UNIVERSITY OF PORT HARCOURT

A TERM PAPER
ON

AUTOMATION OF A WATER TREATMENT PLANT

BY
GROUP ONE

FUTUGHE TOJU REX G2021/MENG/CHE/FT/003

EKWEBELEM EZICHI G2021/MENG/CHE/PT/005
OGIDE BLESSEDMAN DECEMBER G2021/MENG/CHE/FT/006
MARTINS OLUCHUKWU ONYEIJEN G2021/MENG/CHE/FT/002

COURSE: ADVANCED PROCESS DYNAMICS AND CONTROL

COURSE CODE: CHE 808.2

DEPARTMENT: CHEMICAL ENGINEERING

COURSE LECTURER: DR I. J. OTARAKU

OCTOBER 2023.
Contents
INTRODUCTION...........................................................................................................................................3
BENEFITS OF AUTOMATION.......................................................................................................................3
PROCESSES OF WATER TREATMENT PLANT...............................................................................................5
COAGULATION AND FLOCCULATION CONTROL.....................................................................................7
PH CONTROL...........................................................................................................................................8
SEDIMENTATION CONTROL SYSTEM......................................................................................................9
FILTRATION...........................................................................................................................................10
DISINFECTION (POST TREATMENT)......................................................................................................14
CONCLUSION.............................................................................................................................................15
REFERENCES..............................................................................................................................................16
INTRODUCTION

Water is one of the most essential resources for human life, and ensuring its quality and safety is
paramount. Water treatment plants (WTPs) play a pivotal role in treating raw water from various
sources to make it safe for consumption and other essential uses. However, the processes involved in
water treatment can be complex, requiring precise control, continuous monitoring, and rapid response
to changing conditions. This is where automation and control systems come into play.

Water treatment is not merely about the removal of visible impurities; it also involves eliminating
invisible contaminants, pathogens, and maintaining the desired chemical composition. The traditional
manual operation of WTPs, reliant on human operators, has proven effective over the years but is not
without limitations. Human error, inconsistent decision-making, and the need for constant vigilance can
sometimes compromise the quality and efficiency of water treatment processes.

The integration of automation and control systems has revolutionized the way WTPs function. These
systems, including Supervisory Control and Data Acquisition (SCADA), Programmable Logic Controllers
(PLCs), sensors, and data acquisition technologies, have transformed water treatment into a highly
efficient, reliable, and safe process. Automation not only reduces human intervention but also enhances
the precision and consistency of water treatment operations, thereby ensuring that the treated water
consistently meets stringent quality standards.

In this term paper, we will delve into the world of automation and control in water treatment plants. We
will explore the fundamental processes involved in water treatment and the challenges faced in manual
operations. Moreover, we will discuss the critical need for automation in water treatment, emphasizing
its role in improving efficiency, accuracy, and reliability. By examining the benefits, challenges.

BENEFITS OF AUTOMATION
Automation in water treatment plants also offers a wide array of benefits, including resource
optimization, energy efficiency, cost reduction, error elimination, precise control, data
reliability, real-time monitoring, adaptive responses, remote access, and enhanced resilience.
These advantages collectively contribute to the efficient and sustainable provision of clean and
safe drinking water while minimizing operational risks and costs. Some of its benefits are as
follows

Resource Optimization

 Precise control of chemical dosages minimizes waste and reduces operational costs.
 Efficient management of energy usage through automation leads to energy savings and
lower environmental impact.

Energy Efficiency

 Smart control of equipment and machinery ensures energy consumption aligns with
demand, reducing electricity costs.
 Energy efficiency measures contribute to a decrease in greenhouse gas emissions,
promoting environmental sustainability.

Labor Cost Reduction

 Automation streamlines routine tasks, reducing the need for manual labor.
 Operators can focus on more complex and critical aspects of plant operation, enhancing
productivity.

Elimination of Human Error

 Automation significantly reduces the risk of human error in water treatment processes.
 Consistent and error-free operations ensure that water quality standards are
consistently met.

Precise Dosage Control

 Advanced sensors and control algorithms ensure precise chemical dosage

  Accurate dosing prevents under- or over-treatment, ensuring compliance with
regulatory standards.

Reliable Data Logging

 Continuous data collection and logging provide valuable historical data for plant
performance analysis and decision-making.
 Data-driven insights support process optimization and troubleshooting.

PROCESSES OF WATER TREATMENT PLANT

The process of water treatment plant is shown in the Figure below.
Water treatment is a multifaceted process that involves several stages aimed at purifying raw
water from various sources into safe and potable drinking water. The effectiveness of this
process depends on the quality of the source water and the specific treatment methods
employed. In general, water treatment can be divided into several key steps:

I. Mixing
II. Coagulation and Flocculation
III. Sedimentation
IV. Filtration,
V. Disinfection

Firstly, raw water comes into the coagulation tank and after that goes for flocculation where the
flocks are formed. Sludge from the sedimentation tank goes into the thickener for thickening
process and the supernatant goes into the filtration tank where the suspended particles get
removed.

Table 1: Processes with their applications

Process Equipment Control parameter

Chemical handling and Solution tank, Turbulence pH and turbidity testing in

feeding channel, Stirrer laboratory.

Coagulation and flocculation RCC tank, blades with gear Mixing of alum solution into
box, Motor water and formation of floc.

Sedimentation RCC tank with tube settler Suspended particles are

removed by settling.
 Filtration Rapid sand filter, valve, Removal of turbidity and
pump coarse particle.

Disinfection Feed valve Chlorine dosing to remove

bacteria and residual
chlorine.

The process of chemical feeding and handling includes the addition of alum as per the quality of
raw water. The process needs online control and monitoring so that the system can work
efficiently. To purify water from the particulate matter, filtration is considered to be the most
reliable technique.

The process of water treatment consists of several stages for production of pure water. Each
stage consist particular equipment setup which has defined control functions and the process
equipment and control parameters for each stage have been described in Table 2.

The operation of the system can be fully (in Automatic mode) controlled by the Programmable
logic controller (PLC) and software. The system components are controlled with the help of the
PLC, which communicates with the software. The data sent by the PLC is stored in the server in
prescribed formats; this data is used by software for decision making and report generation.

Table 2: Possible control parameters in the process

COAGULATION AND FLOCCULATION CONTROL

This is the process of monitoring and adjusting the coagulation and flocculation process to
ensure that it is operating efficiently and effectively. Coagulation and flocculation are essential
processes for removing suspended solids, turbidity, and other contaminants from water.
However, the efficiency of these processes can be affected by a number of factors, including the
type and dosage of coagulants and flocculants used, the pH of the water, and the mixing
conditions.

Coagulation and flocculation control can help to improve the performance of water treatment
plants in a number of ways, including increased efficiency, Improved water quality, reduced
costs and improved safety. There are a number of different strategies and technologies that can
be used to control coagulation and flocculation. The best approach for a particular plant will
depend on the specific needs of the plant and the characteristics of the water being treated. A
promising technology worth mentioning is Flocculation Pulse Detection technology, which
gauges the relative change in the size of impurities during the water flocculation process. An
important advantage of this technology is its immunity to the presence of any impurities in water,
effectively addressing a limitation of the streaming current detector (SCD) as an effective
method for automatic coagulant dosing control technology.

PH CONTROL

Many researchers have considered the clarification stage as the central process of whole water
treatment process. It is here that pH control strategies will be focused, since pH is a fundamental
factor controlling the performance of the clarification process. On the coagulation processes, it
may be necessary to use an acid and/or a base for pH correction purposes to reach the best
removal of pollutants. However, pH control with an acid and a base is more complex due to the
multi-actuator set-up and also the bi-linear effects caused by differing solution strengths. The
control strategy for pH control is shown in Figure 2. In the system, raw water and other
chemicals get mixed in the flash mixer and the pH is measured by the feedback controller and
the desired clarification is adjusted accordingly. Conductivity, flow rate and pH of raw water are
controlled by the feed-forward model.
Figure 2: PH control strategy

SEDIMENTATION CONTROL SYSTEM

A sedimentation control system in water treatment is a crucial component responsible for

managing the sedimentation process within a treatment plant. This physical water treatment
process allows larger solid particles, including sand, silt, clay, and organic matter, to settle out of
the water through gravity. The primary purpose of a sedimentation control system is to remove
larger solid particles from raw water, improving its clarity and quality for further treatment and
various applications.

Automation is essential for sedimentation control. Control systems regulate parameters such as
flow rate, detention time, and the operation of skimmers, scrapers, or sludge removal equipment.
Level sensors and instruments monitor and control water levels.

For a sedimentation control system in a water treatment plant specifically, the following
components and technologies are commonly used for control and automation:

 Programmable Logic Controllers (PLCs): PLCs are central control units that manage the
operation of sedimentation processes. They execute control algorithms and coordinate the
functioning of equipment and mechanisms.
 Human-Machine Interface (HMI) Systems: HMIs provide operators with a visual
interface to monitor and control sedimentation processes. They display real-time data,
alarms, and status information related to the sedimentation basins.

 Sensors and Instruments: Various sensors and instruments are employed to measure key
parameters within the sedimentation process. These may include turbidity sensors, water
level sensors, and flow meters to ensure optimal operation.

 Control Valves and Actuators: Control valves regulate the flow of water within the
sedimentation basins. Actuators are used to adjust the positions of valves and control the
flow rates effectively.

 Automated Sludge Removal Mechanisms: Automated systems, such as sludge rakes,

scrapers, or suction mechanisms, are used to remove settled sludge from the bottom of
sedimentation basins. Control systems manage these mechanisms to prevent excessive
sludge buildup.

 Control Algorithms and Logic: Control systems utilize algorithms and logic to optimize
the sedimentation process. This may involve adjusting influent flow rates, chemical
dosages, or sludge removal schedules based on real-time data.

 Communication Networks: Communication networks facilitate data exchange between

control components, sensors, and the central control system. This includes wired and
wireless technologies to transmit real-time data.

 Remote Monitoring and Control: In some cases, remote monitoring systems allow
operators to access data and make adjustments to the sedimentation control process from
off-site locations. This enhances flexibility and responsiveness.

 Alarm Systems: Alarm systems are set up to generate alerts when specific conditions or
thresholds are met, helping operators promptly address issues or deviations from desired
parameters.
FILTRATION

Two common filtration processes, gravity filters and pressure filters, are utilized in water
treatment. While similar, pressure filtration occurs within closed steel tanks (vertical or
horizontal) and employs sand or sand/anthracite media. Smaller pressure filter systems may
use diatomaceous earth. A typical description refers to a gravity filter system in medium to
large-scale water treatment plants.

Gravity filters are large concrete bays with underdrains supporting filter media and
distributing backwash water evenly. "U" shaped wash-water troughs collect and remove
backwash water. Cleaning can be achieved through agitators, surface wash, or introducing air
into backwash water. These systems have five or six valves associated with the filter bay,
depending on the backwash procedure and regulatory requirements. Control valves include
influent, effluent, drain, and backwash. The fifth valve is for agitator water supply or air, and
the sixth is the "filter-to-waste" valve, mandated in some states to prevent turbidity spikes in
the clearwell. In filtration mode, treated water enters the filter box, flows through the media,
and exits through effluent piping controlled by a rate-of-flow controller, commonly using a
venturi meter, flow transmitter, and filter effluent valve. As head loss across the filter rises,
the effluent valve adjusts to maintain flow. Filtration is both physical and chemical, trapping
particles while attracting suspended ones to filter media. Filter run times vary based on water
quality and initial cleanliness, ranging from 15 to over 100 hours. Over time, filter media can
form "mudballs" due to sticky floc, potentially clogging the filter. An automatic backwash
system uses a "loss-of-head" transmitter to signal high head loss, triggering a backwash
sequence.

Backwash Sequence: There are presently three backwash procedures in use: manual,
automatic, and semi-automatic. In the manual mode, an operator sequentially operates all
valves and initiates pump start/stops manually. In the automatic mode, the control system
handles all sequencing tasks. The automatic backwash process is triggered automatically
when the control system detects a high loss-of-head alarm, a high turbidity alarm, or when a
predefined filter run-time has been reached. In the semi-automatic mode, the operator
manually initiates the automatic backwash sequence upon receiving a high loss-of-head
alarm, a high turbidity alarm, or when a set filter run-time has been attained.

The process for a standard air/water backwash sequence with filter-to-waste in a

sand/anthracite multi-media filter can be outlined as follows:

1. Close the influent valve.

2. Check for the influent valve “closed” limit switch signal.

3. Start alarm timer for “closed” limit switch signal. (Alarm on time out. Stop backwash
sequence and reset alarm timer on receipt of limit switch signal).

4. Draw down the filter level to a preset level above the media.

5. Check for the level switch signal.

6. Close the effluent valve.

7. Check for the effluent valve “closed” limit switch signal.

8. Open the drain valve.

9. Check for the drain valve “open” limit switch signal.

10. Start alarm timer for “open” limit switch signal. (Alarm on time out. Stop backwash
sequence and reset alarm timer on receipt of limit switch signal).

11. Start the air blower.

12. Check for blower start (discharge pressure switch)

13. Open the air scour valve.

14. Check for air scour valve “open” limit switch signal.
15. Start alarm timer for “open” limit switch signal (alarm on time out. Stop backwash
sequence and reset alarm timer on receipt of limit switch signal).

16. Start the backwash pump.

17. Check for pump start (discharge pressure switch)

18. Modulate backwash valve open to preset low rate flow.

19. Stop blower when filter level reaches preset level below bottom of wash troughs.

20. Close air scour valve

21. Check for air scour valve “closed” limit switch.

22. Start alarm timer for “closed” limit switch signal. ( alarm on time out. Stop backwash
sequence and reset alarm timer on receipt of limit switch signal).

23. Ramp backwash flow rate to preset high rate.

24. Time backwash to preset time or monitor turbidity of backwash water in drain.

25. Ramp backwash rate down at preset rate to promote re-stratification of the filter media.

26. Close backwash valve.

27. Check for backwash valve “closed” limit switch.

28. Start alarm timer for “closed” limit switch signal (alarm on time out. Stop backwash
sequence reset alarm timer on receipt of limit switch signal).

29. Stop backwash pump.

30. Close drain valve.

31. Check for drain valve “closed” limit switch.

32. Start alarm timer for “closed” limit switch signal (alarm on time out. Stop backwash
sequence and alarm timer on receipt of limit switch signal).

33. Open influent valve.

34. Check for preset level in filter.

35. Modulate filter-to-waste valve though filter flow controller.

36. Time filter-to-waste (or monitor effluent turbidity).

37. Close filter-to waste valve.

38. Check for filter-to-waste valve “closed” limit switch signal.

39. Start alarm timer for “closed” limit switch signal (alarm on time out. Stop backwash
sequence and reset alarm timer on receipt of limit switch signal).

40. Activate effluent valve control through rate of flow controller.

Electric motor-operated actuators are commonly paired with butterfly valves for on/off and
modulating control in gravity filters. These valves are configured to move from fully open to
fully closed (or vice versa) within one to two minutes. The activation of valve limit switches
is crucial for both operational and safety purposes. Alarm timers are set to notify operators if
the valve limit switch remains inactive during the backwash sequence.

To determine the necessary post-treatment chemical amounts, the process automation and
control system measures, regulates, and calculates the individual filter effluent flows.
Manually performing tasks such as controlling valve sequences, safety checks, adjusting
backwash flow rates, and managing filter-to-waste can be challenging and time-consuming,
taking 30 minutes or more for a complete backwash. While programmable logic controllers
(PLCs) are effective for on/off control, they have limitations when it comes to integrating
modulating control, flow measurement, and data archiving. Distributed control systems excel
 in control capabilities and data management but lack ladder logic programming for
sequencing.

DISINFECTION (POST TREATMENT)

Disinfection is the final step in water treatment, and it is essential for ensuring that the water is
safe to drink. Disinfection kills or inactivates harmful microorganisms, such as bacteria, viruses,
and protozoa, that can cause waterborne diseases.

Disinfection is the process of sanitizing filtered water before it is pumped into the distribution
system. This is done to ensure that the water remains safe throughout the distribution system and
to the consumer's tap. The most common disinfection method used in water treatment is
chlorination. Chlorine is a powerful disinfectant that is effective against a wide range of
microorganisms. Chlorine can be added to water in the form of a gas, liquid, or solid.

The amount of chlorine that needs to be added to water depends on a number of factors,
including the type and concentration of microorganisms in the water, the pH and temperature of
the water, and the desired contact time. Contact time is the amount of time that the chlorine
needs to be in contact with the water in order to be effective. Water plant automation and control
systems play an important role in post-treatment disinfection. These systems can be used to
monitor and control the following:

 Chlorine feed rate

 Contact time

 Residual chlorine levels

CONCLUSION
Automation and control systems are indispensable tools for modern water treatment plants. They
enable efficient and reliable operations, ensuring that communities have access to clean and safe
water. By continuously investing in technology upgrades, cybersecurity measures, and training
for operators, water treatment facilities can enhance their performance, reduce operational costs,
and meet stringent regulatory requirements. Additionally, the integration of sustainability
initiatives and advanced analytics can further improve plant efficiency and environmental
impact.

As populations grow and environmental challenges increase, the role of automation and control
in water treatment will become even more critical. By embracing innovation and best practices,
water treatment plants can provide a reliable and sustainable supply of clean water for current
and future generations.

REFERENCES

Alshihri, M. M., & Shoukry, A. A. (2020). Artificial intelligence techniques for water treatment and
distribution systems: A review. Journal of Water Supply: Research and Technology-AQUA, 69(8), 628-
645.

Di Bernardo, M., Di Bernardo, L., & Fazzino, S. (2013). Control and automation of wastewater treatment
plants. Springer Science & Business Media.

Nardi, A. T., & Boaventura, R. A. R. (2009). Automation and control in water and wastewater treatment
plants: A review. Journal of Water Process Engineering, 1, 123-142..
U.S. Environmental Protection Agency. (2021). Water Treatment Manual: Disinfection. Retrieved from
https://www.epa.ie/pubs/advice/drinkingwater/pt2.pdf

Wang, P. (2019). Control and automation of wastewater treatment processes: A review. Environmental
Science and Pollution Research, 26(6), 5368-5385.