Professional Documents
Culture Documents
Table of content:
2 P&ID Sheet 1 - Decanters, Reduction Units and Transfer tank T0301 ..............................................8
2.1 General introduction ...................................................................................................................... 8
2.2 Decanter DC3301 and DC3321 – M33x1, M33x2, V33x1, V33x8 and V33x5 ............................. 9
Description ...........................................................................................................................9
Settings ..............................................................................................................................10
Alarms ................................................................................................................................10
2.3 Feed pump and flow control feed decanter – P34x1, V34x3 and FIC34x1 ................................ 11
Description .........................................................................................................................11
Settings ..............................................................................................................................11
Alarms ................................................................................................................................12
2.4 Flocculant dosing control decanter – P19x1, F19x1, LC1902, V19x3 and FIS19x2 .................. 13
Description .........................................................................................................................13
Settings ..............................................................................................................................13
Alarms ................................................................................................................................14
2.5 Reduction unit – RU33x1 ............................................................................................................ 14
Description .........................................................................................................................14
Settings ..............................................................................................................................14
Alarms ................................................................................................................................15
2.6 Transport screw decanters – TS4601 ......................................................................................... 15
Description .........................................................................................................................15
Settings ..............................................................................................................................15
Alarms ................................................................................................................................15
2.7 Transfer tank T0301 – LC0301, MX0301 and P0301 ................................................................. 16
Description .........................................................................................................................16
Settings ..............................................................................................................................16
Alarms ................................................................................................................................16
3 P&ID Sheet 2 – Flocculant make-up unit T1901, Flocculator PF0801 and flotation unit FU2501 .17
3.1 General introduction .................................................................................................................... 17
3.2 Flocculator PF0801 – Flocculant dosing pump P1801, V1813 and FIS1802 ............................. 18
Description .........................................................................................................................18
Settings ..............................................................................................................................18
Alarms ................................................................................................................................19
3.3 Flotation unit FU2501 – Aeration and Skimmer – P2501, V2513, PIS2501, PIS2502, FIS2501
and SC2501 ................................................................................................................................ 19
Description .........................................................................................................................19
Settings ..............................................................................................................................20
Alarms ................................................................................................................................21
3.4 Flotation unit FU2501 – Drains – V2505, V2508A, V2508B and SG3701 .................................. 21
Description .........................................................................................................................21
Settings ..............................................................................................................................22
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Alarms ................................................................................................................................22
3.5 Flotation unit FU2501 – Sludge compartment – LC2502 and P2502 ......................................... 22
Description .........................................................................................................................22
Settings ..............................................................................................................................23
Alarms ................................................................................................................................23
3.6 Flocculant make up-unit T1901 – Various components .............................................................. 23
Description .........................................................................................................................23
Settings ..............................................................................................................................27
Alarms ................................................................................................................................28
4 P&ID Sheet 3 – Pump pit T0101, Curved screen CS0501, Buffer tank T321 and flotation unit
FU2801 ...................................................................................................................................................30
4.1 General introduction .................................................................................................................... 30
4.2 Pump pit T0101 and curved screen CS0501 – LC0101, P0101, V0501 and V0502 .................. 31
Description .........................................................................................................................31
Settings ..............................................................................................................................32
Alarms ................................................................................................................................32
4.3 Buffer tank T0321 – LC0321, MX0321 and P0321 ..................................................................... 33
Description .........................................................................................................................33
Settings ..............................................................................................................................33
Alarms ................................................................................................................................33
4.4 Flotation unit FU2801 – Aeration and Skimmer – P2801, V2813, PIS2801, PIS2802, FIS2801
and SC2801 ................................................................................................................................ 34
Description .........................................................................................................................34
Settings ..............................................................................................................................35
Alarms ................................................................................................................................35
4.5 Flotation unit FU2801 – Drains – V2805, V2808A, V2808B and SG3741 .................................. 36
Description .........................................................................................................................36
Settings ..............................................................................................................................36
Alarms ................................................................................................................................37
4.6 Flotation unit FU2801 – Sludge compartment – LC2802 and P2802 ......................................... 37
Description .........................................................................................................................37
Settings ..............................................................................................................................37
Alarms ................................................................................................................................38
5 P&ID Sheet 4 (part 1 of 3) – Selector tank T2301, Caustic dosing P1501, anoxic tank T2401,
aeration tank T3001 and blower control BW30x1 .............................................................................39
5.1 General introduction .................................................................................................................... 39
5.2 Selector tank T2301 – Level LC2301, Mixer MX2301 and feed pump P2301 ............................ 40
Description .........................................................................................................................40
Settings ..............................................................................................................................40
Alarms ................................................................................................................................41
5.3 Selector tank T2301 – pH measuring QIC2301, neutraliser tank T1501 and dosing pump P1501
..................................................................................................................................................... 41
Description .........................................................................................................................41
Settings ..............................................................................................................................43
Alarms ................................................................................................................................44
5.4 Anoxic T2401 – Level LC2401, mixer MX2401 and feed pump P2401 ...................................... 44
Description .........................................................................................................................44
Settings ..............................................................................................................................44
Alarms ................................................................................................................................44
5.5 Aeration tank T3001 – level LC3001, feed pumps P3002 and P3022 ........................................ 45
Description .........................................................................................................................45
Settings ..............................................................................................................................45
Alarms ................................................................................................................................46
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5.6 Aeration tank T3001 – Oxygen measuring QIC3001A/B and blowers BW3001, BW3021 and
BW3041 ....................................................................................................................................... 46
Description .........................................................................................................................46
Settings ..............................................................................................................................49
Alarms ................................................................................................................................51
6 P&ID Sheet 4 (part 2 of 3) – Flocculant make-up unit T1821, Flocculator PF0901 and flotation
unit FU2601 ...........................................................................................................................................52
6.1 General introduction .................................................................................................................... 52
6.2 Flocculator PF0901 – Flocculant dosing pump P1821, V1833 and FIS1822 ............................. 53
Description .........................................................................................................................53
Settings ..............................................................................................................................53
Alarms ................................................................................................................................54
6.3 Flotation unit FU2601 – Aeration and Skimmer – P2601, V2613, PIS2601, PIS2602, FIS2601
and SC2601 ................................................................................................................................ 54
Description .........................................................................................................................54
Settings ..............................................................................................................................55
Alarms ................................................................................................................................56
6.4 Flotation unit FU2601 – Drains – V2605, V2608A, V2608B and SG3721 .................................. 56
Description .........................................................................................................................56
Settings ..............................................................................................................................57
Alarms ................................................................................................................................57
6.5 Flotation unit FU2601 – Sludge compartment – LC2602 and P2602 ......................................... 57
Description .........................................................................................................................57
Settings ..............................................................................................................................58
Alarms ................................................................................................................................58
6.6 Flotation unit FU2601 – Excess sludge valve V2635, and sludge return valves V2655 and
V2675 .......................................................................................................................................... 59
Description .........................................................................................................................59
Settings ..............................................................................................................................60
Alarms ................................................................................................................................60
6.7 Flocculant make up-unit T821 – Various components ................................................................ 60
Description .........................................................................................................................60
Settings ..............................................................................................................................64
Alarms ................................................................................................................................65
7 P&ID Sheet 4 (part 3 of 3) – Flocculator PF0921 and flotation unit FU2701 ...................................66
7.1 General introduction .................................................................................................................... 66
7.2 Flocculator PF0921 – Flocculant dosing pump P1841, V1853 and FIS1842 ............................. 67
Description .........................................................................................................................67
Settings ..............................................................................................................................67
Alarms ................................................................................................................................68
7.3 Flotation unit FU2701 – Aeration and Skimmer – P2701, V2713, PIS2701, PIS2702, FIS2701
and SC2701 ................................................................................................................................ 68
Description .........................................................................................................................68
Settings ..............................................................................................................................69
Alarms ................................................................................................................................70
7.4 Flotation unit FU2701 – Drains – V2705, V2708A, V2708B and SG3721 .................................. 70
Description .........................................................................................................................70
Settings ..............................................................................................................................71
Alarms ................................................................................................................................71
7.5 Flotation unit FU2701 – Sludge compartment – LC2702 and P2702 ......................................... 71
Description .........................................................................................................................71
Settings ..............................................................................................................................72
Alarms ................................................................................................................................72
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7.6 Flotation unit FU2701 – Excess sludge valve V2735, and sludge return valves V2755 and
V2775 .......................................................................................................................................... 73
Description .........................................................................................................................73
Settings ..............................................................................................................................74
Alarms ................................................................................................................................74
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Process control and functional description
P000245-FDS-RevA (As Built)
WWTP Sobono Energy - Biotech Farms - Philippines
The WWTP (Waste Water Treatment Plant) will be controlled by 1 PLC system, that controls the
equipment in a total of 5 electrical control panels. There will be a 6th control panel that is actually based
on relay technics. Reference of these panels:
Project P000245:
Control panel 1 – P1 - Main control panel, consisting of PLC system
Control panel 2 – P2 – Decanter panel
Control panel 3 – P3 – Blower panel BW3001
Control panel 4 – P4 – Blower panel BW3021
Control panel 5 – P5 – Blower panel BW3041 (Danfoss panel)
Project P000246:
Control panel 6 – P6 (No reference on panel itself) - Control panel T0101/CS0501 (relay technics)
The PLC system is VIPA Speed7 series and the HMI is a Siemens Comfort panel. There will also be a
SCADA system, delivered by third party.
The following documents will be used as a reference for this function description:
P&ID P000245-PID-Rev.F Sheet 1 till 4.
The status of the individual equipment (off, running, failure, etc.) is also visualised in the HMI display.
Functional difference between Manual, Off and Automatic mode is described in next paragraphs.
There are always exceptions where these components are used in combination. E.g.: a pump, using
its own block valve, may only use one combined M-0-A switch.
For all other safeties (like low level alarms, etc.), it will individually be decided if it is overruled in Manual
mode.
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WARNING: It is operators responsibility to monitor the equipment carefully, when operated in manual
mode.
Off mode
The selected component will be switched Off (or closed in case of valves), independent of PLC
programming.
Auto control
The rest of this document will describe the Automatic control of the WWTP. Be aware that a single
component in Manual mode (or in Off mode) can have consequences for the rest of the equipment that
is in Automatic mode.
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typical value may be mentioned in the upcoming chapter on those components. Typical example: The
run-detection delay of a frequency drive does not have to be adjustable.
NWT will by default not show any alarms of equipment that is switched off.
When equipped with a unit switch, and regular start/stop control is based on a level sensor, it is common
that a software trigger switch is available as well. Normally the unit starts when level rises above start
level setpoint, and it stops again when below stop level setpoint. After using a unit switch operator
would have to wait until level is back above start setpoint. When operator wants to use the equipment
straight away, trigger switch can be used, and it does no longer wait for the level to be above start
setpoint. Obviously, level cannot be less that stop setpoint.
Windings of motors, as well as housing of motor/pump can be protected against high temperatures.
Possible protections are Clixon (thermoclick), PT100, PTC, NTC, and other type of measurements. In
all cases, the motor should be switched off, and alarm generated, and no earlier restart of the motor
than detection by operator. Commonly a reset must be given, either on protection, on VSD/Softstarter
or (and sometimes additionally) on the reset button of the control panel. Operator should take action if
alarm comes more often.
All common alarms in these area’s will not specifically be explained in the chapters.
There are many alarms that are caused by internal panel faults, and causing larger parts of the WWTP
to shut down. These cause and solution for these alarms are so extensive, that they are not part of this
manual. The text in the alarm message should speak for itself. Some examples:
Emergency stop circuit activated. One of the E-stops in the circuit has been pressed. Reset
the concerning sensor, and press ‘Reset E-stop’ button on the front of panel P1.
Murr 24Vdc control voltage failure. At least one of the electronic fuses in the 24Vdc control
circuits has tripped. Find the channel, and look for short-circuits (or overload situtions) in the
specific 24Vdc circuit.
Communication failure with Profibus or Profinet substation. Check with supplier.
Analog output module … system fault. At least one of the channels of mentioned card comes
with a fault. Remove all analog signals, and check if fault is gone. If yes, re-connect all
signals, and see where alarm comes back. This is where to look for the fault.
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The decanter control is delivered in full by Alfa Laval, including controls. Nijhuis Industries does
communicate with the Alfa Laval BCC (Basic Core Controller), by means of a number of Volt-free
signals.
If start-up procedure if finished, this will be notified to Nijhuis PLC. The concerning block valve V3403
and/or V3423 is opened and feed pump P3401 and/or P3421 is started. Simultaneously with the feed
pump the concerning flocculant dosing pump P1901 and/or P1921 are started, as well as the
concerning reduction unit RU3301 and/or RU3321.
Decanter is now in normal operation mode. The amount of sludge fed to the decanter is kept constant,
by adjusting the frequency of the pump, based on measurement of the flow in the same decanter line
(FIC3401 or FIC3421).
Filtrate water of the decanters is collected in Transfer tank T0301, and thickened sludge of decanter is
transported to bin/container by means of transport screw TS4601. Since transport screw is delivered
and controlled by client, the communication between Nijhuis Industries and client is done again by Volt-
free signals (control panel P1 – Page 133 and Page 134). Nijhuis requests screw to be started, and
client should tell Nijhuis that screw is in operation. This run-detection is mandatory for operating the
decanters.
In automatic control (no operators switch-off, and no failures), the decanters are stopped when the
client takes away the Volt-free signal(s) coming from level in Storage tanks. The feed pump(s),
flocculant pump(s) and reductions units are stopped straight away, while decanter(s) itself will go in a
run-down mode. After emptying, and flushing the decanter it will be stopped. This is all controlled by
Alfa Laval BCC controller.
The Transfer tank T0301 collects the filtrate water, and measures the level with sensor LC0301. Water
is mixed with MX0301, and pumped forward into the WWTP by means of feed pump P0301. Both level
in LC0301, and controls of DAF (Dissolved Air Flotation) unit FU2501 determine the start of this pump.
Originally there used to be a bypass circuit that would directly feed the decanters, without use of feed
pumps P3401 and/or P3421. During engineering phase, this option was removed from project due to
heavy complications.
The following items of the plant are directly controlled and / or affected under this process area of the
works:
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2.2 Decanter DC3301 and DC3321 – M33x1, M33x2, V33x1, V33x8 and V33x5
Description
As mentioned above, the decanter and its components are no longer explained in individual lines, just
in general.
The decanter control is delivered in full by Alfa Laval, including controls. Nijhuis Industries does
communicate with the Alfa Laval BCC (Basic Core Controller), by means of a number of Volt-free
signals (control panel P1 – Pages 155 till 166, 174 till 185 and 186). Each BCC consists of several Alfa
Laval components:
PLC system, located underneath decanter
HMI, located in the front of control panel P1
2 Frequency drives ABB, all in control panel P2
It is client, that actually starts the WWTP. When clients Storage tank is ready to discharge water, this
is communicated to WWTP, by means of Volt-free signals (control panel P1 – Page 133).
Decanter line 1: Contact 133U1
Decanter line 2: Contact 133U2
Upon receiving its start request, decanter will check the following requirements, to determine if it may
start:
Decanter is enabled, and all components are in AUTO mode
Decanter equipment is free of failures
Both main drive and back drive are enabled (as signal is received from BCC controller)
Decanter is ready (as signal is received from BCC controller). Once decanter is actually
running, this signal will switch off.
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If all conditions are met, Nijhuis will send a start request to BCC, and the decanter will initiate its start-
up procedure. All procedures that are controlled from BCC are not part of this document, since neither
Nijhuis, nor operator, is of influence to these procedures.
During all phases, BCC controller will determine both the speed of main drive, as well as backdrive.
During normal operation, the controls will try to maintain the differential speed on a preset value.
During start-up of decanter Nijhuis did already tell BCC that feed and flocculant are ready for operation.
Once decanter is up-to-speed, it will give a signal back, that feed is allowed to be started. Nijhuis will
start both the feed pump, as well as the flocculant dosing pump. Upon doing so, it will also tell BCC that
feed pump is in operation.
When client Storage tank is no longer asking for discharge (133U1 or 133U2), feed and flocculant will
be stopped, and BCC will put decanter is run-down and flush mode. Again, this procedure is not part of
this document, since it is fully controlled by BCC.
Would decanter be stopped in any other way (e.g. failure, or lack of any other start condition), it is
difficult to predict how run-down and flush procedure will look. This can be different for all individual
situations.
Drives M33x1 and M33x2, Flush valve V33x1, Diverter gate valve V33x8 and diverter flush valve V33x5
are all implemented in the BCC control and its procedures. Detailed explanation on these components
should be part of Alfa Laval manuals.
Almost all alarms in relation to decanter are generated in the BCC controller. On the HMI of Alfa Laval
these are all visible. Use Alfa Laval manual to do so. The BCC will only forward one combined failure
signal to Nijhuis PLC, and this alarm is visualized on Nijhuis HMI. Beside this combined Alfa Laval
alarm, there are 2 more alarms that are specific for a decanter (not taking in account E-stop situations,
lack of control voltage, etc.). This could either be the absence of enabled contacts (also coming in by
means of BCC), or the lack of run detection on any of the frequency drives.
The decanters DC3301 and DC3321 come with unit switches. These are explained in general chapter
1.6.
Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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2.3 Feed pump and flow control feed decanter – P34x1, V34x3 and FIC34x1
Description
As mentioned above, the decanter and its components are no longer explained in individual lines, just
in general.
As already described in the chapter about the decanter, the feed of the decanter is started and stopped,
based on the Alfa Laval BCC controller. When BCC tells Nijhuis PLC to start the feed, first the block
valve V34x3 is opened. Only when end-contact detects this valve to be fully opened, the pump P34x1
starts, and feed is activated. Since pump is frequency controlled, it will not immediately stop, when BCC
tells pump to stop. This is why the block valve also comes with an adjustable off delay, so it is not
blocked during ramp down.
The block valve has 2 end-contacts, one for the detection of fully opened, and one for the detection of
fully closed. When valve is opened, in must detect is end-contact ‘open’ within an adjustable amount of
time. Same goes for the detection ‘closed’ when valve is closed. If not, it will generate an alarm. Be
aware that alarm can automatically reset itself, should valve detect its end-contact after all.
Once pump is running, it will try to run on a preset flow setpoint. This is done by means of a PID flow
controller, that will make sure that the frequency of feed pump P34x1 meets the desired flow setpoint
as close as possible. To make a closed loop on the PID controller, the flow is measured by sensor
FIC34x1. This sensor is located on the discharge side of the feed pump. PID works in ‘direct’ mode of
control, meaning that frequency will rise if measured flow is too low.
This flow meter sends a 4-20mA signal to the PLC in the control panel. The HMI will indicate the actual
flow in cubic metres per hour (m 3/h). A digital pulse signal on this same sensor is used in the PLC, to
create a flow totalizer. This value will be visible in the HMI in cubic metres (m3)
Beside the flow control, flow measurement also generates low- and high flow alarms. This is just for
notification, there are no further actions. It is up to the operator to check, and react if necessary.
It is also possible to bypass the automatic PID flow controller, by placing the PID controller in manual
mode. Pumps will now run on pre-set frequency, but start/stop conditions still apply.
During automatic operation of a PID controller, it starts with an on-delay timer. As long as this timer has
not elapsed, the output is already active, but does not yet control. The output value in this on-delay
uses the initial value. This can either be a pre-set value, or it can be be last know value of PID controller
upon last stop. This last option is valid if the value 0.0 is entered for initial setpoint. Once on delay timer
has elapsed, it will start controlling the output value. P, I and D values determine the reactions to
deviations. The minimum and maximum output limitations can be used to limit the control range of the
PID controller. When measured value is on setpoint, or within a deviation of less than entered
deadband, the controller will freeze its output, and will first start to control again if measured flow
becomes outside deadband limits. Therefore it will not use initial value, but always the frozen value.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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2.4 Flocculant dosing control decanter – P19x1, F19x1, LC1902, V19x3 and FIS19x2
Description
As mentioned above, the decanter and its components are no longer explained in individual lines, just
in general.
As already described in the chapter about the decanter, the feed of the decanter is started and stopped,
based on the Alfa Laval BCC controller. In general, the flocculant dosing starts and stops
simultaneously with the feed pump P34x1. This part has been extensively explained in previous
chapters.
Once pump is running, it will try to run on a pre-set capacity, based on flow measuring of FIC34x1.
Therefore an adjustable setpoint is available in liter flocculant per m3 influent sludge. On a regular
interval, the actual flow value of FIC34x1 is taken, and a new capacity for P19x1 is calculated. The
outcome of this calculation is limited in-between a minimum and maximium capacity setpoint. The
outcome is in l/h, but will be linearly scaled back to a frequency value. Up until next calculation, this is
the new frequency for the flocculant dosing pump P19x1. Control is always direct, so increasing the
sludge flow, will lead to increased flocculant dosing (unless maximum has already been reached).
There is a setting in the HMI that determines the control mode of this dosing pump. In automatic mode,
it works as explained above. In manual mode, it will use its manual mode setpoint, but the start/stop
conditions still apply.
The frequency of these flocculant dosing pumps can be rather low, so that impeller on motor becomes
critical in regards to cooling the motor. To overcome this, an additional cooling fan has been mounted
on this pump-motor. This cooling fan runs simultaneously with the pump, and uses an adjustable off
delay, before it switches off.
In the dosing line between pump and decanter additional water is added through a static mixer. This is
the so called post-dilution. This water valve V19x3 is opened simultaneously with the concerning
flocculant dosing pump. The amount of water that is added to the flocculant, is monitored by a flow
switch FIS19x2. If water flow is too low for too long, it will generate an alarm. This alarm is only for
notification, there will be no further actions.
In automatic mode, the run condition of flocculant pump is depending on level detection in flocculant
make-up unit T1901. If level sensor LC1902 detects no more level, it needs to stop the flocculant pump
P19x1, but while doing this, it will also stop decanter, and its feed pump. Further functions of level
sensor LC1902 will be explained in the chapter about the flocculant make up unit T1901.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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P000245-FDS-RevA (As Built)
WWTP Sobono Energy - Biotech Farms - Philippines
P19x1 – Control mode linear control on flow FIC34x1 (*1) Manual or Automatic
mode
*1 : When selecting automatic mode, the linear control is active, and determines the output based on
measured sludge flow. When selecting manual mode, the linear control is deactivated, and the output
value is set to the value in setpoint ‘Desired frequency (or capacity, or position, etc.) ………, when
running in manual mode’. During manual mode, all other start conditions remain active, and is therefore
different from hand mode of a single component.
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
Description
In the feed line to decanter, a reduction unit has been installed. Its sole purpose is the reduction of the
amount of flocculant necessary to operate the decanter. The unit comes with its own control panel,
where communication with Nijhuis PLC is performed by means of Volt-free signals (control panel P1 –
Page 17 and Page 24). One Volt-free signal is used to start the unit, and another Volt-free signal is
used to receive back a central alarm from reduction unit.
The start signal to reduction unit is sent, once both the decanter (of the specific line) and its feed pump
(of that same line) are in operation (both of them in automatic mode). Unit should obviously be free of
failures.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
Description
The decanter splits up the influent sludge in partly filtrate water, and partly solids. These solids are
removed from the WWTP, and to transport them from the decanters to the bin/container/etc. a transport
screw is required. Since transport screw is delivered and controlled by client, the communication
between Nijhuis Industries and client is done again by Volt-free signals (control panel P1 – Page 133
and Page 134). Once Nijhuis requests the screw to be started, the client should tell Nijhuis that screw
is actually in operation. This run-detection is mandatory for operating the decanters. If run detection is
not available, the system will generate an alarm, and decanter will not be in operation.
The conditions for Nijhuis to send the start request for TS4601 are based on client’s request for starting
either one of the decanters. As soon as the request is detected, concerning decanter(s) is/are available,
and there is no high level alarm in T0301, transport screw should be started. Only when run situation is
detected, the decanter(s) will actually start.
When there is no more start request for either one of the decanters, the transport screw will continue
to run in an adjustable off-delay timer. When timer elapsed, the start request of screw will be taken
away, and client can switch off the screw.
Alternatively, it is possible to run the screw 24/7, as long as Nijhuis does receive the run detection.
If transport screw is collecting the solids in a tank, bin or container, client is free to measure the level in
there. If there would be high level (and container needs replacement), client could stop transport screw,
and take away the run signal to Nijhuis. This will automatically lead to the stop of the decanters.
Alternatively this HLA signal could also be implemented into the start request signal for the decanters.
For whatever reason this setting was placed in the HMI among the settings of the Transfer tank T0301.
Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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Description
Transfer tank T0301 is used to collect the filtrate water of the decanters, but it does also collect the
drain water from SG3701 (drain water coming from FU2501). Level in the transfer tank is measured,
and settings are available to create a start/stop setting for both the mixer MX0301 and the start of
flotation unit FU2501 (leading automatically to the start of P0301). Furthermore, there are two settings
to create a high level alarm in this tank. Upon high level detection in this tank, the decanters will be
stopped, as well as the drains of flotation unit FU2501.
The level is measured by a 4..20mA pressure sensor, hanging near the bottom of the tank. This
analogue signal refers to a measuring range, as indicated on sensor type shield. HMI offers the
possibility to re-calibrate this 4…20mA signal, so an empty tank shows 0% and a full tank (just before
draining or overfloating) shows 100%. This calibration will be done by our commissioning engineer.
Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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3 P&ID Sheet 2 – Flocculant make-up unit T1901, Flocculator PF0801 and flotation unit FU2501
Inside the DAF unit, the particles that can be separated from the waste water, will either sink to the
bottom (heavy particles), or will be forced to the surface (light floatable particles). Nijhuis offers a range
of DAF units, where this project uses GDF and IPF units. Technically they are the same, except for the
size of the unit. Highly polluted waste water requires a bigger unit (GDF), while a smaller unit (IPF) can
be used for less polluted water. To make up for the size of the unit, the IPF is equipped with internal
diagonal plate, to force the wastewater into a pre-defined flow-path. This make it easier for the heavier
particles to sink to the bottom, and the floatable particles to come to the surface.
DAF unit FU2501 is a GDF type
Before wastewater is entering the DAF unit, it will first pass a flocculator. The flocculator is a tubing
system, where chemicals are added into the wastewater. The length and shape of the flocculator
determines the amount of mixture of chemicals with the water. Additionally, saturated water of the DAF
unit’s aeration system, can be injected as well.
In this specific flocculator, the chemical dosing only consists of flocculant from make-up unit T1901.
The sole purpose of wastewater/flocculant mixing, is to bind the floatable particles, and create flocks
that can more easily be brought to the surface.
Flocculant injection can be done on 2 different positions in the flocculator. Commissioning engineer will
set up the most ideal connection.
DAF unit is based on an overfloat principle to the effluent. This will maintain a pre-defined level in the
flotation unit, that can be adjusted within a certain range by the commissioning engineer. When in
operation, the unit is started by pumping around water, through a saturation pipe. The discharge
pressure of this recirculation system could be approx. 5 Bar. Compressed air with a pressure of approx.
6 Bar is added in the pipe. The water absorbs the air and the mixture is released in the flotation unit.
Water remains in the unit, while the air will flow to the surface of the unit, creating an upward flow of air
all through the unit. The floatable particles will be forced to surface, after which the skimmer drive can
remove them into a so called ‘sludge compartment’ of the DAF unit.
Heavy particles will collect in designed areas, and are periodically drained back into the WWTP.
Commonly a sand gutter will take care that only the water returns, and the heavy particles can be
removed by operator.
T1901 is a flocculant make-up unit, that works stand alone. The make-up procedure is explained in
detail in the concerning chapter. The third (and last) compartment is used to pump prepared flocculant
to both decanters (P1901 and P1921), as well as the flocculator (P1801). The level sensor in this
compartment protects these pumps from running dry.
The following items of the plant are directly controlled and / or affected under this process area of the
works:
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3.2 Flocculator PF0801 – Flocculant dosing pump P1801, V1813 and FIS1802
Description
The function of the flocculator has been explained in the general introduction. From control point of
view, there is not much to explain about the flocculator as a unit. The only component that needs
explanation is the flocculant dosing pump P1801. The level in Transfer tank T0301 determines the start
of flotation unit FU2501. Once start-up procedure of flotation unit has finished, the feed pump P0301
will be started, and simultaneously the flocculant dosing pump P1801 will be started.
The capacity of this pump is pre-set, but adjustable in HMI. Value is entered in L/h, but internally in the
Nijhuis PLC scaled back into a frequency value (Hz).
In the dosing line between pump and decanter additional water is added through a static mixer. This is
the so called post-dilution. This water valve V1813 is opened simultaneously with the flocculant dosing
pump P1801. The amount of water that is added to the flocculant, is monitored by flow switch FIS1802.
If water flow is too low for too long, it will generate an alarm. This alarm is only for notification, there will
be no further actions.
In automatic mode, the run condition of flocculant pump is depending on level detection in flocculant
make-up unit T1901. If level sensor LC1902 detects no more level, it needs to stop the flocculant dosing
pump P1801. Further functions of level sensor LC1902 will be explained in the chapter about the
flocculant make up unit T1901.
Any cause of stop for flocculant dosing pump P1801, does not lead to a full stop of flotation unit FU2501
and its feed pump P0301.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
3.3 Flotation unit FU2501 – Aeration and Skimmer – P2501, V2513, PIS2501, PIS2502, FIS2501 and
SC2501
Description
The functional explanation of the aeration and skimmer system have already been mentioned in the
general introduction of this chapter.
The level inside Transfer tank T0301 determines the start and stop of flotation (DAF) unit FU2501.
There is both a start procedure of the DAF unit, as well as a stop procedure.
Start procedure
The recirculation pump P2501 is started, and it awaits pressure switch PIS2501 to detect high enough
pressure (ca. 5 Bar). Upon detection of this pressure, the aeration valve V2513 is opened, compressed
air is introduced (ca. 6 Bar), and the aeration/saturation system will start to create an upward airflow
inside the DAF unit. This period takes an adjustable amount of time, after which the feed pump P0301
is allowed to be started. Flocculant pump P1801 will follow right after
During start procedure, and during normal operation, the skimmer drive is operated in an adjustable
pulse-and pause mode.
Stop procedure
The feed pump P0301 and flocculant dosing pump P1801 are stopped. From here, the stop procedure
is in 2 phases. In phase 1, the aeration valve V2513 remains opened, and recirculation/saturation
remains active. In phase 2, the aeration valve V2513 is closed, but recirculation pump P2501 will
continue to de-aerate the system. The periods of both phases take adjustable amounts of time. When
time period of phase 2 has elapsed, the recirculation pump and skimmer drive are stopped as well.
During phase 1 of the stop procedure, the skimmer continues to operate in pulse-/pause mode, but in
phase 2 is runs continuous.
Recirculation pump
Recirculation pump is in operation during start procedure, normal operation and stop procedure. The
recirculation pump is only stopped in case of failure with pump itself, or when the pressure switch
PIS2501 does not detect enough flow, for a continuous period of 30 seconds with running pump. This
situation generates an alarm, and stops the DAF unit. An operator reset is required.
Aeration valve
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The aeration valve is in operation during start procedure, normal operation and during phase 1 of the
stop procedure. In all situations, the aeration valve is immediately stopped, when pressure switch
PIS2501 does no longer detect its minimum pressure. When pressure comes back, valve is opened
again, but it takes a minimum (adjustable) amount time till feed pump is restarted.
Skimmer drive
Skimmer drive generally works in pulse- and pause mode. Both are adjustable in HMI. When a value
of 0 seconds is entered for the pause time, this pulse-/pause mode is de-activated, and the skimmer is
in continuous mode, obviously dependant to its start conditions. During normal conditions, the skimmer
drive is started during start procedure, normal operation, and during stop procedure(s) of DAF unit. In
phase 2 of the stop procedure, the skimmer will always run continuously.
Skimmer drive, skims off the floating layer of sludge into the sludge compartment. There is a level
sensor in this compartment, that can also generate a high level alarm. In case of a high level alarm, the
skimmer is stopped. Would the stop of skimmer take a longer time period, as defined by setting ‘on
delay stop feed pump on standstill skimmer’, another alarm is generated, and the feed to DAF unit is
stopped. Normally the aeration will remain in operation during this alarm.
Skimmer drive always runs at an adjustable frequency.
Recirculation may be controlled by a softstarter. In that case, the Nijhuis PLC does allow for a certain
amount of time to receive a RUN detection, before an alarm is generated. This time is adjustable.
The flotation unit FU2501 comes with a unit switch, as well as a trigger start switch. These are both
explained in general chapter 1.6.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
3.4 Flotation unit FU2501 – Drains – V2505, V2508A, V2508B and SG3701
Description
As mentioned in the general introduction, the heavy particles gather in pre-designated areas of the DAF
unit. These need periodical draining, by shortly opening a valve in the lowest point of the area. The
particles, along with water are drained back to Transfer tank T0301. To separate the sand and other
particles before T0301, a sand gutter SG3701 is installed. The construction of this gutter is in such way,
that only the water part should be returned to T0301. Operator should clear the sand gutter periodically.
The sand gutter, as well as the pipework, can only handle the opening of one drain valve at a time.
All steps of the drains cycles are adjustable in the HMI. Draining is only active, when feed pump to DAF
unit is in operation, otherwise DAF unit would be emptied. When there is a high level alarm in Transfer
tank T0301, DAF unit can remain in operation, but only the drain valves are temporary disabled.
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Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
Description
All the sludge is skimmed of the water surface into the sludge compartment. Inside this compartment
level is measured, and with two setpoints a start and stop level are created for sludge pump P2502.
The level is measured by a 4..20mA pressure sensor, installed near lowest point of this compartment.
This analogue signal refers to a measuring range, as indicated on sensor type shield. HMI offers the
possibility to re-calibrate this 4…20mA signal, so an empty compartment shows 0% and a full
compartment (just before draining or overfloating) shows 100%. This calibration will be done by our
commissioning engineer.
Generally the sludge pump is only depending on the start- and stop level in the sludge compartment.
The sludge is pumped back to a sludge tank (or bin, or container) belonging to client. Since Nijhuis PLC
does not have any control over the level in that tank/bin/container, a Volt-free contact is supplied, that
can be connected by client. If tank/bin/container is ready to accept sludge from WWTP, the input signal
133U4 (Control panel P1 – Page 133) should be HIGH, so Nijhuis knows that pump P2502 is allowed
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to start. If client breaks this input signal, pump P2502 will automatically stop, and an alarm is generated.
If client does not wish to use this option, input signal 133U4 must be wire-bridged.
Above input signal 133U4 can be one of the causes for the sludge compartment to reach high level
alarm. Again, two adjustable setpoints define the start and stop of this specific alarm. The consequence
of a high level alarm will be the stop of skimmer drive SC2501. If this situation remains active for too
long, it may eventually result in the stop of feed pump P0301. See chapter about the skimmer SC2501.
Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
Description
The flocculant make-up unit T1901 was purchased as a unit, and all equipment was already pre-
installed into a junction box. Nijhuis had to connect the flocculant dosing pumps, and it was decided to
exchange two of the original components for more common Nijhuis instrumentation: FIS1901 and and
LC1902. Since Nijhuis did the full PLC control of the unit, we can give an extensive explanation of this
unit.
This chapter does not include the actual dosing pumps, these are part of the chapters about decanter
and flocculator.
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Flocculant make-up unit T1901 comes with a unit switch. This switch has been explained in the general
chapter 1.6. The information of this chapter is only valid in case unit switch is in automatic mode.
The pulse contact accumulates the amount of pulses detected, during actual make-up batch. On each
detection of a pulse, the value entered to be the ‘K factor’, is added to the ‘Total water volume, detected
by pulse contact’. This is only for verification, and not used in the automatic control. The moment a
new batch make-up starts, this value is reset to 0 Liters.
The analogue flow signal does also accumulate the total amount of water supplied, it just uses an
integration over the total amount of time necessary to finish the actual batch. This value is presented in
the setting ‘total water volume detected by integration’. Although this is a read-only value, this is actually
the value used in the automatic control. The moment a new batch make-up starts, this value is reset to
0 Liters.
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The outcome of this formula is checked, so it does not exceed the values in ‘capacity dosing screw
DD1901, at minimum frequency’ and ‘capacity dosing screw DD1901, at maximum frequency’. If so,
the calculated value is replaced by the minimum or maximum value.
There are two more settings, that define the minimum and maximum frequency, belonging to the
minimum and maximum capacity. Both settings are related to the minimum and maximum calibration
setting, as set up by commissioning engineer, and these are not to be changed. The calculated capacity
(Kg/h) is scaled back to a calculated frequency (Hz).
During active make-up of a new batch, the output frequency of dosing screw DD1901 is continuously
updated, based on above calculation.
The overdosing factor can only contain values inbetween 1.00 and 3.00x. Overdosing may be required,
due to the fact that dosing screw is started with a number of delays. This can be during first start of
make-up cycle, but this can also be due to the start/stop setpoints of the dosing screw itself. When in
operation, it needs to make up the ‘lost’ time. Generally the value will have to be set on a value rather
close to 1.00, but make-up should be able to finish on desired concentration.
The calculated capacity (Kg/h) is also accumulated by the PLC, so the total amount of powder supplied,
during actual batch is recorded. This calculation is done by integration of the calculated capacity, over
the total amount of time necessary to finish the actual batch. This value is presented in the setting ‘total
powder quantity dosing screw DD1901’. Obviously, the calculation is only done while dosing screw is
in operation. Although this is a read-only value, this is actually the value used in the automatic control.
The moment a new batch make-up starts, this value is reset to 0 grams.
While making up a new batch of flocculant, there is a continuous calculation of that actual concentration
in the make-up unit. Formula is:
The make-up is designed to achieve the ‘desired concentration flocculant batch’. PLC control works
with two values around this setpoint.
In general the dosing screw starts when ‘calculated concentration actual flocculant batch’ becomes less
than the value defined by point 1. The dosing screw will stop again once the ‘calculated concentration’
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becomes higher than the value defined by point 2. This is create a deadband, and prevent the dosing
screw from many start/stops.
The heater on the dosing screw is activated on a continuous power supply. There are no controls for
this component. We are currently investigating whether or not we should also modify this to a pulse-
/pause power supply. UNDER CONSTRUCTION.
Vibrator M1901
While dosing screw is in operation, the vibrator will be active in a pulse-/pause mode. The pulse time
(‘on time vibrator’) can be rather short (e.g. 1 sec.), and pause time (‘off time vibrator’) can be a little
longer (e.g. 10 sec.). The function is solely to have the flocculant powder drop to the bottom of the
powder compartment properly.
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Low level alarm is generated when the level is below ‘low level alarm’ setpoint, for a longer time than
defined in the setpoint ‘on delay low level alarm LC1902’. The alarm will automatically be reset if level
is back to a higher value. This alarm will cause all flocculant dosing pumps (P1801, P1901 and/or
P1921) to stop.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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4 P&ID Sheet 3 – Pump pit T0101, Curved screen CS0501, Buffer tank T321 and flotation unit
FU2801
Buffer tank T0321 and flotation unit FU2801 are in close range to the WWTP (P000245). That is why
these components and controls were implemented in the main control panel P1.
Pump pit T0101 and curved screen CS0501 are in the slaughterhouse area and much further away
from the WWTP. To prevent the use of very long cables, it was decided to install a local panel near
this equipment. The controls are not too complicated, and that is why this panel is not PLC controlled,
but control is based on old-fashion relay technics. Since it takes a trained electrician to read (and
understand) a relay schematic, this control is also implemented in this document.
Slaughterhouse water is collected in pump pit T0101. From here it is pumped to buffer tank T0321,
while passing a curved screen. This screen makes sure that the bigger particles are removed from the
water, and collected in a local bin (T0501).
In buffer tank T0321 the water is mixed, and from here it is pumped to the Selector tank T2301, while
passing through a Nijhuis ‘Flotation’ system. The flotation unit, uses the principle of Dissolved Air
Flotation, and that is why it may also be referred to as DAF unit. Unlike FU2501, there is no flocculator
in this system.
Inside the DAF unit, the particles that can be separated from the waste water, will either sink to the
bottom (heavy particles), or will be forced to the surface (light floatable particles). Nijhuis offers a
range of DAF units, where this project uses GDF and IPF units. Technically they are the same, except
for the size of the unit. Highly polluted waste water requires a bigger unit (GDF), while a smaller unit
(IPF) can be used for less polluted water. To make up for the size of the unit, the IPF is equipped with
internal diagonal plate, to force the wastewater into a pre-defined flow-path. This make it easier for the
heavier particles to sink to the bottom, and the floatable particles to come to the surface.
DAF unit FU2801 is a IPF type
DAF unit is based on an overfloat principle to the effluent. This will maintain a pre-defined level in the
flotation unit, that can be adjusted within a certain range by the commissioning engineer. When in
operation, the unit is started by pumping around water, through a saturation pipe. The discharge
pressure of this recirculation system could be approx. 5 Bar. Compressed air with a pressure of
approx. 6 Bar is added in the pipe. The water absorbs the air and the mixture is released in the
flotation unit. Water remains in the unit, while the air will flow to the surface of the unit, creating an
upward flow of air all through the unit. The floatable particles will be forced to surface, after which the
skimmer drive can remove them into a so called ‘sludge compartment’ of the DAF unit.
Heavy particles will collect in designed areas, and are periodically drained back into the WWTP.
Commonly a sand gutter will take care that only the water returns, and the heavy particles can be
removed by operator. In regards to the drain water of FU2801, it is returned to buffer tank T0321.
The following items of the plant are directly controlled and / or affected under this process area of the
works:
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4.2 Pump pit T0101 and curved screen CS0501 – LC0101, P0101, V0501 and V0502
Description
The level sensor in pump pit T0101 is also a pressure sensor, that is hanging near the bottom of the
pit. The sensor itself is connected directly onto a level controller (Endress & Hauser RIA452). Our
commissioning engineer will set-up this controller is such way, that 0% reading matches an empty tank,
and 100% reading matches a tank that is as good as full. The settings chapter gives a little more
information on the set-up, but there are obviously more detailed manuals made by manufacturer.
Based on level sensor LC0101 the level controller creates a start and stop setpoint for the curved
screen. In regards of water flow the curved screen is just a static component, that just filters the bigger
particles from the water, and collects those in a bin. The water flows further into the system to the
general WWTP area, tank T0321. To prevent clogging of the screen, it is periodically cleaned by means
of spray bar. Beside the water valve that provides water to the spray bar (V0501), there is also a
pneumatic valve (V0502) that moves the entire spray bar from top to bottom, when energized. Once
de-energized, it will move back to its ‘rest’ position in the top of the unit.
Upon start command by LC0101, the spray cycle is activated, and the feed pump P0101 is started with
a minor on-time delay (setting by means of timer relay 20K1 inside the control panel P6). Feed pump
P0101 does not have any other start conditions, except for failures with the pump itself. However, if
client desires, it is possible to connect the high level state in buffer tank T0321 into the start condition.
This obviously requires a rather long cable inbetween control panel P1 and P6. This connection is
explained in the next chapter about buffer tank T0321.
Upon stop command by LC0101 the feed pump P0101 is stopped straight away.
Level controller of LC0101 does also create a high level alarm contact. Beside giving an alarm, this
contact is not used in the automated control of the WWTP. However, if client desires, this contact can
be used in the supply line to pump pit T0101. E.g.: when water is pumped from the slaughterhouse to
T0101, this contact could be used to stop that particular pump. Internal HAZOP should determine the
need for this. Just in case: This contact 18K3 is located on page 17 of control panel P6.
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During first stage (normal operation – feed active), the relay 21K4 defines a pulse- and pause time,
where entire cleaning will only be active during pulse time. It is most likely that 21K4 starts with pulse,
and then follows the procedure pause-pulse-pause-etc.
During second stage (off-delay curved screen – feed inactive), the relay 21K4 is disregarded, and
cleaning is continuous.
When cleaning is active (both stages), the water spray valve V0501 will be opened, and the pneumatic
valve V0502 will follow a down-up-down-etc. cycle until cleaning is no longer active. The up- and down
time for V05002 are defined by timer relay 21K1. Commissioning engineer will set-up the proper timer
settings.
After the second stage, the curved screen goes to stand-by and places the spray bar in the top position
(V0501 and V0502 closed).
Settings
The following settings shall be available for configuration by the operator, by means of:
Available timer relays inside the control panel P6:
Available controller on the front of control panel P6 (JUMO, Endress & Hauser, or similar).
There are separate manufacturer’s manuals on the controllers, and therefore not part of this
document.
*1: When function type ‘Min.’ is selected in the RIA 452, the setpoint actually defines the stop value,
while the setpoint + the offset value creates the start value. In this example it is start of relay 1 is at 50%
and stop at 30%. For relay 3 the alarm is generated at 90%, and the alarm is reset at 85%.
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed (by
means of LED’s) on the front of control panel P6. Alarms in relation to field components are generally
notified in RED, general failures regarding emergency stop, lack of control voltage, lack of main power
supply are notified by the absence of WHITE LED’s.
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Control panel P6, offers the possibility to use another Volt-free contact, that can be used as ‘General
Alarm’ for the entire control panel. Refer to page 25 of control panel P6 (P000246).
Description
Buffer tank T0321 is used to collect the water from the slaughterhouse area, but it does also collect the
drain water from SG3741 (drain water coming from FU2801). Level in the buffer tank is measured, and
settings are available to create a start/stop setting for both the mixer MX0321 and the start of flotation
unit FU2801 (leading automatically to the start of P0321). Furthermore, there are two settings to create
a high level alarm in this tank. Upon high level detection in this tank, the main control panel P1, switches
LOW (off) a Volt-free contact 132K2 (Control panel P1 – Page 133A). If client wishes to do so, this
contact can be connected in earlier mentioned relay panel P6 (page 17; 17K1 and 17K2). If this option
is used, the high level detection will automatically switch off feed pump P0101. An internal HAZOP at
client will have to decide if this is a good thing to do, or actually a bad solution. If either 17K1 and/or
17K2 are not used, they need a wire-bridge.
The level is measured by a 4..20mA pressure sensor, hanging near the bottom of the tank. This
analogue signal refers to a measuring range, as indicated on sensor type shield. HMI offers the
possibility to re-calibrate this 4…20mA signal, so an empty tank shows 0% and a full tank (just before
draining or overfloating) shows 100%. This calibration will be done by our commissioning engineer.
Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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4.4 Flotation unit FU2801 – Aeration and Skimmer – P2801, V2813, PIS2801, PIS2802, FIS2801 and
SC2801
Description
The functional explanation of the aeration and skimmer system have already been mentioned in the
general introduction of this chapter.
The level inside Buffer tank T0321 determines the start and stop of flotation (DAF) unit FU2801. There
is both a start procedure of the DAF unit, as well as a stop procedure.
Start procedure
The recirculation pump P2801 is started, and it awaits pressure switch PIS2801 to detect high enough
pressure (ca. 5 Bar). Upon detection of this pressure, the aeration valve V2813 is opened, compressed
air is introduced (ca. 6 Bar), and the aeration/saturation system will start to create an upward airflow
inside the DAF unit. This period takes an adjustable amount of time, after which the feed pump P0321
is allowed to be started.
During start procedure, and during normal operation, the skimmer drive is operated in an adjustable
pulse-and pause mode.
Stop procedure
The feed pump P0321 is stopped. From here, the stop procedure is in 2 phases. In phase 1, the aeration
valve V2813 remains opened, and recirculation/saturation remains active. In phase 2, the aeration valve
V2813 is closed, but recirculation pump P2801 will continue to de-aerate the system. The periods of
both phases take adjustable amounts of time. When time period of phase 2 has elapsed, the
recirculation pump and skimmer drive are stopped as well.
During phase 1 of the stop procedure, the skimmer continues to operate in pulse-/pause mode, but in
phase 2 is runs continuous.
Recirculation pump
Recirculation pump is in operation during start procedure, normal operation and stop procedure. The
recirculation pump is only stopped in case of failure with pump itself, or when the pressure switch
PIS2801 does not detect enough flow, for a continuous period of 30 seconds with running pump. This
situation generates an alarm, and stops the DAF unit. An operator reset is required.
Aeration valve
The aeration valve is in operation during start procedure, normal operation and during phase 1 of the
stop procedure. In all situations, the aeration valve is immediately stopped, when pressure switch
PIS2801 does no longer detect its minimum pressure. When pressure comes back, valve is opened
again, but it takes a minimum (adjustable) amount time till feed pump is restarted.
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If pressure does come back within these 30 seconds, the aeration valve is re-opened, and the timer ‘on
delay start feed pump’ is restarted. It requires timer to finish, before feed pump is restarted.
Skimmer drive
Skimmer drive generally works in pulse- and pause mode. Both are adjustable in HMI. When a value
of 0 seconds is entered for the pause time, this pulse-/pause mode is de-activated, and the skimmer is
in continuous mode, obviously dependant to its start conditions. During normal conditions, the skimmer
drive is started during start procedure, normal operation, and during stop procedure(s) of DAF unit. In
phase 2 of the stop procedure, the skimmer will always run continuously.
Skimmer drive, skims off the floating layer of sludge into the sludge compartment. There is a level
sensor in this compartment, that can also generate a high level alarm. In case of a high level alarm, the
skimmer is stopped. Would the stop of skimmer take a longer time period, as defined by setting ‘on
delay stop feed pump on standstill skimmer’, another alarm is generated, and the feed to DAF unit is
stopped. Normally the aeration will remain in operation during this alarm.
Skimmer drive always runs at an adjustable frequency.
Recirculation may be controlled by a softstarter. In that case, the Nijhuis PLC does allow for a certain
amount of time to receive a RUN detection, before an alarm is generated. This time is adjustable.
The flotation unit FU2801 comes with a unit switch, as well as a trigger start switch. These are both
explained in general chapter 1.6.
Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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4.5 Flotation unit FU2801 – Drains – V2805, V2808A, V2808B and SG3741
Description
As mentioned in the general introduction, the heavy particles gather in pre-designated areas of the DAF
unit. These need periodical draining, by shortly opening a valve in the lowest point of the area. The
particles, along with water are drained back to Buffer tank T0321. To separate the sand and other
particles before T0321, a sand gutter SG3741 is installed. The construction of this gutter is in such way,
that only the water part should be returned to T0321. Operator should clear the sand gutter periodically.
The sand gutter, as well as the pipework, can only handle the opening of one drain valve at a time.
All steps of the drains cycles are adjustable in the HMI. Draining is only active, when feed pump to DAF
unit is in operation, otherwise DAF unit would be emptied. When there is a high level alarm in Buffer
tank T0321, DAF unit can remain in operation, but only the drain valves are temporary disabled.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
Description
All the sludge is skimmed of the water surface into the sludge compartment. Inside this compartment
level is measured, and with two setpoints a start and stop level are created for sludge pump P2802.
The level is measured by a 4..20mA pressure sensor, installed near lowest point of this compartment.
This analogue signal refers to a measuring range, as indicated on sensor type shield. HMI offers the
possibility to re-calibrate this 4…20mA signal, so an empty compartment shows 0% and a full
compartment (just before draining or overfloating) shows 100%. This calibration will be done by our
commissioning engineer.
Generally the sludge pump is only depending on the start- and stop level in the sludge compartment.
The sludge is pumped back to a sludge tank (or bin, or container) belonging to client. Since Nijhuis PLC
does not have any control over the level in that tank/bin/container, a Volt-free contact is supplied, that
can be connected by client. If tank/bin/container is ready to accept sludge from WWTP, the input signal
133U5 (Control panel P1 – Page 133) should be HIGH, so Nijhuis knows that pump P2802 is allowed
to start. If client breaks this input signal, pump P2802 will automatically stop, and an alarm is generated.
If client does not wish to use this option, input signal 133U5 must be wire-bridged.
Above input signal 133U5 can be one of the causes for the sludge compartment to reach high level
alarm. Again, two adjustable setpoints define the start and stop of this specific alarm. The consequence
of a high level alarm will be the stop of skimmer drive SC2801. If this situation remains active for too
long, it may eventually result in the stop of feed pump P0321. See chapter about the skimmer SC2801.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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5 P&ID Sheet 4 (part 1 of 3) – Selector tank T2301, Caustic dosing P1501, anoxic tank T2401,
aeration tank T3001 and blower control BW30x1
These water flows are mixed by mixer MX2301, and then pumped to the anoxic tank T2401. Beside the
level of the selector tank (LC2301), also the pH is measured by an analogue sensor (QIC2301). When
pH value is out of limit, neutralizer pump P1501 will add chemicals to restore pH to acceptable values.
The type of used chemicals determines if the additional will result in the pH to rise (caustic types), or
make the pH drop (acid types). In the HMI option menu, this preference switch can be used to define
what type of chemicals are actually connected to the selector tank.
Commonly dosing pump P1501, directly withdraws the chemical fluid from an IBC container. A so-called
suction-lance is inserted in the IBC. On the bottom of this lance, a float detects eventual absence of
level, and generate an alarm. At that point chemicals are stopped, and operator should exchange the
IBC.
The amount of chemicals dosed into selector tank, may be controlled in two different ways. Either it is
based on PID controlled dosing on measurement of pH sensor QIC2301, or it is based on the ‘bucket’
principle. Both of them are further explained in the upcoming chapter about T1501 and P1501.
From selector tank, the water is pumped into the anoxic tank T2401 and forwarded into the aeration
tank T3001 by pump P2401 in the bottom off both tanks. By means of overfloating in the higher part of
the tanks, the water circulates back into the anoxic tank. This recirculation is continuous.
The water in the anoxic tank is also mixed with MX2401. Both the level in anoxic tank (LC2401) and in
aeration tank (LC3001) are measured, and used in the controls.
Inside the aeration tank the oxygen is measured as well. This is actually done by two identical sensors
(QIC3001A and QIC3001B). Sensors are compared against each other, and an alarm is generated if
deviation is too high. Operator is able to choose (preference switches in HMI), which sensor is active
on the controls, or optionally if both sensors are active. In this last situation, the average value is used
of both measurements.
Based on measured oxygen value, the blower control is activated. PID control will determine the
capacity of air required to be inserted into the aeration tank. Level in aeration tank needs to be sufficient.
Two of the blowers are softstarter controlled (60Hz each) and one is frequency controlled (25…60Hz).
Different combination of blowers allows for a wider range of frequencies (and therefore air supply to
aeration system).
Based on level measurement in the aeration tank (LC3001), different setpoints determine the start and
stop levels for flotation units FU2601 and FU2701. The effluent flow of the aeration tank is split up over
2 different ‘floc-flot’ lines, but it is obviously also possible to run one line only. If quantity allows ofcourse!
The feed to line 1 is taken care of by feed pump P3002, and the feed to line 2 is taken care of by feed
pump P3022. There are some service valves that allow this to be different, but this is all based on
manual (operator) control.
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The following items of the plant are directly controlled and / or affected under this process area of the
works:
5.2 Selector tank T2301 – Level LC2301, Mixer MX2301 and feed pump P2301
Description
Selector tank T2301 collects a number of water/sludge flows, and mixes this with mixer MX2301.
Level in the selector tank is measured, and settings are available to create a start/stop signal for the
mixer MX2301, the feed pump P2301, and the neutraliser pump P1501.
Furthermore, there are two settings to create a high level alarm in this tank. Upon high level detection
in this tank, the different feeds to the selector are stopped.
The level is measured by a 4..20mA pressure sensor, hanging near the bottom of the tank. This
analogue signal refers to a measuring range, as indicated on sensor type shield. HMI offers the
possibility to re-calibrate this 4…20mA signal, so an empty tank shows 0% and a full tank (just before
draining or overfloating) shows 100%. This calibration will be done by our commissioning engineer.
The additional condition for P2301 to run, is the absence of a high level alarm in the anoxic tank (defined
by LC2401).
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
5.3 Selector tank T2301 – pH measuring QIC2301, neutraliser tank T1501 and dosing pump P1501
Description
The pH value in the selector tank is measured by means of a sensor, that is connected to a local
transmitter. Beside read-out and set-up, this transmitter also provides a 4..20mA signal to forward the
measurement to the PLC controls.
The pH value inside the selector tank is controlled by means of a neutraliser dosing pump P1501. This
can either be a caustic pump to bring up the pH value, or a acid pump to bring down the pH value. The
type of pump is defined in the preference settings of the HMI, so PLC know how to do the controls. The
neutraliser is pumped from buffer T1501, by means of a suction lance that is located inside an IBC (or
chemical tank). Inside this suction lance a float is installed, that measures the presence of fluid. In case
of absence, it generates an alarm, and it stops the dosing pump. This situation does not stop the rest
of the WWTP, but may be of consequence to the effluent quality.
At all times the neutraliser dosing must meet the following conditions:
There shall be no level alarm in the neutraliser buffer T1501
The water level inside the selector tank is above start/stop level for P1501 (LC2301)
The mixer in the selector tank is in operation
The measured pH value is above or below start/stop level for P1501 (QIC2301). In case of
acid control, the pH must be above start/stop pH settings (pH start level contains higher value
than pH stop level). In case of caustic control, the pH must be below start/stop pH settings
(pH start level contains lower value than pH stop level).
The neutraliser dosing is based on pulse-/pause mode. Dosing can only be active during
pulse time. Upon pH start (based on pH start/stop level QIC2301) the pulse-/pause control
always restarts with pulse. If pulse-/pause mode is not required, enter 0.0 minutes for the
pause time, and this option is disabled.
Pump P1501 to be free of failures.
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To limit the full range of the dosing pump, it is possible to limit the output value of the PID controller.
This can be done for the minimum value, as well as the maximum value.
It is common, not to use te pulse-pause option in this method. Therefore enter 0.0 minutes as pause
time.
The option of automatic PID mode is generally only used, when the retention time of the water in the
selector is rather short.
It is common, not to use te pulse-pause option in this method. Therefore enter 0.0 minutes as pause
time.
The option of manual PID mode is generally only used, during test periods.
The option of ‘bucket principle’ is generally only used, when the retention time of the water in the
selector is rather long.
In all situations, the pH value is monitored, and an alarm is generated if pH value is too low for too long.
Same when it is too high for too long. All alarm settings for pH and time are adjustable. Both alarms are
only for indication, and there is no further action.
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Settings
The following settings shall be available for configuration by the operator via the HMI:
Setting Typical Adjustable range
Start level dosing pump neutraliser P1501 – LC2301 22.0 % 0.0 - 9999.9 %
Stop level dosing pump neutraliser P1501 – LC2301 17.0 % 0.0 - 9999.9 %
--- --- ---
Setpoint PID pH controller selector tank – Capacity dosing pump … pH 0.0 – 9999.9 pH
neutraliser P1501 – QIC2301
On delay PID pH controller – QIC2301 45.0 sec. 0.0 – 9999.9 sec.
Initial out PID pH controller – QIC2301 (*1) 0.0 L/h 0.0 - 9999.9 L/h
Proportional gain PID pH controller (P-factor) – QIC2301 8.000 % 0.000 – 999.999 %
Integral action PID pH controller (I-factor) – QIC2301 4.000 sec. 0.000 – 999.999 sec.
Derivative action PID pH controller (D-factor) – QIC2301 0.000 sec. 0.000 – 999.999 sec.
Deadband PID pH controller – QIC2301 0.2 pH 0.0 – 9999.9 pH
Minimum output value PID pH controller – QIC2301 0.0 L/h 0.0 - 9999.9 L/h
Maximum output value PID pH controller – QIC2301 30.0 L/h 0.0 - 9999.9 L/h
Actual output PID pH controller – Capacity dosing pump neutraliser … L/h n.a.
P1501 – QIC2301 (READ ONLY)
--- --- ---
Capacity dosing pump neutraliser P1501, when running on hand or in 5.0 L/h 0.0 - 9999.9 L/h
manual PID mode – QIC2301
pH stop level dosing pump P1501 7.2 pH 0.0 – 9999.9 pH
pH restart level dosing pump P1501 6.2 pH 0.0 – 9999.9 pH
Pulse time dosing pump neutraliser P1501 2.0 min. 0.0 – 9999.9 min.
Pause time dosing pump neutraliser P1501 2.0 min. 0.0 – 9999.9 min.
Actual pulse time dosing pump neutraliser P1501 (READ ONLY) … min. n.a.
Actual pause time dosing pump neutraliser P1501 (READ ONLY) … min. n.a.
On delay pH alarm selector tank – QIC2301 180.0 sec. 0.0 – 9999.9 sec.
Low pH alarm selector tank – QIC2301 5.8 pH 0.0 – 9999.9 pH
High pH alarm selector tank – QIC2301 7.5 pH 0.0 – 9999.9 pH
*1 : Entering 0.0, disables initial output option, and controller uses last known values.
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
5.4 Anoxic T2401 – Level LC2401, mixer MX2401 and feed pump P2401
Description
Anoxic tank T2401 receives the water from the selector tank, and continuously circulates this water
over the aeration tank.
Level in the anoxic tank is measured, and settings are available to create a start/stop signal for the
mixer MX2401, and the feed pump P2401.
Furthermore, there are two settings to create a high level alarm in this tank. Upon high level detection
in this tank, the feed to the anoxic tank is stopped.
The level is measured by a 4..20mA pressure sensor, hanging near the bottom of the tank. This
analogue signal refers to a measuring range, as indicated on sensor type shield. HMI offers the
possibility to re-calibrate this 4…20mA signal, so an empty tank shows 0% and a full tank (just before
draining or overfloating) shows 100%. This calibration will be done by our commissioning engineer.
Mixer MX2401 is started by a softstarter. That is why the Nijhuis PLC does allow for a certain amount
of time to receive a RUN detection, before an alarm is generated. This time is adjustable.
The additional condition for P2401 to run, is the absence of a high level alarm in the anoxic tank
(LC2401), as well as the absence of high level alarm in the aeration tank (LC3001). The unit switch of
aeration tank T3001 should be on automatic mode. The feed pump P2401 runs on an adjustable
frequency.
Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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5.5 Aeration tank T3001 – level LC3001, feed pumps P3002 and P3022
Description
Aeration tank T3001 receives the water from the anoxic tank and circulates it back into this same anoxic
tank. Simultaneously, water is withdrawn from the aeration tank, and pumped over two ‘floc-flot’
systems to the effluent channel.
Level in the aeration tank is measured, and settings are available to create a start/stop signal for the
blowers BW30x1, which are explained in the next chapter about oxygen control. Level measuring also
creates signals for the start of flotation unit FU2601, and the start of flotation unit FU2701. The start of
these flotation unit will automatically lead to the start of respective feed pumps P3002 and P3022.
Furthermore, there are two settings to create a high level alarm in this tank. Upon high level detection
in this tank, the feed from the anoxic tank is stopped.
The level is measured by a 4..20mA pressure sensor, hanging near the bottom of the tank. This
analogue signal refers to a measuring range, as indicated on sensor type shield. HMI offers the
possibility to re-calibrate this 4…20mA signal, so an empty tank shows 0% and a full tank (just before
draining or overfloating) shows 100%. This calibration will be done by our commissioning engineer.
The additional condition for feed pump P3002 (flotation unit FU2601) is the presence of the Volt-free
contact 133K3 (Control panel P1 – Page 133). This contact allow client to disable the effluent, whenever
this effluent channel, effluent tank, or something else, should not be able to receive the water. This
contact must be wire-bridged if not needed.
This same Volt-free contact is used for the start condition of feed pump P3022 (flotation unit FU2701).
The unit switch of aeration tank T3001 should be on automatic mode. General chapter 1.6 explains
more about the unit switch.
The level in the aeration tank may vary, and therefore the head-pressure of both feed pumps P3002
and P3022. To maintain a constant flow of water through the flotation units FU2601 and FU2701, the
frequency is adjusted linearly, where the pump reduces the frequency at higher level, and increases
the frequency at lower level. The linear calculation is based on a minimum and maximum level in the
aeration tank (LC3001), a minimum frequency at maximum level, and a maximum frequency at
minimum level (P3002 and P3022). Every adjustable interval time, a new calculation is done, and the
actual frequency of P3002 and P3022 are adjusted.
Would feed pump P3002 or P3022 be started on hand, another adjustable frequency becomes valid.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
5.6 Aeration tank T3001 – Oxygen measuring QIC3001A/B and blowers BW3001, BW3021 and
BW3041
Description
The oxygen is measured in the aeration tank. This is done by means of 2 oxygen sensors, that are both
connected to their own local transmitters. Beside local read-out of the measurement, each transmitter
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also provides 2 analogue 4…20mA signals to the control panel. Sensor does not only measure oxygen,
but also temperature. The preference settings in the HMI allow the operator to select, which sensor
(QIC3001A or QIC3001B) is used for the controls. In case none of the sensors is enabled, an alarm is
generated. In case both sensors are enabled, the average value of the two is calculated.
The HMI refers to this average value, but be aware that there is no actual average, if only one sensor
is enabled.
The both oxygen sensors are compared against each other, and it is determined what the deviation
between the two sensors is. In case the deviation is exceeded an adjustable max. value, an alarm is
generated. Alarm requires operator reset. In case of doubt on one of the sensors, disable that one for
further controls, and enable the other one.
Both oxygen sensors can generate a low oxygen alarm, as well as a high oxygen alarm. Both alarms
come with an adjustable time delay. These alarms are only for indication, no further actions are taken
in the controls.
In both oxygen sensors the temperature is measured as a second value. The aeration tank can
generate an alarm based on either one of the sensors. This can be a low temperature alarm, and also
a high level alarm. Both alarms come with an adjustable time delay. These alarms are only for indication,
no further actions are taken in the controls.
In regards to the oxygen control, the unit switch of the aeration tank T3001 is assumed to be in
automatic mode. See general chapter 1.6 for further information.
Based on the measured oxygen value, an adjustable start-, and stop level define the start of the oxygen
control in general. If oxygen level drops below start level, the oxygen control is activated. In case the
level raises above stop level, the oxygen control is de-activated. It is optional what to do in the de-
activated state of the oxygen control. A preference switch in the HMI can enable or disable the pulse-
pause control on the so called ‘above oxygen stop level’ situation. Disabling this option will result in all
blowers to be off, during the entire period that oxygen control is de-activated. Enabling this option will
result in the blower to run in a pulse- pause mode (always starting with pause). This will make sure that
aeration tank is shortly aerated (and mixed) every now and then, and prevent the settling of particles to
the bottom of the tank.
The amount of blowers can be determined by operator. The frequency during pulse-/pause mode can
be entered as a value in-between 25 and 180Hz. There are 2 softstarter controlled blowers (each
defined to be 60Hz), and 1 VSD controlled blower (being able to run in-between 25 and 60Hz). The
entry is put into a so-called splitter box, that calculates back the value into the amount of blowers
required. Some examples:
Request for 25 Hz, will result in the VSD blower BW3041 to run alone, at 25Hz.
Request for 120 Hz, will result in one of the softstarter blowers (BW3001 or BW3021), and the
VSD blower (BW3041 at 60Hz) to run
Request for 135 Hz, can not be achieved, and will result in the same situation as 120Hz.
Etc.
The control arranges for another blower to take over, in case another one is switched off, or does have
a failure. A little tricky situation is valid when BW3041 is switched of (or in failure). The remaining
possible frequencies are now limited to 0, 60 and 120Hz. Would setpoint require 30Hz, it is only possible
to run 60Hz, and that is what will happen, during pulse-pause mode.
The above splitter box information, is also valid for the manual PID mode. This is also a preference
setting in the HMI. The oxygen control has to meet all required start conditions, but the PID uses the
value as set in the setpoint ‘desired frequency blowers BW30x1, when running in manual PID mode’.
PID adjustment of output value will not be activated. This value can also be in-between 25 and 180Hz.
Again, some ranges can’t be set, due to unavailability. Same when VSD blower BW3041 is not
available, the others will have to take over, but have only limited possibilities.
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The two softstarter controlled blowers (BW3001 and BW3021) are running on preference. If only one
of them is needed, the one to be preferent (preferential blower) will start. The preference between the
two mentioned blowers is automatically exchanged once splitter box requires at least on of them to be
started. The preference is also automatically changes to the other blower, if one has a failure, or is
actually switched off.
The disadvantage of bigger sized motors, is their limitation in the amount of starts per hour. In general,
a blower motor should not be started more than 6 times per hour. This can be easily achieved by
entering a minimum on time, as well as a minimum off time, of 5 minutes each. Meaning that when
blower has started, it will run at least for 5 minutes, even when there are stop conditions (not alarm
related ofcourse). Once blower is stopped, it is stopped for at least 5 minutes, even when there are new
start conditions.
To prevent bigger load on the incoming power, bigger sized motors should not be started
simultaneously, so the blowers come with a ‘starting time’ setpoint. When a blower is started, the other
2 blowers are blocked from starting for the specified amount of time.
Blowers BW3001 and BW3021 are controlled by a softstarter. In that case, the Nijhuis PLC does allow
for a certain amount of time to receive a RUN detection, before an alarm is generated. This time is
adjustable.
Oxygen (blower) control may also be on PID control. Preference setting (HMI) should be on automatic
mode. During entire oxygen start condition, the PID control determines an output value, that has to be
translated to the right amount of blowers, at the right frequencies. This is done by the same splitter box,
as explained above. The output value of the PID controls can be found in the settings (25-180Hz). The
VSD blower BW3041 is the first blower to be started, and the calculated frequency for this blower is
also shown in the settings. Both values are READ ONLY ofcourse.
Assuming that actual oxygen value is below setpoint, you will notice the first blower (BW3041) to control
all the way up to 60Hz. PID control will control further till 85Hz, after which the preferent softstarter
activates BW3001 or BW3021. At this point BW3041 will go back to 25Hz. Again, BW3041 will control
further till 60Hz (referring to 120Hz on the PID control output). It is only at the point where PID control
passes 145Hz, before the non-preferent softstarter is also started, and BW3041 goes back to 25Hz.
Assuming that actual oxygen value is above setpoint and all three blowers are in operation, you will
notice the blower (BW3041) to control all the way down to 25Hz (referring to 145Hz on the PID control
output). PID control will control further till 120Hz, after which the non-preferent softstarter de-activates
BW3001 or BW3021. At this point BW3041 will go back to 60Hz. Again, BW3041 will control further
down till 25Hz (referring to 85Hz on the PID control output). It is only at the point where PID control
passes 60Hz, before the preferent softstarter is also de-activated, and BW3041 goes back to 60Hz.
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but the output may also be temporary frozen, once the measured value is with the range of setpoint
plus its Deadband, and the setpoint minus its Deadband.
Upon start of blower control, the PID controller starts with an on-delay. During this period, the output of
the blower(s) will be as defined by the initial value (unless set-up to be 0.0 Hz). In that last case, it will
restart with the value it was last stopped with. Only after the on-delay, the actual PID controlling is
activated. If an initial value is entered (other than 0.0Hz), this value should be in the range of 25 to
180Hz.
To limit the full range of the three blowers, it is possible to limit the output value of the PID controller.
This can be done for the minimum value, as well as the maximum value. Be aware that this value comes
in the range of 25 to 180Hz.
It is important that the setpoint of the oxygen controller lays not too close to the setpoint ‘oxygen stop
level’. Any short overshoot of oxygen measuring may cause the entire blower control, to stop
completely. Any PID control can only work if it can properly work/control around its setpoint.
Due to the minimum on- / off time of the individual blowers, as well as the gaps in controllable frequency
ranges, the entire PID control will not be fluently at all times. A little altitude around setpoint should be
acceptable.
When running blower BW3041 on hand, another setting is valid. Obviously, this setting can only contain
values in-between 25 and 60Hz.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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6 P&ID Sheet 4 (part 2 of 3) – Flocculant make-up unit T1821, Flocculator PF0901 and flotation unit
FU2601
Inside the DAF unit, the particles that can be separated from the waste water, will either sink to the
bottom (heavy particles), or will be forced to the surface (light floatable particles). Nijhuis offers a range
of DAF units, where this project uses GDF and IPF units. Technically they are the same, except for the
size of the unit. Highly polluted waste water requires a bigger unit (GDF), while a smaller unit (IPF) can
be used for less polluted water. To make up for the size of the unit, the IPF is equipped with internal
diagonal plate, to force the wastewater into a pre-defined flow-path. This make it easier for the heavier
particles to sink to the bottom, and the floatable particles to come to the surface.
DAF unit FU2601 is a GDF type
Before wastewater is entering the DAF unit, it will first pass a flocculator. The flocculator is a tubing
system, where chemicals are added into the wastewater. The length and shape of the flocculator
determines the amount of mixture of chemicals with the water. Additionally, saturated water of the DAF
unit’s aeration system, can be injected as well.
In this specific flocculator, the chemical dosing only consists of flocculant from make-up unit T1821.
The sole purpose of wastewater/flocculant mixing, is to bind the floatable particles, and create flocks
that can more easily be brought to the surface.
Flocculant injection will be injected in a pre-engineered location. The amount of flocculant required, will
be determined by the commissioning engineer.
DAF unit is based on an overfloat principle to the effluent. This will maintain a pre-defined level in the
flotation unit, that can be adjusted within a certain range by the commissioning engineer. When in
operation, the unit is started by pumping around water, through a saturation pipe. The discharge
pressure of this recirculation system could be approx. 5 Bar. Compressed air with a pressure of approx.
6 Bar is added in the pipe. The water absorbs the air and the mixture is released in the flotation unit.
Water remains in the unit, while the air will flow to the surface of the unit, creating an upward flow of air
all through the unit. The floatable particles will be forced to surface, after which the skimmer drive can
remove them into a so called ‘sludge compartment’ of the DAF unit.
Heavy particles will collect in designed areas, and are periodically drained back into the WWTP.
Commonly a sand gutter will take care that only the water returns, and the heavy particles can be
removed by operator.
T1821 is a flocculant make-up unit, that works stand alone. The make-up procedure is explained in
detail in the concerning chapter. Compared to make-up unit T1901, this unit consists of 2 compartments
only, where second compartment is used to pump prepared flocculant to the flocculator, by means of
the flocculant dosing pump P1821. The level sensor in this compartment protects this pumps from
running dry.
The following items of the plant are directly controlled and / or affected under this process area of the
works:
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6.2 Flocculator PF0901 – Flocculant dosing pump P1821, V1833 and FIS1822
Description
The function of the flocculator has been explained in the general introduction. From control point of
view, there is not much to explain about the flocculator as a unit. The only component that needs
explanation is the flocculant dosing pump P1821. The level in Aeration tank T3001 determines the start
of flotation unit FU2601. Once start-up procedure of flotation unit has finished, the feed pump P3002
will be started, and simultaneously the flocculant dosing pump P1821 will be started.
The capacity of this pump is pre-set, but adjustable in HMI. Value is entered in L/h, but internally in the
Nijhuis PLC scaled back into a frequency value (Hz).
In the dosing line between pump and flotation unit additional water is added through a static mixer. This
is the so called post-dilution. This water valve V1833 is opened simultaneously with the flocculant
dosing pump P1821. The amount of water that is added to the flocculant, is monitored by flow switch
FIS1822. If water flow is too low for too long, it will generate an alarm. This alarm is only for notification,
there will be no further actions.
In automatic mode, the run condition of flocculant pump is depending on level detection in flocculant
make-up unit T1822. If level switch LS1822 detects no more level, it needs to stop the flocculant dosing
pump P1841. Further functions of level switch LS1822 will be explained in the chapter about the
flocculant make up unit T1821.
Any cause of stop for flocculant dosing pump P1821, does not lead to a full stop of flotation unit FU2601
and its feed pump P3002.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
6.3 Flotation unit FU2601 – Aeration and Skimmer – P2601, V2613, PIS2601, PIS2602, FIS2601 and
SC2601
Description
The functional explanation of the aeration and skimmer system have already been mentioned in the
general introduction of this chapter.
The level inside Aeration tank T3001 determines the start and stop of flotation (DAF) unit FU2601.
There is both a start procedure of the DAF unit, as well as a stop procedure.
Start procedure
The recirculation pump P2601 is started, and it awaits pressure switch PIS2601 to detect high enough
pressure (ca. 5 Bar). Upon detection of this pressure, the aeration valve V2613 is opened, compressed
air is introduced (ca. 6 Bar), and the aeration/saturation system will start to create an upward airflow
inside the DAF unit. This period takes an adjustable amount of time, after which the feed pump P3022
is allowed to be started. Flocculant pump P1821 will follow right after
During start procedure, and during normal operation, the skimmer drive is operated in an adjustable
pulse-and pause mode.
Stop procedure
The feed pump P3002 and flocculant dosing pump P1821 are stopped. From here, the stop procedure
is in 2 phases. In phase 1, the aeration valve V2613 remains opened, and recirculation/saturation
remains active. In phase 2, the aeration valve V2613 is closed, but recirculation pump P2601 will
continue to de-aerate the system. The periods of both phases take adjustable amounts of time. When
time period of phase 2 has elapsed, the recirculation pump and skimmer drive are stopped as well.
During phase 1 of the stop procedure, the skimmer continues to operate in pulse-/pause mode, but in
phase 2 is runs continuous.
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The PLC is programmed, that once the DAF unit is in operation, it remains in operation, and only the
feed pump is stopped. If DAF unit was not yet in operation, it will not bother to start.
Recirculation pump
Recirculation pump is in operation during start procedure, normal operation and stop procedure. The
recirculation pump is only stopped in case of failure with pump itself, or when the pressure switch
PIS2601 does not detect enough flow, for a continuous period of 30 seconds with running pump. This
situation generates an alarm, and stops the DAF unit. An operator reset is required.
Aeration valve
The aeration valve is in operation during start procedure, normal operation and during phase 1 of the
stop procedure. In all situations, the aeration valve is immediately stopped, when pressure switch
PIS2601 does no longer detect its minimum pressure. When pressure comes back, valve is opened
again, but it takes a minimum (adjustable) amount time till feed pump is restarted.
Skimmer drive
Skimmer drive generally works in pulse- and pause mode. Both are adjustable in HMI. When a value
of 0 seconds is entered for the pause time, this pulse-/pause mode is de-activated, and the skimmer is
in continuous mode, obviously dependant to its start conditions. During normal conditions, the skimmer
drive is started during start procedure, normal operation, and during stop procedure(s) of DAF unit. In
phase 2 of the stop procedure, the skimmer will always run continuously.
Skimmer drive, skims off the floating layer of sludge into the sludge compartment. There is a level
sensor in this compartment, that can also generate a high level alarm. In case of a high level alarm, the
skimmer is stopped. Would the stop of skimmer take a longer time period, as defined by setting ‘on
delay stop feed pump on standstill skimmer’, another alarm is generated, and the feed to DAF unit is
stopped. Normally the aeration will remain in operation during this alarm.
Skimmer drive always runs at an adjustable frequency.
Recirculation may be controlled by a softstarter. In that case, the Nijhuis PLC does allow for a certain
amount of time to receive a RUN detection, before an alarm is generated. This time is adjustable.
The flotation unit FU2601 comes with a unit switch, as well as a trigger start switch. These are both
explained in general chapter 1.6.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
6.4 Flotation unit FU2601 – Drains – V2605, V2608A, V2608B and SG3721
Description
As mentioned in the general introduction, the heavy particles gather in pre-designated areas of the DAF
unit. These need periodical draining, by shortly opening a valve in the lowest point of the area. The
particles, along with water are drained back to Selector tank T2301. To separate the sand and other
particles before T2301, a sand gutter SG3721 is installed. The construction of this gutter is in such way,
that only the water part should be returned to T2301. Operator should clear the sand gutter periodically.
The sand gutter, as well as the pipework, can only handle the opening of one drain valve at a time.
All steps of the drains cycles are adjustable in the HMI. Draining is only active, when feed pump to DAF
unit is in operation, otherwise DAF unit would be emptied. When there is a high level alarm in Selector
tank T2301, DAF unit can remain in operation, but only the drain valves are temporary disabled.
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Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
Description
All the sludge is skimmed of the water surface into the sludge compartment. Inside this compartment
level is measured, and with two setpoints a start and stop level are created for sludge pump P2602.
The level is measured by a 4...20mA pressure sensor, installed near lowest point of this compartment.
This analogue signal refers to a measuring range, as indicated on sensor type shield. HMI offers the
possibility to re-calibrate this 4…20mA signal, so an empty compartment shows 0% and a full
compartment (just before draining or overfloating) shows 100%. This calibration will be done by our
commissioning engineer.
Generally the sludge pump is only depending on the start- and stop level in the sludge compartment.
In this specific situation, the sludge return can follow 3 different paths:
Excess sludge to client – Selection valve V2635
Sludge return valve to selector tank – Selection valve V2655
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The control of these selection valves is explained in the next chapter. It is pretty clear that there are
different conditions valid for the three different paths.
In either of the three different paths, feed pump P2602 will only be started if the concerning path is
confirmed to have a fully opened valve. All mentioned valves come with end-contacts to feed-back the
opened and the closed position.
There can be different causes for the sludge compartment to reach high level alarm. Again, two
adjustable setpoints define the start and stop of this specific alarm. The consequence of a high level
alarm will be the stop of skimmer drive SC2601. If this situation remains active for too long, it may
eventually result in the stop of feed pump P3002. See chapter about the skimmer SC2601.
Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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6.6 Flotation unit FU2601 – Excess sludge valve V2635, and sludge return valves V2655 and
V2675
Description
All the sludge is skimmed of the water surface into the sludge compartment. Inside this compartment
level is measured, and with two setpoints a start and stop level are created for sludge pump P2602.
There are now 3 different locations where this sludge may be pumped to, already partly explained in
previous chapter of sludge compartment. The valid location selection are made by means of three
selection valves:
Excess sludge valve V2635
Sludge return valve to selector tank V2655
Sludge return valve to anoxic/aeration tank V2675
All three valves are checked for correct opening and closing, by means of end-contacts. If the end-
contact of the open position (of selected path) is not detected, the pump is not allowed to run. The
closed detection is just used for generating an alarm. The operators should check the functioning of the
valve/pump combination in case specific alarms appear. Since it takes a certain amount of time for the
valve to open or close, the alarm comes with an adjustable time delay.
General opening condition for this valve is also the presence of the ‘client ready for sludge
F2501/FU2601/FU2701’ contact. See chapter about sludge pump P2602.
General opening condition for this valve is also the absence of high level alarm in the selector tank.
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case the pump P0301 or P0321 would be running, but V2655 comes up with an opening alarm, the
sludge return is switched over to V2675.
Valve V2675 is also used as block valve, meaning that it will close when pump P2602 is not allowed to
run (no level in sludge compartment, or client not ready), or when pump P2602 is not able to run
(generally when suffering from a failure, or being switched off). Pump P2602 will only be activated once
valve V2675 detected to be open.
General opening condition for this valve is also the absence of high level alarm in the aeration tank.
For all three valves, an adjustable off delay is valid. This is necessary, since sludge pump P2602 is
frequency controlled, and valve cannot be closed before pump is completely stopped.
Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
Description
The flocculant make-up unit T1821 comes from the range of Nijhuis in-house developed make-up
stations. The unit works stand-alone, and fully automated. The unit consists of 2 compartments, where
first compartment is used to prepare a new batch, while second compartment stores the ready-to-use
flocculant.
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The only signal that connects with the rest of the WWTP, is the low level alarm in the second
compartment. Lack of level here, will stop the flocculant dosing pumps P1821 and P1841, to prevent
them from running dry. How this affects the control of the rest of the WWTP, can be different per project.
Generally the main water flow needs to kept going, so it is only the flocculant dosing that stops. This
can be good explanation for poor/worse results in the effluent water quality.
Flocculant make-up unit T1821 comes with a unit switch. This switch has been explained in the general
chapter 1.6. The information of this chapter is only valid in case unit switch is in automatic mode.
Another setting ‘maximum water volume for one batch’ determines the amounts of pulses required,
before make-up is ended, and cycle goes to step 2. Actual volume of current batch is displayed as read
only value (‘Actual water volume – Read only). Obviously, detection of high level alarm in first
compartment will also stop the make-up, and close the water supply valve V1823.
The amount of run-time per pulse of flow sensor can be rather low. It would be strange to start the
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screw for minor amounts of time. The actual run of DD1821 may be extended until a minimum amount
of total-run time has been ‘gathered’. This value is adjustable as ‘minimum on time dosing screw’. When
stop volume of the batch is reached, this minimum on time is ignored, and dosing screw will finish its
count-down to zero.
First of all, the PLC system determines the run-time for DD1821, valid for one detection of flow pulse
FIS1821. This value can be explained as:
Calculated on-time dosing screw on every pulse of FIS1821 [sec.] = (A x C x 60) / B, where
A = Desired concentration batch [%]
B = Capacity dosing screw [grams/minute]
C = K-Factor flow meter pulses [litres/pulse]
In an example where
A= 0,3% (or equivalent 3 gram/litre)
B = 363 grams/minute]
C = 10 litres/pulse
Calculated on time (per pulse) is 4,95 seconds.
Upon every detection of a pulse (FIS1821), the total accumulated on-time of the screw is added with a
value of 4,95. Only during step 1, and taken that water valve is opened. Upon every second that dosing
screw is in operation, the value is decreased with 1,00. Beside all other conditions, Dosing screw can
only be in operation when accumulated on-time of screw is above 0,0 seconds.
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A pulse contact that is connected to a digital input of the Nijhuis PLC system. This input gives
a pulse whenever the sensor detects a certain amount of litres to have passed. This is called
the K-factor of the pulse contact. A typical value is 10 Litres per pulse.
In both cases the signal is only accepted when make-up is activated on level request, and when water
valve V1823 has actually been energized.
While preparing a batch of flocculant, the flow sensor is checked over an adjustable amount of time,
defined by ‘measuring period filling speed alarms’. By the end of this period, the actual amount (during
this period) must exceed the value of ‘minimum filling speed alarm’, and not pass the value ‘maximum
filling speed alarm’. If that would be the case, an alarm is generated, and make-up procedure is
stopped, until operator hits the reset button.
Actual volume value of current measuring period is available as read only value in the HMI.
After a successful measuring period, a new period is started, and all values are reset to 0. The filling
speed alarms can no longer be activated if water valve is closed.
Be aware that the accumulated volumes can only add values as defined by the K-factor.
There are 2 adjustable level setpoints that create following switch/alarm points:
Low level preparation section. This is both used to generated a (properly) delayed low level
alarm, as well a decent switching point to start the make-up cycle (step 1)
High level alarm preparation section.
Both low level alarm, and high level alarm are merely for information.
Low level alarm has an adjustable on-delay time, defined by ‘on delay low alarm preparation section’.
Upon detecting a low level alarm, the water valve V1823 will be closed, and dosing screw may be
stopped.
High level alarm has a pre-set on-delay of 5 seconds, and another pre-set off-delay of 60 seconds.
Upon detecting a high level alarm, the water valve V1823 will be closed, and dosing screw may be
stopped. Make sure that high level setpoint is set higher than the value that should be theoretically be
reached when low level setpoint is added with the contents defined by ‘maximum water volume for one
batch’ setpoint.
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Once make-up cycle starts (step 1), the dosing screw will not be started until at least the ‘minimum watr
volume for starting mixer and dosing screw’ timer has elapsed. From here on the start and stop of the
dosing screw, are dependent on the total accumulated on-timer, as explained earlier in this chapter.
Obviously, the water valve must be opened, and there should not be any failure issue with mixer or
dosing screw.
To prevent dosing screw from starting/stopping too often, the accumulated ‘total on-time dosing screw’
should contain a minimum value. Once water volume of total batch is detected, this limitation is no
longer valid.
The heater on the dosing screw is activated on a continuous power supply. There are no controls for
this component.
Vibrator M1821
While dosing screw is in operation, the vibrator will be active in a pulse-/pause mode. The pulse time
(‘on time vibrator’) can be rather short (e.g. 1 sec.), and pause time (‘off time vibrator’) can be a little
longer (e.g. 10 sec.). The function is solely to have the flocculant powder drop to the bottom of the
powder compartment properly.
Mixer MX1821
Mixer is in operation during entire make-up cycle (step 1), as well as the ripening time (step 2). The first
start of mixer, knows the same limitation as already explained for the dosing screw. The dosing screw
will have to be activated at least once, to start mixers. After that, dosing screw may stop, but mixers
can remain in operation. After the make-up has finished, the mixers will remain active until ripening
timer has elapsed. This time is adjustable by means of setpoint ‘ripening time mixer’.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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Inside the DAF unit, the particles that can be separated from the waste water, will either sink to the
bottom (heavy particles), or will be forced to the surface (light floatable particles). Nijhuis offers a range
of DAF units, where this project uses GDF and IPF units. Technically they are the same, except for the
size of the unit. Highly polluted waste water requires a bigger unit (GDF), while a smaller unit (IPF) can
be used for less polluted water. To make up for the size of the unit, the IPF is equipped with internal
diagonal plate, to force the wastewater into a pre-defined flow-path. This make it easier for the heavier
particles to sink to the bottom, and the floatable particles to come to the surface.
DAF unit FU2701 is a GDF type
Before wastewater is entering the DAF unit, it will first pass a flocculator. The flocculator is a tubing
system, where chemicals are added into the wastewater. The length and shape of the flocculator
determines the amount of mixture of chemicals with the water. Additionally, saturated water of the DAF
unit’s aeration system, can be injected as well.
In this specific flocculator, the chemical dosing only consists of flocculant from make-up unit T1821.
The sole purpose of wastewater/flocculant mixing, is to bind the floatable particles, and create flocks
that can more easily be brought to the surface.
Flocculant injection will be injected in a pre-engineered location. The amount of flocculant required, will
be determined by the commissioning engineer.
DAF unit is based on an overfloat principle to the effluent. This will maintain a pre-defined level in the
flotation unit, that can be adjusted within a certain range by the commissioning engineer. When in
operation, the unit is started by pumping around water, through a saturation pipe. The discharge
pressure of this recirculation system could be approx. 5 Bar. Compressed air with a pressure of approx.
6 Bar is added in the pipe. The water absorbs the air and the mixture is released in the flotation unit.
Water remains in the unit, while the air will flow to the surface of the unit, creating an upward flow of air
all through the unit. The floatable particles will be forced to surface, after which the skimmer drive can
remove them into a so called ‘sludge compartment’ of the DAF unit.
Heavy particles will collect in designed areas, and are periodically drained back into the WWTP.
Commonly a sand gutter will take care that only the water returns, and the heavy particles can be
removed by operator.
T1821 is a flocculant make-up unit, that works stand alone. The make-up procedure is explained in
detail in the concerning chapter. Compared to make-up unit T1901, this unit consists of 2 compartments
only, where second compartment is used to pump prepared flocculant to the flocculator, by means of
the flocculant dosing pump P1841. The level sensor in this compartment protects this pumps from
running dry.
The following items of the plant are directly controlled and / or affected under this process area of the
works:
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7.2 Flocculator PF0921 – Flocculant dosing pump P1841, V1853 and FIS1842
Description
The function of the flocculator has been explained in the general introduction. From control point of
view, there is not much to explain about the flocculator as a unit. The only component that needs
explanation is the flocculant dosing pump P1841. The level in Aeration tank T3001 determines the start
of flotation unit FU2701. Once start-up procedure of flotation unit has finished, the feed pump P3022
will be started, and simultaneously the flocculant dosing pump P1841 will be started.
The capacity of this pump is pre-set, but adjustable in HMI. Value is entered in L/h, but internally in the
Nijhuis PLC scaled back into a frequency value (Hz).
In the dosing line between pump and flotation unit additional water is added through a static mixer. This
is the so called post-dilution. This water valve V1853 is opened simultaneously with the flocculant
dosing pump P1841. The amount of water that is added to the flocculant, is monitored by flow switch
FIS1842. If water flow is too low for too long, it will generate an alarm. This alarm is only for notification,
there will be no further actions.
In automatic mode, the run condition of flocculant pump is depending on level detection in flocculant
make-up unit T1822. If level switch LS1822 detects no more level, it needs to stop the flocculant dosing
pump P1841. Further functions of level switch LS1822 will be explained in the chapter about the
flocculant make up unit T1821.
Any cause of stop for flocculant dosing pump P1841, does not lead to a full stop of flotation unit FU2701
and its feed pump P3022.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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WWTP Sobono Energy - Biotech Farms - Philippines
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
7.3 Flotation unit FU2701 – Aeration and Skimmer – P2701, V2713, PIS2701, PIS2702, FIS2701 and
SC2701
Description
The functional explanation of the aeration and skimmer system have already been mentioned in the
general introduction of this chapter.
The level inside Aeration tank T3001 determines the start and stop of flotation (DAF) unit FU2701.
There is both a start procedure of the DAF unit, as well as a stop procedure.
Start procedure
The recirculation pump P2701 is started, and it awaits pressure switch PIS2701 to detect high enough
pressure (ca. 5 Bar). Upon detection of this pressure, the aeration valve V2713 is opened, compressed
air is introduced (ca. 6 Bar), and the aeration/saturation system will start to create an upward airflow
inside the DAF unit. This period takes an adjustable amount of time, after which the feed pump P3022
is allowed to be started. Flocculant pump P1841 will follow right after
During start procedure, and during normal operation, the skimmer drive is operated in an adjustable
pulse-and pause mode.
Stop procedure
The feed pump P3022 and flocculant dosing pump P1841 are stopped. From here, the stop procedure
is in 2 phases. In phase 1, the aeration valve V2713 remains opened, and recirculation/saturation
remains active. In phase 2, the aeration valve V2713 is closed, but recirculation pump P2701 will
continue to de-aerate the system. The periods of both phases take adjustable amounts of time. When
time period of phase 2 has elapsed, the recirculation pump and skimmer drive are stopped as well.
During phase 1 of the stop procedure, the skimmer continues to operate in pulse-/pause mode, but in
phase 2 is runs continuous.
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The PLC is programmed, that once the DAF unit is in operation, it remains in operation, and only the
feed pump is stopped. If DAF unit was not yet in operation, it will not bother to start.
Recirculation pump
Recirculation pump is in operation during start procedure, normal operation and stop procedure. The
recirculation pump is only stopped in case of failure with pump itself, or when the pressure switch
PIS2701 does not detect enough flow, for a continuous period of 30 seconds with running pump. This
situation generates an alarm, and stops the DAF unit. An operator reset is required.
Aeration valve
The aeration valve is in operation during start procedure, normal operation and during phase 1 of the
stop procedure. In all situations, the aeration valve is immediately stopped, when pressure switch
PIS2701 does no longer detect its minimum pressure. When pressure comes back, valve is opened
again, but it takes a minimum (adjustable) amount time till feed pump is restarted.
Skimmer drive
Skimmer drive generally works in pulse- and pause mode. Both are adjustable in HMI. When a value
of 0 seconds is entered for the pause time, this pulse-/pause mode is de-activated, and the skimmer is
in continuous mode, obviously dependant to its start conditions. During normal conditions, the skimmer
drive is started during start procedure, normal operation, and during stop procedure(s) of DAF unit. In
phase 2 of the stop procedure, the skimmer will always run continuously.
Skimmer drive, skims off the floating layer of sludge into the sludge compartment. There is a level
sensor in this compartment, that can also generate a high level alarm. In case of a high level alarm, the
skimmer is stopped. Would the stop of skimmer take a longer time period, as defined by setting ‘on
delay stop feed pump on standstill skimmer’, another alarm is generated, and the feed to DAF unit is
stopped. Normally the aeration will remain in operation during this alarm.
Skimmer drive always runs at an adjustable frequency.
Recirculation may be controlled by a softstarter. In that case, the Nijhuis PLC does allow for a certain
amount of time to receive a RUN detection, before an alarm is generated. This time is adjustable.
The flotation unit FU2701 comes with a unit switch, as well as a trigger start switch. These are both
explained in general chapter 1.6.
Settings
The following settings shall be available for configuration by the operator via the HMI:
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Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
7.4 Flotation unit FU2701 – Drains – V2705, V2708A, V2708B and SG3721
Description
As mentioned in the general introduction, the heavy particles gather in pre-designated areas of the DAF
unit. These need periodical draining, by shortly opening a valve in the lowest point of the area. The
particles, along with water are drained back to Selector tank T2301. To separate the sand and other
particles before T2301, a sand gutter SG3721 is installed. The construction of this gutter is in such way,
that only the water part should be returned to T2301. Operator should clear the sand gutter periodically.
The sand gutter, as well as the pipework, can only handle the opening of one drain valve at a time.
All steps of the drains cycles are adjustable in the HMI. Draining is only active, when feed pump to DAF
unit is in operation, otherwise DAF unit would be emptied. When there is a high level alarm in Selector
tank T2301, DAF unit can remain in operation, but only the drain valves are temporary disabled.
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Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
Description
All the sludge is skimmed of the water surface into the sludge compartment. Inside this compartment
level is measured, and with two setpoints a start and stop level are created for sludge pump P2702.
The level is measured by a 4..20mA pressure sensor, installed near lowest point of this compartment.
This analogue signal refers to a measuring range, as indicated on sensor type shield. HMI offers the
possibility to re-calibrate this 4…20mA signal, so an empty compartment shows 0% and a full
compartment (just before draining or overfloating) shows 100%. This calibration will be done by our
commissioning engineer.
Generally the sludge pump is only depending on the start- and stop level in the sludge compartment.
In this specific situation, the sludge return can follow 3 different paths:
Excess sludge to client – Selection valve V2735
Sludge return valve to selector tank – Selection valve V2755
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The control of these selection valves is explained in the next chapter. It is pretty clear that there are
different conditions valid for the three different paths.
In either of the three different paths, feed pump P2702 will only be started if the concerning path is
confirmed to have a fully opened valve. All mentioned valves come with end-contacts to feed-back the
opened and the closed position.
There can be different causes for the sludge compartment to reach high level alarm. Again, two
adjustable setpoints define the start and stop of this specific alarm. The consequence of a high level
alarm will be the stop of skimmer drive SC2701. If this situation remains active for too long, it may
eventually result in the stop of feed pump P3022. See chapter about the skimmer SC2701.
Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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7.6 Flotation unit FU2701 – Excess sludge valve V2735, and sludge return valves V2755 and
V2775
Description
All the sludge is skimmed of the water surface into the sludge compartment. Inside this compartment
level is measured, and with two setpoints a start and stop level are created for sludge pump P2702.
There are now 3 different locations where this sludge may be pumped to, already partly explained in
previous chapter of sludge compartment. The valid location selection are made by means of three
selection valves:
Excess sludge valve V2735
Sludge return valve to selector tank V2755
Sludge return valve to anoxic/aeration tank V2775
All three valves are checked for correct opening and closing, by means of end-contacts. If the end-
contact of the open position (of selected path) is not detected, the pump is not allowed to run. The
closed detection is just used for generating an alarm. The operators should check the functioning of the
valve/pump combination in case specific alarms appear. Since it takes a certain amount of time for the
valve to open or close, the alarm comes with an adjustable time delay.
General opening condition for this valve is also the presence of the ‘client ready for sludge
F2501/FU2601/FU2701’ contact. See chapter about sludge pump P2702.
General opening condition for this valve is also the absence of high level alarm in the selector tank.
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case the pump P0301 or P0321 would be running, but V2755 comes up with an opening alarm, the
sludge return is switched over to V2775.
Valve V2775 is also used as block valve, meaning that it will close when pump P2702 is not allowed to
run (no level in sludge compartment, or client not ready), or when pump P2702 is not able to run
(generally when suffering from a failure, or being switched off). Pump P2702 will only be activated once
valve V2775 detected to be open.
General opening condition for this valve is also the absence of high level alarm in the aeration tank.
For all three valves, an adjustable off delay is valid. This is necessary, since sludge pump P2702 is
frequency controlled, and valve cannot be closed before pump is completely stopped.
Settings
The following settings shall be available for configuration by the operator via the HMI:
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
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