OBJECTIVES:

The objectives of the project were to (1) identify costs, benefits, and risks associated with
complete water treatment plant (WTP) plant automation; (2) identify the levels of
automation needed for unattended operation; (3) review regulatory requirements related
to unattended operation; (4) develop an economic analysis method useful to utility
decisions makers for evaluating the life-cycle cost/benefits of automation investments;
and (5) develop automation case studies demonstrating the approach.
BACKGROUND:
Water utilities are facing a number of trends that are having a broad impact on operations,
maintenance, and capital expenditures including increasing labor, energy, and chemical
costs. Advanced automation is viewed as a tool that can help to minimize the impacts of
many of these. Complete automation of water treatment plants, where the facilities run
unattended for some period of time, is used by many utilities as a cost savings strategy.
However, many utilities have not implemented complete automation yet for a variety of
reasons. An economic assessment methodology for automation projects would be useful
to utility decision makers.
HIGHLIGHTS:
This report provides the following information:
1. The current levels of automation available, requirements of different processes, and
regulations that impact automation decisions
2. Real world insight from other utilities including wastewater, hydroelectric, fossil fuel
power, and international water utilities
3. Comprehensive cost data for plant automation including design, capital costs, labor,
and maintenance allowing the rapid development of budgetary cost estimates for projects
under consideration
4. Utility case studies and sample economic calculations to enhance understanding of the
issues and concepts
5. Typical risks and practical mitigation measures based on utility experience
APPROACH:
The study included questionnaires, a review of literature and applicable regulations, an
evaluation of current economic analysis techniques, industry best practices, and case
studies. A water utility focus group provided guidance during the project. The intent of
this project was not to perform a statistically representative survey of the water industry
regarding this topic, but to provide several utility automation experiences for
consideration. To that end, six automation case studies were completed and are
documented in the report.
RESULTS/FINDINGS:
Automation is well established in the water treatment industry. However, better
instrumentation would help alleviate concerns about unattended operation. The
researchers discovered that unattended plant operation correlates well with plant size.
Most small surface water treatment plants are operated unattended while large plants,
over 100 mgd, are continuously attended.
Utilities do not apply a consistent methodology for cost-benefit analysis of automation
projects and it can be difficult to justify every automation project based solely on the
return on investment (ROI), that is, the tangible benefits. Adopting a more
comprehensive balanced approach which considers both tangible and intangible
(strategic) benefits is not only more helpful in justifying an automation project, but also
more realistic. An investigation of typical savings produced by applying advanced
automation showed the following range of values: chemical savings of typically 15 to 40
percent; labor savings of typically 5 to 30 percent, with some higher values reported with
unattended operation; and energy savings of typically 5 to 35 percent. Some of these
savings may be attributable to applying a greater level of automation. Not all these
savings are attributable exclusively to unattended operation.
A major conclusion drawn from the research was that water utilities should employ
recognized industry methodologies for justifying automation projects. A formal approach
has been conspicuously lacking in the past. Developing a credible business case helps
clarify project goals and scope and enables management to make informed decisions. The
methodologies and tools provided as part of this report should help utility staff meet this
goal.
IMPACT:
This report includes information on the current levels of automation available, other
industry experience, and cost information; utility case studies and sample economic
calculations to enhance understanding the issues and concepts; and tools that will allow a
tailored analysis to the unique utility automation situations. The authors believe that the
report provides a unique and comprehensive source of information, methodologies, and
examples for use by decision makers involved in the evaluation and planning of water
treatment plant automation projects, specifically, automation projects that facilitate
unattended operations. The report provides information not only on the technical aspects
of automation but also from a business perspective.
MULTIMEDIA: