
Compact RTU all in one (Remote Terminal Unit)
Small applications require optimized solutions. The compact RTU offers:
preconfigured ready to use applications,
management of up to four pumps,
storage of measurements and events,
integrated RTU communication and is able to be integrated in Telemetry
architectures based on a broad range of standard protocols such as IEC, Modbus
and DNP3.
RTU functionality integrated in modular PLC (Programmable Logic Controller)
RTU functions and PLC flexibility forms the basis of the integrated Schneider Electric
offer.
Offering Master and Slave communication opens the door to different architectures.
Our solutions are based on reliable and industrially proven hardware, designed for
the harsh environment of wastewater pumping stations. The Modicon PLC range
offers a wide choice to meet the different requirements.
SCADA: the central point (Supervision Control And Data Acquisition)
Due to the large distances in pumping networks, seamless communication
integration is the key to monitoring, operating and maintaining such applications.
Our offer includes standard SCADA features such as scalability, reporting,
redundancy and diagnostics, as well as specific RTU functions such as IEC
protocols and the handling of modems, time stamped alarms and data. Data
can be exchanged easily in several well known formats such as dBase, SQL, Oracle
and several others, for subsequent processing using Office tools.

Telemetry system

Schneider Electric access control and video

security offer
Even before the
heightened awareness
brought on by terrorist
threats, many public
and private institutions
alike had already started
incorporating video
security into critical
infrastructures.
Video security provides
the visual images
necessary to improve
situation awareness,
deter vandalism,
theft or other crime,
accelerate response and
management decisions,
and increase overall
public and staff safety.
More generally,
treatment plants and
pumping stations place
increasingly greater
demands on security
systems.
The security control
system is the critical
component in meeting
these new demands.

25

You have to adapt

the process to
regulation changes

Waste disposal
Sand
Grease

Gas and reagent

injection
Storage /
Dosing
Compressors

Untreated
wastewater

Screening / Pumping

26

Grease and sand removal

Physical and chemical

treatment
Coagulation / Flocculation

Regulations are raising the water quality level requirements.

The quantity of information that must be analysed, processed and
acted upon increases constantly.
Sludge treatment, air treatment and biological treatment are
examples of units that need to be added or improved in many
wastewater treatment plants.
The flexibility and evolution capability of our PLC based solutions
make them suitable for the functional unit improvements required
in the treatment process.

>>>
Sludge processing
Digestion
Stabilisation
Thickening
Dewatering
Incineration

Air treatment
Ventilation
Scrubbing
towers

Quality
measurements
and discharge

Biological treatment
Bacteria / Activated sludge

Settling / Clarification

27

28

Distributed control architectures

To keep up with the flexibility needed in terms of process evolution and the need to
integrate different packages such as sludge treatment, distributed control architecture is
the best choice. Its structure of independent functional units, each equipped with
a modular PLC (Programmable Logic Controller) connected via an industrial network
to the SCADA (Supervision Control And Data Acquisition) system provides a reliable
and flexible solution. Such architectures can easily be modified or extended by adding
new functional units. Data exchange and synchronisation are based on standard
industrial Ethernet protocols. Our solutions are based on reliable and industrially
proven hardware, designed for the harsh environment of wastewater treatment plants.
Automation islands as an integration platform
The easy integration of digital and analog signals, motor starters and variable speed
drives is the key to improving and adapting water process applications
in a flexible way. Compatibility with various networks and field busses allows device
layout standardisation only the communication interface has to be adapted.
This standardisation leads to higher flexibility and cost savings at the engineering
and commissioning stages.
Effective SCADA system to monitor, analyse and optimize the water process
To reach the quality targets set by regulations, the SCADA system has to log and treat
all the relevant process information needed to monitor the plant. Schneider Electrics
SCADA system logs data in standard formats such as dBase, SQL and Oracle.
Process Analyst is the perfect tool for analyzing the different process data such as
measurements, alarm and digital data sources in one single environment the intuitive
user interface quickly provides the operator with the relevant information.
Upgrading of Electrical Distribution and Motor Control
Schneider Electric is able to offer Electrical Distribution equipment retrofits as a solution
to meet the increasing level of quality requirements. For example, modern equipment
with embedded power monitoring and communication can be implemented for better
and easier energy management. Variable speed drives are very adaptive tools for easier
process adjustment and more accurate process control.
Latest PLC technologies
Scalable migration is one of the key features offered by the Schneider Electric PLC
range:
existing Inputs/Outputs can be kept, a new generation of processor provides new
services and increases the performance of the application,
even when all the hardware has to be changed, the software can be converted
and reused with the latest hardware to benefit from the new features.
All these upgrading features provide flexibility, high performance and cost effectiveness
for the process control, and protect previous investments.

29

Water
treatment
overview
architectures
T1
autonomous water treatment plant
Water treatment
plants
For both drinking
water and wastewater
treatment, 4 different
sizes of plants have
been distinguished
according to
destination and size:
plant size can be
expressed by the
quantity of water
treated per day, or by
the equivalent number
of inhabitants.

Inhabitants
m3/day (drinking water or waste water)
Motors
Power demand
Instruments

1,000 10,000
1,000 5,000
16
25 125 kVA
10

T2
small water or wastewater treatment plant
Inhabitants
m3/day (drinking water or waste water)
Motors
Power demand
Instruments

10,000 100,000
5,000 50,000
50
125 1250 kVA
100

T3
medium water or wastewater treatment plant
Inhabitants
m3/day (drinking water or waste water)
Motors
Power demand
Instruments

100,000 500,000
50,000 200,000
200
1.25 5 MVA
300

T4
large water or wastewater treatment plant
Inhabitants
500,000 1,000,000
m3/day (drinking water or waste water) 200,000 1,000,000
Motors
500
Power demand
5 25 MVA
Instruments
1,000

30

31

Water pumping stations

Overview
architectures
P1
small lifting, pumping and tank station
Remote water
pumping stations
Three different types of
pumping station have
been distinguished
according to
destination and size:

Number of pumps
Power demand
Instruments

2
< 500 kVA
4

For each type of

water treatment plant
or pumping station,
Schneider Electric
has a dedicated and
adaptable solution for
Electrical Distribution
and automation
functions.

P2
pumping and small booster station
Number of pumps
Power demand
Instruments

4
100 1000 kVA
12

P3
booster or complex pumping station
Number of pumps
Power demand
Instruments

32

5 10
500 5000 kVA
50

33

You need
services in
all countries

34

To support your water process throughout its life cycle,

from the design stage, during operation and to modernization,
we offer various services available in all countries.
Our network of qualified partners and our projects and service
centres are at your disposal and are able to provide a unique
power & control services offer.
Design phase services
To help and assist you to ensure efficient solutions for your project
and high performance operation:
consultancy and expert services,
energy efficiency solutions,
critical power solutions.
Operating phase services
To avoid unexpected downtime of your application, ensure a constant performance
level and to reduce operating costs:
maintenance and spare parts management,
site audits and repairs,
training.
Modernization phase services
To reduce risks after a long period of operation and improve the performance
of applications, we can provide services to redesign and modernize your installed
power & control base:
diagnostics and feasibility studies,
retrofit expertise and consultancy,
project support.
A Flexible Approach
Our systematic approach to upgrades and retrofits is the key to extending equipment
life at a fraction of the replacement cost. We upgrade or replace circuit breakers with
new technology; develop switchgear retrofit solutions; recondition LV and MV power
circuit breakers; replace or repair drives.
We conduct power quality and harmonic studies to identify previously undiagnosed
problems that can reduce equipment life and interfere with reliable operation.
As the upgrades come online, our installation services verify that the new equipment
is damage-free, properly installed, and ready to meet optimum performance
standards.

35

Make the most

of your energy

Schneider Electric Industries S.A.S

Head Office
89, bd Franklin Roosevelt
94504 Rueil-Malmaison
www.schneider-electric.com
INFED102008EN

As standards and equipment are subject to change, please ask for confirmation of the
information given in this document.
Design: nb notabene
Photos: Schneider Electric, Christian Rausch, nb notabene
Print: Numica
06 / 2008