Category Archive: Automated Industrial Systems

PLCs and SCADA Systems in the Wastewater Treatment Industry

From cooking and drinking to bathing and washing to product manufacturing to waste management, water plays a role in many of our day-to-day applications. Once it has served its role in these applications, it is not simply discarded. It is categorized as wastewater—also referred to as sewage—and sent to a wastewater treatment facility, where it is cleaned up for reuse. This water use cycle ensures we maintain a sustainable supply of safe water for the future.

The wastewater treatment process is highly complex, requiring accurate and precise measurement and control over various equipment (e.g., pumps, purifiers, and filters) and equipment parameters (e.g., pressure, flow, and filtration). By integrating measurement and control technologies into operations, wastewater facilities can ensure they achieve and maintain the proper process conditions for effective and efficient water and wastewater treatment. In recent years, programmable logic controllers (PLCs) and supervisory control and data acquisition (SCADA) systems have grown in popularity within the industry as facilities work to manage the increase in wastewater stemming from rising water use across the residential, commercial, and industrial sectors.

Importance of PLCs in Wastewater Treatment

Programmable logical controllers (PLCs) are ruggedized digital computers often utilized for industrial process automation. They can be used to automate a single process or machine function or an entire system setup by stopping, starting, slowing, or speeding equipment operation in response to inputs from connected devices (e.g., control panels and sensors).

In the wastewater industry, these devices help ensure treatment operations proceed smoothly with little to no human operator involvement. Some of the equipment they are typically used to control include filtration and aeration units.

Compared to older automation technology (e.g., relays and timing mechanisms), PLCs have a number of advantages, such as:

  • Greater ease of use. PLCs require less time and resources to integrate as they can simply be reprogrammed to suit different process requirements and restrictions. In contrast, older automation technologies needed to be rewired to accommodate new specifications.
  • Better process reliability. PLCs automate equipment operation based on data provided by various sensors and input devices. This function ensures the process conditions remain appropriate at any given time.
  • Lower labor requirements. Automating wastewater treatment operations reduces the workload of human operators, freeing them up to focus on other important facility tasks.

Importance of SCADA Systems in Wastewater Treatment

PLCs are an essential component of supervisory control and data acquisition (SCADA) systems. SCADA systems consist of a collection of hardware and software components that collect, transmit, and distribute data across various devices within a network. The information can then be analyzed to determine whether any system adjustments are needed.

In the wastewater treatment industry, these systems are used to ensure the quality of the processed water. They provide graphical and numerical data about different process instruments and equipment and enable human operators to adjust operations accordingly in response to the provided information. These functions help ensure conditions during water treatment operations remain at effective and safe levels.

Some of the benefits of integrating SCADA systems in water and wastewater treatment facilities include:

  • Improved use of existing infrastructure and resources
  • Reduced risk of operator overload in situations where multiple system alarms may occur within a short period of time
  • Enhanced monitoring of remote and vulnerable sites
  • Decreased costs for utility companies and customers
  • Better oversight over systems and processes
  • Automated data collection and reporting operations

PLC and SCADA Solutions for the Wastewater Treatment Industry at Turner

PLCs and SCADA systems are key to improving water quality, increasing process efficiency, reducing labor costs, and more in wastewater treatment facilities. If you’re looking to integrate them into your facility, turn to the experts at Turner Integrated Systems.

We design, manufacture, and install control systems for a wide range of industries, including the wastewater treatment industry. Whether you need assistance with PLC programming and implementation, SCADA integration, hazardous areas design, or something else, we’ve got you covered. We will deliver an appropriate control solution and discuss how to properly use and maintain it to ensure it operates smoothly.

To learn more about our control system capabilities and how we can benefit your wastewater treatment facility, contact us today.

What is Industrial Automation?

 

What is Industrial Automation

Industrial automation uses computerized robotic control systems to facilitate the use of manufacturing equipment with minimal human intervention. Unlike manual industrial processes, automation does not require manual human operation of each mechanical aspect of the manufacturing process. 

Benefits of Industrial Automation

Automation has become the mainstay of industrial manufacturing due to its overwhelming cost efficiency and risk mitigation. Ongoing innovations and technological advancements have allowed manufacturers to upgrade their systems to increase product quality and overall productivity without the need for increased labor costs. 

Productivity

Industrial automation increases productivity, as the equipment can be programmed to run 24/7 at greater speeds than manually operated machinery. In addition, there is less worry about scheduling for holidays and weekends for an entire crew of employees. Production can continue apace without interruptions.

Quality

Since the parameters are programmed using computer software, there is less likelihood of costly mistakes due to human error. Automation further allows for more consistent and reliable product quality without the minute variations that commonly occur between workpieces in manual production.

Flexibility

Rather than having to adjust or install equipment for production shifts, automated systems can be configured to allow users to program changes with less manual intervention, facilitating faster and more reliable production adjustments.

Accuracy

Automated systems work in tandem with each part of the system, thereby reducing the risk of error between system components. In addition, computer software is pre-programmed for more accurate production.

Safety

Fewer workers will be needed on the line, and automated safety devices ensure that workers will spend less time in the vicinity of dangerous equipment as it operates. 

Disadvantages of Industrial Automation

The only real disadvantage of industrial automation is the initial investment. While upfront costs may seem intimidating, they are easily offset by the energy and labor savings, enhanced production, and reduced energy use and material waste.

Types of Industrial Automation Systems

Industrial automation is used in a wide variety of manufacturing and fabrication industries. A variety of automation systems have been developed to suit the needs of different applications.

Fixed or Hard Automation

Fixed automation, or hard automation, is used for the performance of a simple and repetitive task. This method is ideal for high-volume production with little variation, as modifications to fixed automation equipment can be expensive and time-consuming.

Programmable Automation

Programmable automation is ideal for batch production, as the automated equipment may be reprogrammed or changed out for each new design. The process requires manual adjustment of machinery between batches.

Flexible or Soft Automation

Flexible automation, or soft automation, uses computer software to direct manufacturing equipment. The equipment used in flexible automation allows for production adjustment without equipment changes.

Integrated Automation

Integrated automation takes from all of the above technologies and combines them into one manufacturing system that is capable of both large-scale and batch production through the use of a computerized control system and a variety of versatile machines. 

Industrial Automation Tools

Industrial automation relies on multiple internal tools. Below is a short list of the most common automation tools.

Programmable Logic Controller (PLC)

A PLC is an industrial computer control system used to manage automatic operations for pre-programmed manufacturing and industrial operations. This system constantly processes and analyzes information from sensors throughout the operation.

Supervisory Control and Data Acquisition (SCADA)

A SCADA system uses sensors and PLC systems throughout the manufacturing process to acquire and record data and events for analysis to enhance and improve system operations.

Human Machine Interface (HMI)

An HMI or Human Machine Interface is the user interface that connects an operator to the controller for an industrial system. The interface consists of hardware and software that allow user inputs to be translated as signals for machines that, in turn, provide the required result to the user. An HMI offers a visual representation of the operation of the machine providing real-time data.

Distributed Control System (DCS)

The DCS is the network that monitors and connects all of the devices and interfaces within the automated system.

Industrial Control Systems with Turner Integrated Systems

At Turner Integrated Systems, we are pleased to provide the highest quality industrial control systems in the industry. For more information on our automated industrial systems, contact us today!