Automation

in
Water Treatment Plant
Systems
Loo Shu Pey
Business Development Manager

FESTO Malaysia

E-Mail.: shu_pey_loo@festo.com
Phone : 012 2383782

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 Festo the Company

Headquarters Esslingen (near Stuttgart)

Established 1925
own companies in 52 countries world wide
Approved dealers in further 36 countries
Service and support in 176 countries world wide
Turnover 1.2 billion Euro
Export 55%
Employees 10,050
Investment in R & D 7%

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Festo the Company

Customer Service Centre St. Ingbert-Rohrbach

world wide delivery volume 6,500,000 items/year
approx. 29,000/day
over 70 tonnes/day

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 Festo Malaysia

HQ in Kuala Lumpur with Branches at Penang,

Ipoh, Malacca and Johor Baru.
Extablish in 1978.
80 employees with 50% technical staff.
ISO 9000 Certified Company

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Existing Technology

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Pneumatic technology

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Pneumatic Solution Gate Valve

47,000 N @ 6bar air

supply

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Pneumatic Solution Penstock Valve

47,000 N @ 6bar air supply

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Pneumatic Solution Butterfly Valve

8,800 Nm @ 6bar air supply

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Pneumatic Actuators
Function

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 Comparison
Electrical vs Pneumatic

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Control of process valves by using pneumatic
actuators
State of the art Advanced technology with FESTO
with controllable electrical actuators controllable actuators
Linear and rotary actuation

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 Electric actuator -HV power cable / 415V/50Hz 3-phase
- 5 cables

-Control cable max. 24V/DC

-3 x overheat detectors / electrical winding
-2 x 2 torque switch
-2 x 2 mechanical limit switch
-1 x flasher unit for running indication

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 Pneumatic actuator -Air-connection from ring-main
-tubing of plastics / metallic

-Control cable max. 24V/DC

-2 x 2 mechanical/proximity limit switch
-1 x 2 solenoid valve

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 Electrical / pneumatic connection
6 bar
3-phase Compressed Air
Power supply 415VAC supply
(5 core) (2 tubes)
Control Control
Cable Cable , 24VDC
(min. 12 cores) (2 cores)

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 Electrical / pneumatic connection

Power Cable
Amour Cable 4 X 2.5 mm (min)

Control Cable
Electrical Actuators
Amour Cable 12 X 2.0 mm
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 Electrical / pneumatic connection
Sensors 24VDC
Pneumatic Cable Sensor Box
Actuator

Festo Polymer Tubing

Festo Pneumatic Actuators

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 Number of motors

If we want to operate 48 units of butterfly valves,

For electrical actuators solution:-

You need to operate 48 units of motors.
415AC

If we want to operate 48 units of butterfly valves,

For pneumatic actuators solution:-
You only need 2 units of motors.

2 units of compressors 24VDC

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 Cost structure of systems : Electric / Pneumatic
actuators + logic control
in
Investment

Basic price
for
Valve-terminal

Pneumatic
Valves in
Valve-terminal

No of Process Valves / Actuators

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Pneumatic actuator sealing system

Complete piston with slide

ring
Pressure compensation slots for pressure reduction
Cylinder diameter e.g. DN
160
Slide-strap
Sealing
Sealing
End position damper

Form geometrical seat Pressure activating slot

Piston of Al-alloy
Static O-ring sealing

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 Pneumatic actuator

Festo Pneumatic Linear Festo Pneumatic Quator

Actuator Turn Actuator
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 Closing / Opening
time ON 2 sec.
OFF 20 sec. Adjustable !!
Drive speed +
Re-adjustable
Fixed !! output speed
output speed BOTH
+ directions
Frequency controller independant
required
for speed change

Minimum Closing time Minimum Closing time

Knife-Gate Knife-Gate
DN 200 = 30 sec. DN 200 = 2 sec.
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 ON OFF / Control actuator &
guaranteed mechanical life- time

ON-OFF Control ON-OFF & Control

-20,000 cycle -200,000 cycle -2,000,000 Cycle
-25% duty cycle + add price -25% duty cycle -100% Duty cycle

1 actuator design

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 ON OFF actuator Control actuator

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 Power failure
Energy / power failure Configurable
Safety Position
Either control & / or 1. ON
Power supply failure 2. OFF
= STOP 3. Hold

Manual

Knife- Gate DN 200

Requires min.
16 x 40 = 640
Turns on the
handwheel

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 Enclosure on PA actuators requires fully
encapsulated actuators to IP 67

- Heat up
-Limited cycle duty
- 20.000 ON-OFF
-200.000 Control
-Permanent heating required
because of condensation
- No internal corrosion protection
- IP subjected to strict conditions
-IP 68
with unlimited under water
Installation
-No temperature influence
-No influence by moisture

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 Protection again Lightning

-Not sensitive to lightning.

-Only solenoid coil damage

=
-Electrical and Electronic component
Very Economical
are very sensitive to lightning
=
-Can still run on secondary
Very Expensive
pneumatic supply
-Permanently cannot function
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 Explosive atmospheres

Requires special Standrad

Devices Equipment
WITH =
& adder price Ex safe
Certified (ATEX)
NO
Adder pricing

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 Maintenance + wear & tear

Maintenance:
-Maintenance Free
Maintenance: -No battery required
-Lubrication of gearing -No lubrication required
+ cleaning of spindle thread Oil/grease free
-Water Condensation check
-Regular change of Oil Sealing
-Back up battery replacement

NO contamination
of
Water

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 Spare Part

Electrical actuator Pneumatic actuator

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 Control System for Electrical Actuator

Isolator Panel for Electrical actuator LCP for Electrical actuator

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 Control System for Pneumatic Actuators

LCP for Pneumatic actuators Control system for Pneumatic actuators

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 Friction losses
-Tremendous increase of torque requirements -Piston sealing = pressure dependent
at non- lubricated spindles -1 force/direction
= mechanical damage -Oil- free = NON SLIP STICK
-Torque switch required to prevent motor overload -Exact force determination
- NO Overloading

Low efficiency
with
similar losses
+ High efficiency
wear / tear with
all over the stroke lowest losses
+
less wear / tear
all over the stroke

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 Settings of end positions Torque / Force
adjustment
by
pressure regulator
NO-LIMIT rotary / multi turn actuator

-Required skillful and

trained personnel
-Adjustment & setting must Adjustable
be perfect mechanical
End - stop

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 Process Valve connection

ISO 5211
with
Rendered interchangeability

identical

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 Failure detection
Skilled & trained electricians
needed to check the circuits No special skills required
for failure detection Detection either by
-High Voltage (415 Vac) Air- blow
(DANGEROUS) Or
LED indication
NO
Special measuring
devices
- Low Voltage (24Vdc)
(SAFE)

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 Profibus dp
Bus Communication for E-Actuator
Connection to PLC
via
400 V/50Hz - AC -Profibus dp

Bus - Interface

&
-Plug socket connector
-Relais board
-Power supply board
-Fuse board

&
Required for every
Single actuator
- -

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Bus Communication for P-Actuator Profibus dp

Compressed air 6 bar

+ Hart protocol
Measurement datas :
- Level 4-20 mA
- Pressure 0-10 V
- Flow 4-20 mA
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 Torque values correlating to size of actuator

Nm 30 60 120 250 500

10 30 45 60 65 80 106 120 170 180 230 240 300 360 470 480 550 670 84

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 Price comparison

Nm 30 60 120 250 500

10 30 45 60 65 80 106 120 170 180 230 240 300 360 470 480 550 670 84

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 Valve Size DN
Required torque value - Nm

(Butterfly-Valve)
1200 600

900 Pneumatic actuator 500

400 400

300 300

200 200

100 100

40 Electric actuator 50

20 25
1.000

1.500

2.000

2.500
250

500
50

Price / actuator ()

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 Festo Pneumatic System

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Festo Valve Terminal
1.Electric
Digital : I/O
Analogue : I/O
3.Control
Communication
Interface
-Multipole
-Bus
-........ 2.Pneumatic
Pneumatic Valves
Various combinations
3/2 ; 5/2 ; 5/3 .......
Module for pneumatic connection
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 Modbus connection

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Profibus DP connection

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Control of pneumatic / electric sub systems and .......
Profibus dp
Connection to PLC
via
-Profibus dp

Measurement datas :
- Level 4-20 mA
+ Hart protocol

- Pressure 0-10 V
Record of all
- Flow 4-20 mA
limit switches

Segment coupler
- digital inputs-

Profibus PA

Pneumatic supply :
Control Line :
PLC / BUS Cable:

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.... Electric devices as pumps, actuators ............. As
controller
Connection to PLC
via
-Profibus dp
Pumps Control:

Electric actuators
Electric devices :

Pneumatic supply :
Control Line :
PLC / BUS Cable:

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Pneumatically controlled circuit/using 1 Valve Terminal for
1 Filter ELECTRICAL SIDE PNEUMATIC SIDE

Measurement datas : Clean Back Wash Back

- Level Raw Water Water Water Wash Air
- Pressure
( 3 AI + 1 AO )

Sludge Water Emptying Exhaust Filter

Record of all
limit switches
Manual push buttons for : ( 16 DI )
- Backwash
- Auto / Manual
- Funktion selection Exhaust
( 12 DI + 6 DO ) Filter bottom
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Festo Solutions in water Treatment Plant Control

Connection between Festo Profibus

Valve Terminal and Pneumatic Actuator

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Field-based logical control
PLC,Fieldbus ......
- Bus Structure &
- Multipin structure

Sandfilter X Sandfilter Y

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Pneumatic connection 2 GI Pipe-For Main
Compressed Air

On Off 1 inch Local Control Panel

valve Remote/Local Mode Inlet
Penstock

Service Unit Regulate

and filter condensate
Water
Polymer
Tubing

Drain
Penstock

Filtered Filtered
Water Valve Water Valve
Air Scour Air Scour
Valve Valve
Wash Water Wash Water
Valve Valve
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Bus Structure
e.g. Profibus DP
4-wire system
(Profibus EN 50170)

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 PROPOSE AUTO CONTROL LAYOUT
Wash Water Tank (Level
Compressor Room Control)
Exiting Blowers (Compressor Control)
System

Wash Water Tank

All level sensors

Main for filter bed tanks
Color Touch Screen PLC

Filter Bed No.1 Filter Bed No.2 Filter Bed No.3 Filter Bed No.4 Filter Bed No.5 Filter Bed No.6 Filter Bed No.7 Filter Bed No.8

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 Water Treatment Plant Control System Overview
Plant 1 Plant 2 Plant 3
Filter bed Filter bed Filter bed Filter bed
1 4 1 4 Filter bed 1

Filter bed Filter bed Desludge and Wash Filter bed Filter bed Desludge and Wash
Filter bed 2 Desludge and Wash water
2 5 water 2 5 water

Filter bed Filter bed Filter bed Filter bed Filter bed 3
3 6 3 6

Color Touch
Color Touch Color Touch
Screen
Screen Screen
Main
Main Main
PLC
PLC PLC

Hub Hub
Hub

TCP/IP

TCP/IP
Compressor
Hub
Room

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 Automation with pneumatics a technical and
commercial useful alternative
Process leading system

Ethernet

local SPS / PLC

Fieldbus Fieldbus

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 Communication possibilities
- Remote without cabling
via GSM module
- Cable connection
- Ethernet connection and .

Remote diagnostics possibilty

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Benefits of using pneumatic WITH Bus communication
Tremendous reduction
- of I/O s
- bus nodes in the field Save Field Cabling
- bus cables from field to PLC
- using of diagnostic software for diagnosis top-down
- EEx safety only where necessary
complete electronic controls outside in non- EEx
areas
- combination of bus systems applied to the required solution

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 Pre-assembled

Process Valve
Controls

for ease of use and

installation

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Control cabinet (cubicle) pre assembled

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 Controller for 12 pneumatic
process valves !
Including :
Stainless steel cabinet
Typ CPV-10 valve terminal with :
8 x 3/2 solenoid valves
4 x 5/2 solenoid valves
Profibus-DP Fieldbus
Power supply
Service unit, preassure switches
8x Flow control valves
Connectors
Ready to use
Complete tested
Documentation

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 Compressor system for
water treatment plants

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 Compressed air circuit
PLC, Bus ...
Generation and Preparation

8.5 bar

6.0 bar

Compressor Storage Dryer

Outside area

Dryer

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Compressed air network for water treatment plant
Storage PLC, Bus ...

Dryer 1

8.5 bar
Compressor 1
6.0 bar

Compressor 2
Dryer 2
LCP

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Compressor installation in
a water plant

Compressor station

2 Compressors, redundant
Capacity / supply each 1 m/h

2 Expansion tanks each 1 m

Air expansion tanks are useful for

Running the water plant
for approximately 1 h

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Compressor installation in a water plant

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 Q&A

Thank you

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