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Verticle Data Integration Throuh Interbus

Verticle Data Integration Throuh Interbus

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Published by Salil Chaudhary

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Published by: Salil Chaudhary on Feb 04, 2011
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INTERBUS Used in Water Purification – Vertical Data Integration In these parts, the drinking water that comes straight

from the tap is more pure than many of the bottled drinks available on the market. The processes required to achieve this level of purity are necessarily complex. A recognized specialist in the automation of these processes and the modernization of drinking water treatment and distribution systems is Brüggemann Systemtechnik based in Hanover, Germany, which is increasingly using INTERBUS in its solutions. One of such solutions can be found at the Oerbke waterworks.

Oerbke is not just noteworthy from an administrative point of view: in terms of local government politics, the NATO military training area of Bergen in the Lüneburg heathland is divided into two non-municipal districts, where the eastern part is the non-municipal district of Lohnheide in the Celle administrative district and the western part is the non-municipal district of Osterheide in the Soltau-Fallingbostel administrative district. The Oerbke waterworks are situated in the region of Oerbke, in the non-municipal district of Osterheide, and are under the direct administrative control of the German Minister for Finance. These government-owned waterworks are unique in that they are used to supply good-quality drinking water to military installations in the Bergen training area as well as to the neighboring town of Bad Fallingbostel, which is home to food companies Kraft Foods and Eckes-Granini. The waterworks, which were established in 1936, consist of two identical plants that at the time were the most technologically advanced plants in Europe. "One of the plants is still operating almost in its original state," confides Klaus Brüggemann, Managing Director of Brüggemann Systemtechnik, the company chosen to modernize the waterworks. "For example, terminal blocks from Phoenix Contact have been operating reliably in these waterworks for many years." This was one of the reasons why Brüggemann Systemtechnik also chose to use the innovative automation solutions offered by the Blomberg-based company for the modernization of the Oerbke waterworks.

Template for Vertical Integration Well systems, waterworks, drinking water tanks, filtration systems, and even decarbonization systems are used in the treatment of drinking water. Klaus Brüggemann has 30 years of experience in the networking and modernization of these types of plants. The main clients of the Hanover-based company, which is a member of the Deutsche Vereinigung des Gas- und Wasserfaches e.V. (DVGW, German Technical and Scientific Association for Gas and Water), are city works and municipal drinking water associations. The automation solution that Brüggemann developed for the Oerbke waterworks is not only transparent and seamless, but can also be used as a template for the vertical integration of data. This is because it even includes the commercial department of the district council, where all water consumption data can be accessed online on a workstation computer. From here it is transmitted to the technical department via glass fiber cables. Here, a switch forwards the data to a workstation computer in the waterworks and to a control computer installed with Genesis visualization software. There is an Ethernet connection between the control computer and the RFC 450 Remote Field Controller, which acts as the central control system.

Inline Controller for Remote Communication The RFC controls digital and analog I/O modules, which are used to network the mosaic-type control panel requested by the customer in addition to the PC visualization. The mosaic-type panel displays all the relevant process data for the waterworks. From here, the operator can access processes at the touch of a button in the usual way. Klaus Brüggemann is particularly proud of the company's remote solution: The RFC has two lower-level ILC 200 Inline Controllers, which are connected to the two ILCs of the wells via a branch line using an RS-485 interface. The wells are around 1000 m to 1500 m from the control room. "There are plans to integrate the transformer station control system, which is also an Inline Controller, here in the future," explains Klaus Brüggemann. "This means that it will also be possible to access power consumption data online." HCS fiber optic technology has been used to connect both waterworks. "Both plants can be operated separately," explains the automation specialist. "The redundant concept of the original design has, in a way, been further developed." As there is also a cable from plant 1 to plant 2, even the complete failure of a cable will not result in the failure of the entire bus. In both plants, INTERBUS I/O modules are used for data exchange. All data for check measurements, such as turbidity, pH values, and temperature, is compiled and sent to the management system. In plant 1, an INTERBUS-compatible KS-98 controller from PMA is used to control the pumps. The plant has three water pumps connected in series. "Together, the plants can supply up to 1000 m³ per hour."

Two water pumps connected in series are each controlled with a Lenze frequency inverter and the follow-on pump is controlled with a soft start. "This means that the assignment of the pumps to the drive can be changed," notes Klaus Brüggemann. "This results in a higher level of safety with regard to supply and a uniform load for all pumps."

Extremely Robust From plant 1, a bus branch line, also equipped with two ILC 200 controllers, leads to the water treatment area with filter backwash system. INTERBUS also compiles all the important measured values here, such as the filter water level and the flow of air for atomization. The operator can obtain a brief overview via a Sütron operator panel. From here, data is transmitted to the filters via Inline Controllers, where R-Line solenoid valves from Bürkert are used that communicate directly via INTERBUS. Apart from the valves for the filters, the frequency inverter drive for a flushing water pump in the water treatment area is controlled via INTERBUS. "The structure of plant 2 is exactly the same," explains the drinking water specialist. "The only difference is that old technology is still being used here for the most part." This means that the drives consist of KSB pumps with AEG motors from 1936, which Klaus Brüggemann explains "were then extended with hardwired logic around 23 years ago". The key to this solution: "Modern INTERBUS Inline modules are now used in part to compile the analog data, using Phoenix Contact terminal blocks that have been used for decades." As Brüggemann goes on to explain, "The filter backwash system in plant 2 is the next project and will be connected to INTERBUS this coming fall". In addition, plant 2 contains the emergency power generating system for the waterworks, which is also integrated into the complete system via INTERBUS. In particular, Klaus Brüggemann values the easy operation and openness of INTERBUS. The option of integrating the remote control of external stations via RS-485 communication is an excellent feature, which is also superior to other solutions in terms of price.

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