Columbia University, New York, New York
Donohue & Associates, Chesterfield, Missouri, and Sheboygan, Wisconsin
EB ENVIRONMENTAL, Houston, Texas
Ekologix Earth Friendly Solutions Inc., Waterloo, Ontario, Canada
EMA Canada, Inc., Oakville, Ontario, Canada,
EMA, Inc., Trevose, Pennsylvania, Sacramento, California, and St. Paul, Minnesota
Endress+Hauser Inc., Greenwood, Indiana
EnviroSim Associates Ltd, Hamilton, Ontario, Canada
GHD, Bowie, Maryland
Greeley and Hansen, Chicago, Illinois
Hach, Loveland, Colorado
Hazen and Sawyer, New York, New York
HDR Engineering, Inc., Cleveland, Ohio
HRSD Nansemond Treatment Plant, Suffolk, VirginiaInflection Point Solutions, LLC, Overland Park, Kansas
Johnson Controls, Inc., Westerville Ohio
Lagrange Consulting, Snellville, Georgia
Macon Water Authority, Macon, Georgia
Malcolm Pirnie | ARCADIS U.S., Inc., White Plains, New York and Phoenix, Arizona
modelEAU-Universite Laval, Quebec City, Canada
Parsons Corporation, Pasadena, California
Pondicherry Engineering College, Puducherry, India
San Jacinto River Authority, Conroe, Texas
Schneider Electric, Knightdale, North Carolina
Severn Trent Environmental Services, Fort Washington, Pennsylvania
SoftwareToolbox, Inc., Matthews, North Carolina
Stevens Institute of Technology, Hoboken, New Jersey
Toho Water Authority, Kissimmee, Florida
Chapter 1
Introduction to Automation of Water Resource Recovery Facilities
Robert D. Hill, Ph.D, P.E.
1.0 WHAT IS COMPLETE AUTOMATION DESIGN?
2.0 MOTIVATION FOR UPDATING THIS MANUAL
3.0 TECHNOLOGY AS A STRATEGY, NOT A LIMITATION
4.0 WHAT THIS MANUAL DOES AND DOES NOT INCLUDE
6.0 MANUAL OF PRACTICE CHAPTER CONTENTS
1.0 WHAT IS COMPLETE AUTOMATION DESIGN?
Complete automation design is a philosophy that attempts to fully integrate all dynamics of an automation system design with the goal of eliminating possible errors in design and operation while simplifying the control system. This approach looks at the design of automation hardware, the design of software to be used, the design of application-specific coding, and how to convey these data to the contractor. Accomplishing these goals requires several layers of documentation, with each document designed to address different challenges or potential sources of errors. This manual specifies the type of decisions, text documents, and drawings required to perform a successful complete automation design project.
In this manual of practice (MOP), an automation system includes field instruments, communication of information to a controller such as a programmable logic controller (PLC), the controller itself, algorithms and rules (programming) for manipulating inputs, communications between the controllers and any human–machine interface (HMI), communications to control elements (such as valves and metering pumps), and the control elements themselves.
Complete automation system design requires tremendous attention to detail, arguably more so than other engineering disciplines. The design documents discussed in this manual reflect that attention to detail. Although every project will not need every document discussed herein, each project typically will require decisions on every detail before the automation system can be installed. In other words, someone will decide what to install, where to install it, where to put the wires, and how to program it. Whether that person is a design engineer, a general contractor, an electrical subcontractor, a systems integrator, a programmer, a computer-aided design specialist, an installation electrician, or a laborer digging a conduit trench depends on how complete the design documents are, which, in turn, depend on the owner’s design budget and the designer’s technical competence.
Ideally, the design engineer will make most of the decisions noted in the preceding paragraph. If left unaddressed, other parties may autonomously make decisions that suit their interests but not necessarily the interests of the project as a whole. These autonomous design decisions may result in inconsistencies across the project that can create challenges during installation, commissioning, operation, and future maintenance.
2.0 MOTIVATION FOR UPDATING THIS MANUAL
Although the automation field has matured, it is still changing rapidly. In the 2006 edition of this MOP, the following reasons were given for updating the manual; these are still valid today:
• Researchers and practitioners have improved the understanding of physical, chemical, and biological treatment processes and the best strategies to control them;
• Manufacturers have begun creating field instruments and equipment specifically for the wastewater treatment industry (rather than adapting ones made for other industries);
• Field instruments have typically become less expensive, more accurate, easier to calibrate, and sometimes self-diagnosing because of digital electronics, better human interfaces, and other new technologies;
• Networking and wireless (radio) communications have become less expensive, provide more capabilities, and are widely available (e.g., fiber-optic cabling is now common);
• Programmable logic controllers and distributed control systems (DCSs) are smaller, perform better, have more capabilities, and are less expensive;
• “Standardized”
