Korean purification plant cuts operation cost of water

treatment by migrating from an aging DCS to the

PlantPAx Process Automation System.
Hwado water treatment facility helps reduce operating costs 13%
by installing Rockwell Automation platform.
Solution
PlantPAx Process Automation System
ControlLogix Programmable Automation
Controllers (PACs)
CompactLogix and ControlLogix controllers
RSLogix 5000 software to program the PACs
FactoryTalk View suite and
FactoryTalk Historian
EtherNet/IP network

Results
The single platform - single controller,
software, network resulted in
remarkable savings
Helped reduce installation cost by over 50%
Operation cost cut down by 13% over 2 years
Improved troubleshooting and maintenance to
help reduce unscheduled downtime significantly
Help cut data storage costs due to FactoryTalk
Historian- a smaller but powerful program
than the previous solution

Namyangju Hwado purification plant

Background
The Han River in Korea stretches 514 km, flowing through Seoul and
merging with the Imjim River before it finally reaches the Yellow Sea.
Although it is not a long river, it is an important one because it serves
as the source of drinking water for several cities.
Hwado purification plant in the City of Namyangju, Gyeonggi
Province, is responsible for purifying and supplying safe and clean water
to residents and businesses in Hwado, Hopyung, Pyungnae, Soodong
and Choan. It pumps more than 55,000 m3 a day.
To supply safe and clean water, Hwado purification plant relies
on a control system to handle various water treatment processes.
These include water intake, coagulation, flocculation, sedimentation,
filtration, purification (disinfection) and distribution.

Challenge
Prior to 2005, the plant employed
a distributed control system (DCS)
to run these operations. However,
maintenance costs for the DCS were
high, and it was not always easy
to get prompt and consistent
technical service.
The plant faced another challenge
with the human-machine interface
(HMI) software used with the DCS
system. In the water purification
process, controllers turn pumps
off and on, open and close valves
and send operating conditions
temperature, electricity, flow level
and other relevant data to a master
controller in the main control room.
Visibility of this information through
the HMI software is critical since it
allows operators to monitor and track
all of these parameters.
The database software that the plant
had in place, however, was not able
to display more than 20 days of data
at once. Due to a high volume of
data traffic, retrieving the data
over the network also took a long
time. Furthermore, when making
modifications or adding operations
to the HMI, software had to be
updated on all of the controllers
on which it was installed.

Solutions
Hwado purification plant decided
it needed to update its control
solution. Rather than invest in
another DCS system, however, it
migrated to the PlantPAx Process
Automation System. A core part
of the system are the ControlLogix
Programmable Automation
Controllers (PACs) that help make
up the Rockwell Automation
Integrated Architecture platform.
The plant installed fully redundant
CompactLogix and ControlLogix
controllers. The fully redundant
architecture protects critical
processes from unexpected
shutdowns, allowing programs
to be automatically cross-loaded
from the primary to the secondary
controllers. If the primary controller
fails, control is automatically
switched to the secondary system.

Sedimentation station

The system runs on an EtherNet/IP

network and uses RSLogix 5000
software to program the PACs.
We definitely needed to change
our control platform due to the
high maintenance costs of the DCS
system. We wanted another control
system with lower operating costs
and better flexibility. Rockwell
Automation PlantPAx was the
answer. The high capacity and
advanced Ethernet/IP networking
allowed us to run the facility
effectively and efficiently, said
Ji, Eung-Su, Plant Manager of
Hwado water treatment facility.
Additionally Hwado water treatment
facility desired an HMI that was
interoperable with the PACs, and it
adopted the FactoryTalk View suite.
It allows operators to easily configure
applications anywhere on the network
and make changes to a running
system. Users can directly access
tag information in the controller,
eliminating the need to create
separate HMI tags. In addition,
operators can define graphics
displays once and reference them
throughout a distributed system.
After running FactoryTalk Site Edition
4.0 through 2007 and upgrading to
Site Edition 5.0 in early 2008, the
plant installed FactoryTalk Historian
to collect data at high speeds in real

time. This solution optimizes

processes through the analysis of
historical data. Operators can collect,
store, evaluate and visualize data
using a powerful engine and
reporting tools such as time-series
trends, bar and pie charts, and Pareto
and tabular trends. We didn't hesitate
in migrating our historian after working
with the Rockwell Automaton
controllers and HMI software. Our
experience with the scalability and
interoperability of Integrated
Architecture made it an obvious
choice, explains Ji, Eung-Su. The
plant continued to upgrade and in
2009 installed FactoryTalk ViewPoint,
a web based HMI that provides quick
and easy viewing of plant-floor
applications. It enables a maximum
15 users access to FactoryTalk View
server simultaneously from anywhere
using the simplicity of a Web browser.
Another important element
of the solution was the use of the
Allen-Bradley Powermonitor 3000.
Twenty-three sets were installed
in the pumping station, electrical
room, purification equipment and
water-discharging equipment to
monitor the proper power (electrical)
flow at each group of facility.
The Rockwell Automation process
automation solution provided us
greater value from a single platform.

The platform based on Integrated

Architecture optimized control,
production management and
maintenance.

Results
Since migrating from a DCS system
to the Rockwell Automation PlantPAx
process automation system, the single
platform single controller, software,
network resulted in significant TCO
(Total Cost Ownership) savings helping
to reduce installation costs by over
50%. Overall, operation cost has been
cut down by 13% over 2 years according
to the facilitys management. Less time
was spent on troubleshooting and
unscheduled downtime across the

facility was reduced significantly. In

addition, the plant saved data storage
cost due to FactoryTalk Historian.
Overall, the scalability and flexibility of
the Rockwell Automaton PlantPAx
solution has helped Hwado water
treatment facility concentrate on its
number one priority delivering safe,
clean water to its customers as
efficiently as possible.

The results mentioned above are specific to Hwado Treatment Facilitys use
of Rockwell Automation products and services in conjunction with other
products. Specific results may vary for other customers.

Main Control Room with FactoryTalk View suite

Filtration station and electrical room with CompactLogix

Powermonitor 3000 in electrical facility

FactoryTalk Historian Site Edition

Allen-Bradley, ControlLogix, Integrated Architecture, Kinetix, MP-Series, PanelView, Rockwell Software and RSLogix are trademarks of Rockwell Automation Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication WATVP-AP003A-EN-E July 2009

Copyright 2009 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.