www.vipa.com

VIPA Environmental Managementfor water / sewage and renewable energy

Global water management

Water is an element which is always available in climatically favorable zones, whereas in other zones man is confronted with permanent water shortage. In addition the global demand is permanently increasing whereby the infrastructure for water production and waste water purifica-tion has to increase successively, economically and in a future-proof way.

An essential part of water manage-ment is comprehensive water produc-tion and storage, as well as economic-al distribution of our drinkable water. Waste water purification and with it the

One of our most valuable raw materials is wa-ter. Enormous efforts are required to protect this raw material not only regionally and nationally but also worldwide.

te in all areas of water technology in facility construction, modernization or the networking of outstations. We see ourselves as a partner who under-stands your applications and provides you with required solutions from a single source. Our motto is to provide good service as well as experienced and customer oriented consulting – also of course on site.

water protection of rivers, reservoirs and lakes for bathing have to be in accordance with ever increasing standards and legal regulations. Finally, there is the matter of flood protection to control the effects of climatic change in an intelligent way.

The protection of our water reservoirs is important for future energy and agricultural demands that protect the natural eco system and are able face the requirements of a global society. This management is a challenge for all those involved in planning, implementation and innovati-on of the products to be deployed.

No matter which segment of water management you are in, VIPA, as a system provider, supports you to solve your tasks and requirements. With the deployment of highly modern products we were able to successfully participa-

Sewage plantWater management

Water supply

Renewable energy

The main focus of VIPA’s activities is in the area of combined heat and power plants (CHP) in combination with biogas plants. This form of alter-native and decentralized generation of electric power is gaining more and more importance in Germany.

Biogas plantSince it is not foreseeable how long our fossil fuels such as oil or natural gas will still be available, new methods of energy extraction become more and more important. One option is biogas production. The principle and the construction of a biogas plant are relatively simple.

Biogas plants are most often construc-ted in agricultural settings to ensure short distances for energy carriers. All kinds of biomass – organic materials that consists of carbohydrates, proteins and fats - are usable as base materials for biogas production, for example:

• Wastes from slaughterhouses • Animal liquid manure • Sewage sludge • Food remains • Organic waste

The technology required can´t cope wit-hout sophisticated automation enginee-ring, so this opens up a wide fi eld for VIPA products. We focus on long term cooperation with partners in the fi eld of biogas plants. Our system 200V has already been deployed as the main controller for biogas plants since 1999.We have supported the growing increase of performance and producti-vity of the plants up to the present time

by developing further innovative products. Therefore, a VIPA 300S can today control an entire plant and is networkable with further locations and is adaptable with all modern communi-cation possibilities.

With this brochure we want to give you an overview of solution possibilities with VIPA products for individual stages.

Combined heat and power plantBiogas plant

Water management

Water treatment

Potable water productionHere the untreated water must pass through different proces-ses in order to produce good drinking water in consistent quality, always in suffi cient quantity and then to be fed with constant pressure in the distribution network.

• Removal of suspended solids, cloudiness and discolorations from the well water

• Adaption of the ph value and disinfection of the medium • Addition of different substances for preservation and for facilitating storage of the water

• Storage via corresponding water reservoirs or distribution to elevated tanks

• Pressure regulation for consistent water pressure in the dis-tribution network depending on the consumption situation

Control engineering: • VIPA 200V and 300S controllers are already deployed in most cases and so ensure a very high water quality.

Fountains and pump stations that feed the water into the treatment plants are the basis for good drinking water.

Guide system

Internalprocess

WasserspeicherElevated tanksFountain

LAN / INTERNET

Distributing substation

Distributing substation

Control room Central PLC

Data transmission / remote control

Date transmission / remote control of outstationsGPRS telecontrol technology – a package oriented service for data transmission via mobile network - is used for the transmission of analog and digital process data from outsta-tions to central process control systems. The protocol, developed on TCP/IP basis, is optimized for mini-mum data transmission volume with minimum header. The connection is established from the outstation of the network operator by the local GPRS modem logging into the network. At the connection set-up the outstation receives an internal IP address from the network operator which is not accessible by other participants. If the connection is lost due to poor recepti-on or DSL/internet disturbances, etc., it will be automatically re-established by the GPRS modem. The data is buffered with time stamps on the PLC of the outstation to avoid data loss.

If the PLC is connected directly to the router via Ethernet, the data transmis-sion can also take place via LAN, fixed

line DSL or via satellite (SAT-DSL or Sky-DSL) or via GPRS/EDGE/UMTS/HSPA.

OutstationsThe recording of the process data in the outstation is made via a standard VIPA PLC. At this outstation a GPRS library is installed which is supplied by VIPA. The modem contains a SIM card with a M2M tariff depending on the choice of data volume and provider.

Safety and data protectionThe connection between the outstati-on and the control room is always established by the outstation. When the connection is established, it behaves like a dedicated line and can also be used as a feedback channel to the outstation. So only during an existing connection, data such as instructions or set values can be sent to the outstation via this feedback channel.

Advantages and benefits of a safe data connection between outsta-tions and the control room:

• Cost saving data transmission • Easy Plug & Play installation • Permanently online • Optimized data security mechanism • Support of all IP based transmission media

• The connection is saved via station identification and password (en-coded)

• For data transmission, a second randomly generated key is used for reconnection

• Data is sent actively from the out-station to the control room (sending transmission protocol)

• The GPRS center refuses all data packages, whose formats, enco-dings and contents do not match the expected requirements

• Fixed monthly costs for data trans-mission

Process control system (control room)The process control system is connec-ted to the internet via a hardware router with fi rewall functionality by DSL. Alternatively a fl at volume tariff with dynamic IP address allocation or a Business DSL contract with an alloca-tion of a fi xed IP address can be used. Preferably, a fi xed IP address should be chosen. In the case of a dynamic IP address a service is used so that the control room is permanently reachable from the outstations. At the process control system a GPRS manager is installed and all connected outstations are confi gured.

Guide system

LAN / INTERNET

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Sewage treatment

Influent and mechanical purification

• First treatment step: mechanical removal or filtration of different solids from the sewage water

• Disposal of this solids • Discharge of the sewage water via pumps into the biological purification

Biological purification

• Mixture of sewage water and bio-mass in the aeration basin

• Control of the ventilation system for an optimum oxygen transfer of the bacterial process

• In the case of very high pollution of the sewage water by phosphates and nitrogen, precipitating agents are added to reduce this pollution

Final clarification/ sludge disposals

• Separation of clarified sewage from mud

• Drainage of the mud and extraction of the residual water

• Forwarding the concentrated mud into the digester

• Returning the residual water into the biological purification

• Biogas production in the digester

• Using the purified biogas in the combined heat and power plant for energy production depending on the plant

Retention basin • Depending on the accumulated amount e.g. initially the contamina-ted surface water has to be fed into a retention basin after heavy rain before it can be fed into the normal clarifying process.

Pump stationThe control of the pumps is

carried out in the substations and is connected centralized and decentra-lized to the central controller.

• Control and maintenance of all re-quired sensors and actuators

• Control of a wide range of pump sizes

• Communication with the control room via internal network (Ether-net, PROFINET or PROFIBUS-DP), remote stations can also be connec-ted via two-wire lines, Ethernet or GPRS.

Guide system

Inlet / mech.purification

Biological purification

PrecipitationSeparation

Final clarificationSlugde disposal

Network Network Network Network

PLC PLC PLC PLC

Central PLCHMI

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Retention basin Pump station

FI FI FI FII/O I/O I/O I/O

TCP/IP

Renewable energy types

A short overview of the process operations during biogas production:

• Fermentation of the substrates in the digester and addition of solids; best pro-cess result only at a temperature range of 35° to 40°.

• Stirring unit which keeps the substrate in constant motion, so that the formati-on of scum and sediment is prevented and the biogas produced can easily escape.

• Collection of the fermented substrates in the fi nal disposal site (sludge tank). Here further biogas is also produced.

• Use of the fi nally fermented substrates as high quality manure.

• Preparation of the biogas, especially desulfurization and dehumidifi cation. There are different procedures for both processes that always require precise process control.

• Production of electrical and thermic energy by using biogas in a CHP by power-heat cogeneration.

• Distribution of the electrical energy produced: 20% to 40% for own usage (fermentation plants including stirring device, disintegrator etc.), the rest for feeding into the network.

• Distribution of the thermal energy: 30% to 50% for heating the digesters, the rest for other usage.

To ensure that the individual process always runs in the optimum and econo-mical range, control engineering is required that precisely supervises all procedures and processes all data reliably in the individual procedures. VIPA 300S controllers are already tried and tested worldwide for the regulation and monitoring of entire plants of biomass treatment and energy produc-tion in CHPs.

The VIPA frequency inverters are especially suitable for energy saving in motors deployed. All described control and monitoring functionalities are realizable with only one single control system.

The fl exible memory management and the manifold interfaces on the CPUs enable a compact control system that have an positive effect on the investment and operating costs.

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Our products for your applications

300SThe CPU for the control station: • Communicative and flexible thanks to many interfaces

• Suitable for applications with control intensive tasks with a upgradable memory

• Allows up to 32 modules at a single-line setup.

SLIOOur system for perfect wiring that is combinable with 300S and 200V and also with many other manufacturers. Currently the most advanced system providing a multitude of communication possibilities.

HMI • High contrast visualization and input possibilities on site.

• Your interface to the process.

• Whether AEG, Schneider, Siemens 95U/100U/115/135/155, Klöckner Möller etc. we have the PLC that fits into the space

• Centralized and decentralized applications possible • For partial renewals or complete replacements • Conversion solutions with or partially without rewiring • Communication with systems from other manufacturers via standard interfaces

• If we do not have it, we offer it to you via our partners: Process control system, measurement engineering, accessories

Accessories • S5 conversion modules • Teleservice modules • DP plugs, cable etc.

The controllers Visualization

The reasons why we are better!

Always usable

Data recording and output

200VPerfectly suitable for small and middle-sized centralized and decentralized control tasks:

• Compact design therefore perfect for use in small spaces

• The ideal connection to outbuildings

• Perfect networking to outstations

VIPAGesellschaft für Visualisierung

und Prozessautomatisierung mbH

Ohmstr. 4D-91074 Herzogenaurach

Ph.: +49-9132-744-0Fax: +49-9132-744-1864

Internet: www.vipa.com E-Mail: info@vipa.com