Process Automation Competency
Process Automation Competency
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Content Page
References 14
Festo Didactic 30
Product overview 31
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Why use pneumatics for water systems?
Water is a precious commodity ments of water and wastewater Festo is well placed to give you 56 national companies,
all over the world, one which treatment. Pneumatics, one of this information. A leading 12,000 employees and a dense
humanity needs to be even the indispensable core tech- innovator in manufacturing and customer service network in
more careful in using as con- nologies for automation, has process automation, Festo has more than 170 countries means
sumption levels rise. Industrial the additional advantages of been active for many years in that users all over the world can
automation of potable, and robustness and cost-effective the area of water treatment, rely on us to supply them at very
wastewater treatment plants system solutions. with complete, single-source short notice with components,
ensures customers have access This brochure therefore not only automation solutions tailored subsystems and systems for
to this high quality resource tells you about the advantages to meet the needs of plant automation tasks. For more than
when ever it is needed. of pneumatics, but also informs operators. Including intensive 300,000 industrial customers,
Pneumatics presents a valuable you about stimulating and consultation and support Festo is a valued business
and extremely reliable alter- economical applications in through all the specific project partner.
native to electrical automation potable water treatment and steps of value creation.
systems, especially when it wastewater treatment across
comes to meeting the require- Europe.
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The advantages of pneumatics
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Ethernet
Fieldbus
Valve terminal CPX/MPA in control cabinet Valve terminal CPX/MPA in control cabinet
Butterfly Butterfly
valve with valve with
pneumatic pneumatic
actuator actuator
Example: Waterworks
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Web monitor
Intranet
Valve terminal CPX/VTSA in control cabinet Valve terminal CPX/VTSA in control cabinet
One interface – from the com- defined and standardised inter- Markedly more efficient:
mand level to the field level face between the control systems with pneumatics
The valve terminal forms the system (PLC) and the valve • Save more than 50% in your
central element of the decen- terminal – the fieldbus. budgeting – with fieldbus,
tralised system. In the vicinity Further advantages of this valve terminals and pneumatic
of the process valves, it is ideal universal solution – whether actuators
for quick and simple automa- setting up a new automation • Faster startup and fault
tion solutions in which valves, system or integrating into an elimination
pneumatics and electronics existing one – are the modular, • Considerably simpler
coalesce. The valve terminals easy-to-expand fieldbus design installation
may be fitted in a modular and the ease of connection to • Fewer interfaces due to
structure, depending on the the bus for expansions, without harmonised components and
number of valves. This system making any modification to the modules
solution has just one clearly installed hardware. • Competent and expert advice
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Greater transparency and clarity in operation
Reliability at startup and The positions of the valves are Furthermore, functional blocks
during operation reported by the limit switch or system components can
Valves and their actuators are modules. The LEDs on the input be grouped together and these
usually distributed throughout modules of the valve terminals groupings applied to the
the plant and are therefore show the current valve posi- configuration of the valve
hard to access. Once the plant tion. The same procedure terminals. This helps to auto-
is entirely connected with applies in the case of inspec- mate complex plants in a clear,
wiring and piping, each valve tions. modular, integrated system,
can be tested very simply at dry where everything falls into
startup one by one from the place. The operator benefits
control cabinet. The valves are from greater transparency.
operated with manual override
and applied pilot pressure.
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The advantages at a glance • Valve terminal in the control • Automatic/manual modes,
cabinet wired ready for selectable for clear and
connection definite operating status
• Control cabinets structured • Manual operation also for
in consultation with the inspections or elimination of
operator and plant engineer malfunctions
• Valve terminal takes on the • Signalling by LED for local
role of local controller transparency
• Dry startup to test functioning
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Simple and maintenance-free: the actuators for process valves
Pneumatic actuators provide Very direct for greater The quarter-turn actuator
considerable advantages over reliability principle
electric actuators when it The pneumatic actuator is The actuator’s shaft acts direct-
comes to automated processes, directly flange-mounted to the ly on the stem of the valve,
thanks to their simpler and valve, without any further moving it from 0° to 90°.
more direct setup. gearing. The “Open/Close” The flow of escaping air can be
function action also triggers the restricted, allowing adjustable
limit switches at the same time. actuation speeds. The limit
The result: fewer moving parts switch module indicates the
and greater reliability in func- valve position visually. At the
tioning. same time, the integrated limit
switches are triggered.
Watchdog timing in the control
system allows monitoring
of the opening and closing
operations.
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The linear actuator principle Overall, linear actuators are
In linear actuators, the piston fast and durable: very short
rod acts directly on the gate of time intervals when controlling
the gate valve. In contrast to flow and more than one million
electric actuators, this action strokes in continuous operation
produces no wear, which is make them ideal for reliable
particularly important when and heavy-duty solutions.
the valve is used as a “dosing
valve”, for example, and is
therefore actuated frequently.
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Versatile in application: the actuators for process valves
First-class technology ensures • Special version available for ISO and NAMUR standards
versatile application options up to 20 meters head of fluid • Actuator flange mounting:
for Festo's quarter-turn and pressure, e.g. in drinking EN ISO 5210/5211, DIN 3350
linear actuators: water fountains • Installation of limit switch
• Configured as standard for • Temperature range -20 °C to modules and solenoid valves:
explosive atmospheres up to +80 °C, as standard NAMUR, VDI/VDE 3845
Zone 1 • High-temperature versions
• High corrosion protection for to +120 °C
exposed outdoor use • Low-temperature versions
• Optional: complete stainless to -40 °C
steel versions
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The advantages at a glance:
• Reduced size due to greater power density
• Reduced weight with smaller nominal diameters
• Simple setup and few attached parts
• High switching cycle rate, easy-to-adjust opening and
closing times
• Overload proof and 100% duty cycle, superbly suited to
variable-speed actuation
• Simple connection technology for fast installation
• Maximum of just 2 I/2 O from the point of view of the PLC
• Low current consumption, usually less than 2 A at 24 V DC
• Emergency functions in the event of voltage drop
• Actuation functions: open/close operation, stopping in
intermediate positions, positionable across the entire stroke
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Ultrafiltration plant in Roetgen waterworks
Germany’s biggest ultrafiltrati- then passes through the More than 25,000 cycles p.a. –
on plant is operated by WAG second stage for deacidifying, thanks to pneumatics
Nordeifel in Roetgen. Following hardening and reduction of The ultimate high performance
extensive testing, the company manganese. A further UF plant, with up to 144,000 m3 of
decided to construct a new UF membrane stage is used to treated potable water per day,
plant as a prefiltering stage. treat the backwash water. using a filter surface area of
The reservoir water is now There is regular backwashing approximately 70,000 m2: only
treated in two stages. with chemical-free filtrate or with pneumatics is this techni-
with caustic soda and sulphuric cally and economically feasible.
The first stage separates out acid. The main membrane plant One treatment cycle, consisting
bacteria, viruses and micro- consists of 12 hydraulically of filtering and backwashing,
organisms. The filtered water optimised skids. takes about 30 minutes. That
makes more than 25,000 cycles
per year.
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Festo as a partner for operators, • Definition of the plant The technical solution
planners and plant engineers standards for the pneumatic • Valve terminals with Profibus
• Very close collaboration with valve and actuation technology DP communicating with the
the plant operator and the • Calculating the actuation PCS7-400 from Siemens
planning company in the characteristics for valves • 27 valve terminals
initial design phase CPX/MPA1+2, double pilot
• Consultation and presentation Pneumatic systems rise to the valves, configuration with 5
of the automation solution challenge in areas of: to 24 solenoid valves
• Support in designing the • High switching frequency about • 27 fully assembled and tested
layout of the compressed air 25,000 open/close actuations filter-regulator service units
network and in estimating annually • Accessories such as QS
consumption levels • Short response times between fittings, pressure switches,
2 - 3 seconds to reduce back- on-off valves
wash times
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Pressure filter plant at Kleine Kinzig waterworks in the Black Forest
As well as being a source of The untreated water from the Tried and proven: Pneumatics
drinking water, the Kinzig dam dam flows at a full input The actuation systems were
is also used for flood preven- pressure of about 6 bar from initially planned to be fully
tion, increasing low-water lev- the dam through the preliminary electrical, because of prior
els and renewable energy gen- purification stage. A total of experience with this technol-
eration. Towards the end of eight pressure filters are used. ogy. After intensive investiga-
2004, a new treatment plant After the prefilter stage, it is tion, including study of other
began operating as a prelimi- conveyed through a generator plant operations, the decision
nary purification stage. It is to a discharge basin and from was made in favour of pneu-
designed to maintain the high there into the second filter matics.
quality of the drinking water, stage. The maximum daily
even when the untreated water throughput is around 67,000 m3.
is heavily clouded.
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Decisive factors in favour of • Expert advice during the What components and systems • More than 70 quarter-turn
pneumatics planning phase, also with are used? actuators for wafer-type and
• Reliable technology due to regard to automated • Communication between PLC double-flanged butterfly
the simple structure of all the processes and valve terminal CPX/Typ03 valves, DN 100 to DN 250
pneumatic components • Training of operating via Profibus DP • Filter-regulator service units
• Reductions in cost of capital personnel after startup • 2 valve terminals per control with pressure switches
assets and installation • Close collaboration with the cabinet, tested and delivered • Tubing and accessories
• Robust and maintenance-free valve supplier VAG ready for installation
together with long service life • Long switching times for the • A total of 4 control cabinets
• Easy-to-operate pneumatic actuators of up to 30 sec for the 8 double-row filters
automation
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Waterworks in Briosco for CAP Gestione
CAP supplies 196 cities and Another, new project in Briosco Reliability matters
districts in the Italian regions was now again realised using Good experiences from
of Milan, Lodi and Pavia with system solutions from Festo. previous projects realised
drinking water. For a number Manganese is eliminated by using pneumatics led once
of years now, CAP has been oxidation with subsequent again to an economical solu-
committed to Festo pneumatics filtration in the waterworks. tion. The valves in this plant
as the standard for automation are equipped with manual
in their waterworks. operation and spring-force
closing pneumatic actuators.
Limit switch modules are
mounted on the actuators
for position sensing.
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Decisive factors in favour of • Easy-to-operate pneumatic Festo’s services and systems
pneumatics automation • Modular assembly of
• Quick and simple project • Expert advice during the 14 valves with manual
realisation, because every- planning phase, also operation and single-acting
thing was from a single with regard to automated actuators
source processes • Design and installation of
• Reliable technology due to 2 control cabinets with
the simple structure of all the separately structured valve
pneumatic components terminals, each configured
• Reductions in cost of capital with 7 solenoid valves
assets and installation • Supply of all pneumatic
• Robust and maintenance- component accessories
free together with long
service life
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Central wastewater treatment plant Grésillions, Paris
The SIAAP, an association of the plant rather than the Fully functional: from mecha-
integrating all the municipal conventional activated-sludge nisms to data control
authorities responsible for tanks. Initially, the influent is The main automation task for
sewage disposal in the greater cleaned mechanically with the Festo was the automation of
urban area of Paris, operates aid of screening fixtures and the twenty-eight biological
a central treatment plant in sand traps. This is followed by filters. This also involved data
Grésillions near Paris. In the the biological purification collection and control for all
plant, up to 100,000 m3 of phase, in which the pretreated filter tank data.
wastewater is purified daily, sewage is conveyed through
using a special filtering tech- three different filters. In this
nology in the biological stage phase, the special “Biolest”
procedure comes into opera-
tion, during which denitrifica-
tion takes place.
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Economical, reliable and • Fieldbus connection between • Specialised actuators, 28 x
innovative: the solution the valve terminals and the DLP-250-800-S2, to control
• Significantly faster implemen- central Allen Bradley control the gate valves at influx
tation thanks to coordination system, via DeviceNet. • Comparative measurements
and intensive consultation at • Integrated intelligent func- of air consumption to detect
the start of the project tions (FEC) for local valve any leaks
• Close collaboration with control
plant engineers and the valve • IP67 for an open installation
supplier Fontaine without safety enclosures,
• Installation of 28 decentral- making the solution simpler
ised electric CPX terminals and cheaper
and MPA valve terminals, • Compressed air preparation
each with six valves units for all systems
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Wiesbaden main wastewater treatment plant and Wiesbaden-Biebrich wastewater treatment plant
Since the end of 2006, Wiesba- 1. Biological phosphorus so that nuisance odours are
den’s wastewater has been removal (BPR) virtually eliminated. At the end
treated in just two large plants: 2. Denitrification stage of 2006, construction began
the main wastewater treatment 3. Nitrification stage with on the two new digesters, the
plant and the Biebrich waste- internal recirculation thickener and the powerhouse.
water treatment plant.
The Biebrich wastewater treat- Pneumatics preferred
The main wastewater treatment ment plant is situated in the Before starting work on the two
plant is one of the most modern middle of a residential and treatment plants, the operator
in Europe. Between 45,000 and commercial area. The complete made a clear decision to use
75,000 m3 of sewage is purified purification of about 19,000 m3 pneumatic actuation and auto-
there daily. Phosphorous and of sewage daily using fixed bed mation technology – with the
nitrogen is extracted in a spe- technology therefore takes categorical choice of Festo as
cial “three stage solution”: place inside the building, preferred supplier.
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A winning combination: • Close co-operation with the Festo pneumatics as standard
pneumatics and Festo valve suppliers for gate and • More than 700 actuators for
• Long service life butterfly valves gate and butterfly valves
• Maintenance-free thanks to • Expert advice in the area of • Over 70 type 02 valve
lifetime lubrication actuation and automation terminals built into the
• Sturdy construction and high technology control cabinet
corrosion resistance • Long-term availability of • Connection via fieldbus,
• Use in explosive atmospheres products Profibus DP
without additional costs • Same control cabinet • Filter-regulator service units
• High reliability of all compo- structure for both wastewater with pressure switch for
nents used due to Festo’s treatment plants monitoring of availability
industry standard • Components easily inter- • Push-in fittings and tubes
changeable
• Simple handling for manual
operation
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Central wastewater treatment plant Athens
Psyttalia Wastewater Treatment 12 activated-sludge beds with To control the flow of the bio-
Plant is the name of an ambi- a volume of nearly 300,000 m3 gas generated in the digester,
tious project on the island of and a flow rate of 1,000,000 m3 quarter-turn actuators were
Psyttalia in the Saronic Gulf, per day. used. The biogas generated by
the bay in front of Athens and the fermentation process in the
the port city of Piraus. The Gigantic dimensions: mastered digesters is utilised to meet
wastewater is pumped through with pneumatics the energy requirements of the
a 1.5 km long pipeline from The flow of the sludge into wastewater treatment plant.
the mainland to the waste- the digester vessels is con- The actuators also regulate the
water treatment plant on rocky trolled by pneumatic linear distribution of hot water for
Psyttalia island. The technical actuators of the DLP type. the heat exchangers, which
specifications take on gigantic These act directly on the gate maintain a constant tempera-
proportions: the biological of the valve, enabling variable ture of 36 °C in the digester
treatment stage comprises opening and closing. vessels.
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Founded on trust: decision in • Maintenance-free thanks to Festo pneumatics proves its
favour of Festo systems lifetime lubrication worth – in the Aegean as well
• Established expertise and • Sturdy construction and high • 50 actuators for gate valves
trust built up through long- corrosion resistance, even in in the area of sludge handling
standing collaboration with outdoor areas • 40 quarter-turn actuators for
the responsible plant • Use in explosive atmospheres butterfly valves in the area of
engineers without additional costs biogas and digester heating
• Constant support through the • High reliability of all compo- • Multiple type 03 valve
planning and implementation nents used due to Festo’s terminals built into the
phase industry standard control cabinet
• Long service life of compo- • Connection via fieldbus
nents • Service units with pressure
regulation and filtering
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A good track record is the best recommendation
The examples described • Constant advice and support • High reliability in operation
previously are just a few throughout the phases of • Overall more than 50 % lower
representative projects auto- the project costs when compared with
mated in recent years by Festo • Winning pneumatics solutions purely electrical automation
pneumatics. based on reliable and solutions
There are without a doubt innovative technology
many arguments which speak • Explosion protection,
in favour of Festo’s ingenious corrosion resistance and over
pneumatic solutions. load protection all included
A summary of the most im- • High feasibility and high
portant points: transparency from the field
level to the command level
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That’s why Festo pneumatics Waterworks Wastewater treatment plants Germany Augsburg
continues to prove its worth Darmstadt
today, working hard in more Croatia Butoniga Austria Graz Marburg
than 100 waterworks and more Telfs Mönchengladbach
than 200 wastewater treatment Germany Berlin München, Großlappen
plants every day. The following Bischofswerda Denmark Korsoer Neckarsulm
is a small selection of locations Dresden Sindelfingen
across Europe: Roetgen Stuttgart-Mühlhausen
Wiesbaden
Hungary Tatabanya
Hungary Budapest
Poland Poznan Pecs
Poland Bedzin
Rypin
Nieszawa
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Products and services: benefits for our partners
Choosing the right partner • Consultation and project Close at hand and quick to
from the start is a vital factor engineering respond
in the successful realisation of • Intensive collaboration and • Planning engineers in the
complex ventures. Festo pro- development of the auto- region
vides timely guidance every mation strategy • Replacement parts supply
single step of the way through • Compiling corresponding in the region
projects for water treatment or specifications for the project • 24-hour-replacement parts
sewage disposal. With fast and • CACOS: tool for calculating service
expert advice during planning, the switching time of process
and afterwards as well: valves
• AirCon: tool for calculating
compressed air requirements
• Water/Wastewater planning
manual
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Tailored and targeted: Exactly what you need to help
support services you conclude the engineering
Concrete support across the phase faster, for example.
entire value chain is guaran- To give you reliability in order-
teed with our numerous ing and supply. To simplify
support services. Profit from installation and startup.
the excellent automation know- Or to keep operations running
how of Festo’s specialists. securely and smoothly.
Overall, you increase your plant
availability and reduce your
procurement costs: it all means
added value.
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Festo Didactic
As for any industry, well- down training system. The pro- • Can be used at all qualifica-
grounded training in water cess control system for develop- tion levels
management systems requires ing the skills and knowledge • With attractive product
modelling and learning facili- required for process engineering ranges for project and team
ties that reflect real-world con- is based on the same successful work
ditions. “Learning by doing” concept:
and “process orientation” are A glance through the contents
two principles that are central • Modular station structure of the teaching and training
to the successful achievement • With industrial components courses quickly reveals that
of these training aims. Model- and standards this system provides an effec-
ling of a process engineering • With open interfaces for tive learning environment for
plant on a PC provides one various automation devices technicians working in the
opportunity, alternatively to • Individually configurable and areas of water supply, sanita-
hands-on-training on a scaled- extendable tion, sewerage systems and
related industrial services.
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Partner for water technology
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Festo worldwide