P000245-FDS-RevA As Built

Process control and functional description
P000245-FDS-RevA (As Built)

WWTP Sobono Energy - Biotech Farms - Philippines
Table of content:
1 General introduction on functional design specification ...................................................................5

1.1 General introduction ...................................................................................................................... 5
1.2 Manual – Off – Auto switches ....................................................................................................... 5
Manual mode (Hand) ...........................................................................................................5
Off mode ..............................................................................................................................6
Auto control ..........................................................................................................................6
1.3 NWT standard HMI panels ............................................................................................................ 6
1.4 Measurement failures .................................................................................................................... 6
1.5 Other remarks regarding PLC control ........................................................................................... 6
1.6 Unit and trigger switches ............................................................................................................... 7
1.7 General failures, commonly used .................................................................................................. 7
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
4.2 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
and SC2801 ................................................................................................................................ 34
Description .........................................................................................................................34
Settings ..............................................................................................................................35
Alarms ................................................................................................................................35
Description .........................................................................................................................36
Settings ..............................................................................................................................36
Alarms ................................................................................................................................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
5.2 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
Description .........................................................................................................................53
Settings ..............................................................................................................................53
Alarms ................................................................................................................................54
and SC2601 ................................................................................................................................ 54
Description .........................................................................................................................54
Settings ..............................................................................................................................55
Alarms ................................................................................................................................56
Description .........................................................................................................................56
Settings ..............................................................................................................................57
Alarms ................................................................................................................................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
Description .........................................................................................................................67
Settings ..............................................................................................................................67
Alarms ................................................................................................................................68
and SC2701 ................................................................................................................................ 68
Description .........................................................................................................................68
Settings ..............................................................................................................................69
Alarms ................................................................................................................................70
Description .........................................................................................................................70
Settings ..............................................................................................................................71
Alarms ................................................................................................................................71
Description .........................................................................................................................71
Settings ..............................................................................................................................72
Alarms ................................................................................................................................72
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V2775 .......................................................................................................................................... 73
Description .........................................................................................................................73
Settings ..............................................................................................................................74
Alarms ................................................................................................................................74
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1 General introduction on functional design specification
1.1 General introduction

This process control and functional description is a document set up during the initial commissioning of
the WWTP (Waste Water Treatment Plant). Any modifications in a later stage of the project will require
an update in this document. From the initial revision (Rev. 0), Revisions will be numbered A, B, C, etc.
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.
Sheets 1, 2 and 4 cover the project P000245, also referred to as Scope A + C.

Sheet 3 covers the project P000246, also referred to as Scope B.
1.2 Manual – Off – Auto switches

All individual equipment (motors, pumps, valves, etc.) can separately be switched between Manual,
Off, or Automatic mode with software switches in the HMI display.
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.
Switches may also be referred to as H-O-A switches, where H refers to Hand.
Manual mode (Hand)

Any component in Manual mode, will simply start (or open in case of valves). The PLC will start the
pump, or open the valve, no matter what other conditions are. There will always be certain safeties that
have to be taken into account, even in manual mode:
Motor protections / Circuit breakers
Temperature protections of motors / pumps, like PTC failure, Clixon failure, Run dry protections, etc.
Emergency stop circuits
There are exceptions where these components are used in combination. E.g. a pump, using its own
block valve, will only start if the block valve is detected to be opened. Even when it is in manual mode.
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.
WARNING: Do NOT use off mode for service or maintenance!
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.
1.3 NWT standard HMI panels

The control panel, build as NWT standard, is equipped with a Siemens Comfort HMI display. The
following information is available in the HMI:
- Screens with all measurements (levels, pressures, temperatures, etc.)
- Screens with all analogue control signals (frequency of drives, capacity of dosing pumps, opening
position of valves, etc).
- The calibration of the measurements and the analogue control signals. These are the signals that
calibrate the 4 and 20mA signal with the signal indication in the PLC.
- Hour counters of all motors
- Flow totalizers of flow meters.
- Graphic representations of all equipment in simple overview screens
- All process settings, divided in a menu. The process settings are explained in each chapter for
that specific part of the WWTP.
- Manual – Off – Auto switches per component (also referred to as M-0-A or H-O-A switches)
- Graphs of important measuring signals (for as far as this is not taken care of by optional SCADA
system).
1.4 Measurement failures

The following actions will be taken in case of measurement failures:
- Level measurement (LC) failures:
 Alarm will be activated
- Flow measurement (FIC) failures:
- Quality measurement (QIC) failures:
- Pressure measurement (PC) failures:
- Temperature measurement (TIC) failures:
Depending on the nature of the fault, the signal will generally show its minimum calibration value (e.g.
level of 0%).
1.5 Other remarks regarding PLC control

Most commonly used settings are adjustable by the operator. There are additional settings, that can
only be adjusted by commissioning engineers, but are still available as ‘read only’ values. All these
settings are individually explained / mentioned in the chapters of these specific components. Other
setting (especially timer-delays) can be pre-set in the PLC program, and are therefore not adjustable
by the operator or commissioning engineer. These settings are determined by the programmer, but a
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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.
All LC/FIC/QIC/PC/TIC measurements are analogue 4-20mA measurement signals.
1.6 Unit and trigger switches

All equipment that uses a procedure to be started and stopped will be equipped with software unit
switches. When operator wants to switch off a unit of such kind, all he will have to do is to switch off the
unit switch. Unit will be stopped, but it will follow its full normal stop procedure. There is no need to
switch off all individual components on/around this unit. All it takes for the operator to restart the unit, is
to switch the unit switch back to automatic.
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.
1.7 General failures, commonly used

All motors will be equipped with an overcurrent and short-circuit protection. These can be combined in
single motor protection, but these can also be split up in different modules. Example: The overcurrent
is protected by VSD (frequency drive) or by softstarter, while short-circuit is protected by a circuit
breaker.
Motorprotections, VSD’s, Softstarters, etc. can all be equipped with a RUN-detection contact. The RUN
detection alarm does cover all other conditions. When circuit breaker of a VSD is switched off, this could
be detected by an auxiliary on the breaker, but could just as easy be detected by lack of run detection
after starting the concerning motor.
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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2 P&ID Sheet 1 - Decanters, Reduction Units and Transfer tank T0301

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). There are 2
individual contacts that can start both decanter line 1 (DC3301) and decanter line 2 (DC3321).
If WWTP is ready for operation, it will start the concerning decanter(s) and await its start-up procedure.
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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Plant Tag No Item ref Plant Description

DC3301 / DC3321 M3301 / M3321 Main drive decanter line 1 / line 2
DC3301 / DC3321 M3302 / M3322 Back drive decanter line 1 / line 2
DC3301 / DC3321 V3301 / V3321 Flush valve decanter line 1 / line 2
DC3301 / DC3321 V3308 / V3328 Diverter gate valve decanter line 1 / line 2
DC3301 / DC3321 V3315 / V3335 Diverter flush valve decanter line 1 / line 2
P3401 / P3421 V3403 / V3423 Block valve feed pump decanter line 1 / line 2
P3401 / P3421 P3401 / P3421 Feed pump decanter line 1 / line 2
P3401 / P3421 FIC3401 / Flow measuring feed decanter line 1 / line 2
FIC3421
P1901 / P1921 P1901 / P1921 Flocculant dosing pump decanter line 1 / line 2
P1901 / P1921 F1901 / F1921 Cooling fan flocculant dosing pump decanter line 1 / line 2
P1901 / P1921 V1913 / V1933 Solenoid valve post-dilution flocculant dosing pump decanter line 1 /
line 2
P1901 / P1921 FIS1902 / Flow switch post-dilution flocculant dosing pump decanter line 1 / line
FIS1922 2
RU3301 / RU3321 RU3301 / Reduction unit decanter line 1 / line 2
RU3321
DC3301 / DC3321 TS4601 Transport screw decanter line 1 and line 2
T0301 LC0301 Level measuring transfer tank
T0301 MX0301 Mixer transfer tank
T0301 P0301 Feed pump flotation unit
NOTE: Since both decanter lines work exactly identical, the rest of this document will only explain the
decanter in general. Example: DC33x1 may refer to DC3301 if line 1 is meant, and DC3321 if line 2 is
meant.
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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 Feed pump is free of failures and equipment is in AUTO mode

 Flocculant dosing pump is free of failures and equipment is in AUTO mode
 Flocculant storage tank is without low level alarm
 Transport screw below decanter is running
 There is no High Level Alarm (HLA) in Transfer tank T0301.
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:
Setting Typical Adjustable range

Not applicable n.a. n.a.
Alarms
The following process alarms, derived from plant instrumentation, will be activated and displayed on
the HMI for this particular area of the process.
Page 10 of 74
Component tag Description

DC33x1 Main- or Back drive decanter DC33x1 not enabled
DC33x1 Failure running main drive decanter DC33x1
DC33x1 General failure decanter DC33x1
2.3 Feed pump and flow control feed decanter – P34x1, V34x3 and FIC34x1
Description
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
Page 11 of 74

Off delay block valve feed pump decanter – V34x3 5.0 sec. 0.0 – 9999.9 sec.
On delay failure opening/closing block valve feed pump decanter - V34x3 15.0 sec. 0.0 – 9999.9 sec.
Low flow alarm feed decanter – FIC34x1 … 0.0 – 9999.9 m3/h
m3/h
High flow alarm feed decanter – FIC34x1 … 0.0 – 9999.9 m3/h
m3/h
On delay flow alarms feed decanter – FIC34x1 15.0 sec. 0.0 – 9999.9 sec.
Setpoint PID flow controller – Controlling frequency P34x1 – FIC34x1 … 0.0 – 9999.9 m3/h
m3/h
On delay PID flow controller – FIC34x1 45.0 sec. 0.0 – 9999.9 sec.
Initial out PID flow controller – FIC34x1 (*1) 0.0 Hz 0.0 - 9999.9 Hz
Proportional gain PID flow controller (P-factor) – FIC34x1 8.000 % 0.000 – 999.999 %
Integral action PID flow controller (I-factor) – FIC34x1 4.000 0.000 – 999.999 sec.
sec.
Derivative action PID flow controller (D-factor) – FIC34x1 0.000 0.000 – 999.999 sec.
sec.
Deadband PID flow controller – FIC34x1 0.2 m3/h 0.0 – 9999.9 m3/h
Minimum output value PID flow controller – FIC34x1 25.0Hz 0.0 - 9999.9 Hz
Maximum output value PID flow controller – FIC34x1 50.0Hz 0.0 - 9999.9 Hz
Actual output PID flow controller – Frequency feed pump P34x1 – FIC34x1 … Hz n.a.
(READ ONLY)
Desired frequency feed pump decanter, when running on hand or in manual 30.0 Hz 0.0 - 9999.9 Hz
PID mode – P34x1
--- --- ---
Flow totalizer feed decanter FIC34x1 (READ ONLY) … m3 n.a.
*1 : Entering 0.0, disables initial output option, and controller uses last known values.
FIC34x1 – Control mode PID flow controller (*2) Manual or Automatic

mode
*2 : When selecting automatic mode, PID control is active, and tries to control the output in such way,
that setpoint is kept as close as possible. When selecting manual mode, the PID 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
Page 12 of 74

P34x1 Failure running VSD feed pump decanter
V34x3 Failure opening block valve feed pump
V34x3 Failure closing block valve feed pump
FIC34x1 Low flow alarm influent decanter DC33x1
FIC34x1 High flow alarm influent decanter DC33x1
FIC34x1 Wire break flow measuring influent decanter DC33x1
2.4 Flocculant dosing control decanter – P19x1, F19x1, LC1902, V19x3 and FIS19x2
Description
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
Page 13 of 74

Interval time capacity calculation flocculant dosing pump P19x1 10.0 sec. 0.0 – 9999.9 sec.
Desired capacity flocculant dosing pump P19x1 based on flow measuring … L/m3. 0.0 – 9999.9 L/m3
FIC34x1
Minimum allowed output capacity P19x1 … L/h 0.0 – 9999.9 L/h
Maximum allowed output capacity P19x1 … L/h 0.0 – 9999.9 L/h
Calculated output flocculant dosing capacity P19x1 (READ ONLY) … L/h n.a.
Equivalent frequency P19x1, at calculated capacity (READ ONLY) … Hz n.a.
Capacity flocculant dosing pump P19x1, when running on hand or in … L/h 0.0 – 9999.9 L/h
manual mode
Equivalent frequency P19x1, at selected capacity (READ ONLY) … Hz n.a.
Off delay cooling fan P19x1 – F19x1 60.0 sec. 0.0 – 9999.9 sec.
On delay low flow alarm post-dilution flocculant dosing pump P19x1 – 180.0 sec. 0.0 – 9999.9 sec.
FIS19x2
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

LC1902 Low level alarm preparation section flocculant make-up unit T1901
P19x1 Run dry failure flocculant dosing pump
P19x1 Failure running VSD flocculant dosing pump
F19x1 Failure running cooling fan flocculant dosing pump
FIS19x2 Low flow alarm post-dilution flocculant dosing pump P19x1
2.5 Reduction unit – RU33x1
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
Page 14 of 74

Not applicable n.a. n.a.
Alarms

RU33x1 Circuit breaker polymer reduction unit
RU33x1 General failure polymer reduction unit
2.6 Transport screw decanters – TS4601
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

Off delay transport screw decanters – TS4601 300.0 sec. 0.0 – 9999.9 sec.
Alarms
Page 15 of 74

TS4601 Failure running transport screw
2.7 Transfer tank T0301 – LC0301, MX0301 and P0301
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

Start level mixer MX0301 – LC0301 20.0 % 0.0 - 9999.9 %
Stop level mixer MX0301 – LC0301 15.0 % 0.0 - 9999.9 %
Start level flotation unit FU2501 – LC0301 50.0 % 0.0 - 9999.9 %
Stop level flotation unit FU2501 – LC0301 25.0 % 0.0 - 9999.9 %
High level alarm transfer tank T0301 – LC0301 90.0 % 0.0 - 9999.9 %
Reset high level alarm transfer tank T0301 – LC0301 85.0 % 0.0 - 9999.9 %
Alarms

LC0301 High level alarm transfer tank T0301
LC0301 Wire break level measuring transfer tank T0301
MX0301 Failure running mixer transfer tank
P0301 Temperature failure feed pump flotation unit FU2501
P0301 Failure running feed pump flotation unit FU2501
Page 16 of 74
3 P&ID Sheet 2 – Flocculant make-up unit T1901, Flocculator PF0801 and flotation unit FU2501

The filtrate water of the decanters is collected in Transfer tank T0301. From here it is pumped to the
Selector tank T2301, while passing through a Nijhuis ‘Floc-Flot’ system. The flotation unit, uses the
principle of Dissolved Air Flotation, and that is why it may also be referred to as DAF unit.
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.
works:
Page 17 of 74

PF0801 PF0801 Flocculator
PF0801 P1801 Dosing pump flocculant flocculator
P1801 V1813 Solenoid valve post-dilution flocculant dosing pump flocculator
P1801 FIS1802 Flow switch post-dilution flocculant dosing pump flocculator
FU2501 FU2501 Flotation unit (DAF unit)
FU2501 P2501 Recirculation pump DAF unit
FU2501 PIS2501 Pressure switch recirculation pump
FU2501 V2513 Aeration valve pump DAF unit
FU2501 PIS2502 Pressure switch compressed air
FU2501 FIS2501 Air flow switch compressed air
FU2501 SC2501 Skimmer drive flotation unit
FU2501 V2505 Sand drain valve flotation unit
FU2501 V2508A Sludge drain valve 1 flotation unit
FU2501 V2508B Sludge drain valve 2 flotation unit
SG3701 SG3701 Sand gutter
FU2501 LC2502 Level measuring sludge compartment flotation unit
FU2501 P2502 Sludge pump flotation unit
T1901 Various Various components flocculant make-up unit T1901 (see chapter)
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.
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
Page 18 of 74

On delay low flow alarm post dilution flocculant dosing pump P1801 – 180.0 sec. 0.0 – 9999.9 sec.
FIS1802
Desired capacity dosing pump flocculant PF0801 – P1801 … L/h 0.0 – 9999.9 sec.
Equivalent frequency P1801, at selected capacity (READ ONLY) … Hz n.a.
Alarms

P1801 Run dry failure flocculant dosing pump
P1801 Failure running VSD flocculant dosing pump
FIS1802 Low flow alarm post-dilution flocculant dosing pump P1801
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
Page 19 of 74
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.
Pressure switch PIS2501

Pressure switch directly controls the aeration valve. When minimum pressure is not detected, aeration
valve is closed, while recirculation pump remains in operation. When pressure is absent for a period of
30 seconds, it will stop recirculation pump, and generate an alarm. It requires operator to reset this
alarm.
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.

Pressure switch PIS2502 detects the presence of compressed air. The absence of compressed air,
does not stop the DAF unit, nor its feed. However, it does explain eventual poor performance of the
unit. The alarm is generated after absence of pressure for 30 seconds. The alarm is automatically reset
after pressure is restored for another 30 seconds.
Air flow switch FIS2501

Air flow switch FIS2501 is only active when aeration valve is opened. Switch detects the presence of
compressed air flow. The absence of compressed air flow, does not stop the DAF unit, nor its feed.
However, it does explain eventual poor performance of the unit. The alarm is generated after absence
of flow for 30 seconds. The alarm is automatically reset after flow is restored for another 30 seconds.
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
Page 20 of 74

Off delay recirculation pump P2501 with aeration valve V2513 (stop 30.0 sec. 0.0 – 9999.9 sec.
procedure phase 1)
Of delay recirculation pump P2501 (stop procedure phase 2) 150.0 sec. 0.0 – 9999.9 sec.
On delay failure running softstarter P2501 10.0 sec. 0.0 – 9999.9 sec.
On delay start feed pump P0301 on aeration valve V2513 90.0 sec. 0.0 – 9999.9 sec.
On delay stop feed pump P0301 on standstill skimmer drive SC2501 300.0 sec. 0.0 – 9999.9 sec.
On time (pulse) skimmer drive SC2501 120.0 sec. 0.0 – 9999.9 sec.
Off time (pause) skimmer drive SC2501 120.0 sec. 0.0 – 9999.9 sec.
Desired frequency skimmer drive SC2501 25.0 Hz 0.0 - 9999.9 Hz
High level alarm sludge compartment – LC2502 90.0 % 0.0 - 9999.9 %
Reset high level alarm sludge compartment – LC2502 85.0 % 0.0 - 9999.9 %
Alarms

P2501 Failure running softstarter recirculation pump
PIS2501 Low pressure alarm recirculation pump
PIS2502 Low pressure alarm compressed air flotation unit
FIS2501 Low airflow alarm flotation unit
FU2501 Feed flotation unit stopped due to standstill skimmer
SC2501 Failure running VSD skimmer drive
LC2502 High level alarm sludge compartment flotation unit
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.
Sand drain cycle

Sand drain cycle only has one valve, and does therefore not have an ‘interval’ setting.
When DAF unit is started, and feed becomes active, the sand drain cycle can only be activated after
an adjustable ‘On delay sand drain’ timer. The opening of sand drain valve V2505 will happen based
on an adjustable on- and off time. When valve opens, it remains open for a short period of approx. 3
seconds (adjustable ON time). After the valve closes it remains closed for a longer period of e.g. 60
minutes (adjustable OFF time), and cyclic ON/OFF/ON/etc. repeats itself. If DAF unit, or its feed is
stopped, the actual ON or OFF timer is stored, so the cycle can pick up where it was left. Obviously,
the DAF and its feed must first be activated again for the defined ‘on delay time’.
Page 21 of 74
Sludge drain cycle

Sludge drain cycle has two valves, and does therefore not have an ‘interval’ setting, defining the time
in-between valve V2508A and V2508B.
When DAF unit is started, and feed becomes active, the sludge drain cycle can only be activated after
an adjustable ‘On delay sludge drain’ timer. The opening of first sludge drain valve V2508A, and second
sludge drain valve V2508B, will happen based on an adjustable on-, interval-, on-, and off time. When
first valve opens, it remains open for a short period of approx. 3 seconds (adjustable ON time). After
the valve closes, it awaits an adjustable INTERVAL time of approx. 120 seconds, after which second
valve opens. This valve will remain open for the same short period of approx. 3 seconds (adjustable
ON time). After second valve closes, both valves remain closed for a longer period of e.g. 60 minutes
(adjustable OFF time), and cyclic ON-A/INTERVAL/ON-B/OFF/ON-A/etc. repeats itself. If DAF unit, or
its feed is stopped, the actual ON or OFF timers are stored, so the cycle can pick up where it was left.
Obviously, the DAF and its feed must first be activated again for the defined ‘on delay time’.
Settings

On delay sand drain V2505 120.0 sec. 0.0 – 9999.9 sec.
On time sand drain V2505 3.0 sec. 0.0 – 9999.9 sec.
Off time sand drain V2505 60.0 Min. 0.0 – 9999.9 min.
On delay sludge drains V2508A/B 240.0 sec. 0.0 – 9999.9 sec.
On time sludge drains V2508A/B 3.0 sec. 0.0 – 9999.9 sec.
Interval time sludge drains V2508A/B 120.0 sec. 0.0 – 9999.9 sec.
Off time sludge drains V2508A/B 60.0 Min. 0.0 – 9999.9 min.
Alarms

LC0301 High level alarm transfer tank T0301
3.5 Flotation unit FU2501 – Sludge compartment – LC2502 and P2502
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
Page 22 of 74
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

Start level sludge compartment LC2502 – Start sludge pump P2502 20.0 % 0 - 999.9 %
Stop level sludge compartment LC2502 – Stop sludge pump P2502 15.0 % 0 - 999.9 %
High level alarm sludge compartment – LC2502 90.0 % 0 - 999.9 %
Reset high level alarm sludge compartment – LC2502 85.0 % 0 - 999.9 %
Alarms

LC2502 High level alarm sludge compartment flotation unit FU2501
LC2502 Wire break level measuring sludge compartment flotation unit FU2501
P2502 Run dry failure sludge pump flotation unit FU2501
P2502 Failure running sludge pump flotation unit FU2501
Client Client not ready to receive sludge from FU2501, FU2601 and FU2701
3.6 Flocculant make up-unit T1901 – Various components
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.
The concerning equipment for this chapter is:
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T1901 T1901 Flocculant make-up unit
T1901 V1903 Tap water supply flocculant make-up unit
T1901 FIS1901 Flow detection and measuring tap water supply flocculant make-up
unit
T1901 MX1901 Mixer first compartment flocculant make-up unit
T1901 MX1902 Mixer second compartment flocculant make-up unit
T1901 LC1902 Level measuring third compartment flocculant make-up unit
T1901 DD1901 Dosing screw flocculant make-up unit
T1901 HE1901 Heater dosing screw flocculant make-up unit
T1901 M1901 Vibrator flocculant make-up unit
T1901 LS1901 Low level detection powder compartment flocculant make-up unit
T1901 LS1905 High level detection powder compartment flocculant make-up unit
T1901 P1904 Sludge drain valve 2 flotation unit
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.
Flow measuring tapwater supply FIS1901

The flow measurement in the water supply to the unit, was one of the two measurement that were
exchanged during commissioning. The new flow meter does come with 2 types of measurement:
 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.
 An analogue output signal that gives actual value of the flow in Litres per minute. The
calibration of the 4..20mA makes sure that value in PLC matches the value on the flow meter.
Our commissioning engineers make sure that values match. To prevent this value from
‘jumping around’, the shown value is an average of a couple of measurements over a time
frame of 5 seconds. The result of this value is shown as ‘Actual equalised tapwater flow –
FIS1901’.
In both cases the signal is only accepted when make-up is activated on level request, and when water
valve V1903 has actually been energized.
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.
Level measuring third compartment (preparation section) LC1902

The level measurement is the second component that was exchanged during commissioning. This new
sensor gives a 4…20mA signal to Nijhuis PLC, showing the level in the third compart of the flocculant
make-up unit. Our commissioning engineer will make sure that the shown value is properly calibrated,
so an empty tank shows 0% and a nearly overfloating tank shows 100%.
The first and second compartment of this make-up unit are always filled up till the overfloat level, and
the level will only vary in the third compartment. This is also the compartment where the flocculant
dosing pumps P1801, P1901 and P1921 withdraw their flocculant from.
There are 4 adjustable level setpoints that create following switch/alarm points:
 Low level alarm flocculant make-up unit
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 Low level flocculant make-up unit, to start preparation of a new batch

 High level flocculant make-up unit, to start preparation of a new batch
 High level alarm flocculant make-up unit
The make-up of a new batch of flocculant starts when the level measuring LC1902 detect a level of less
than ‘start preparation’ setting for 5 seconds. The make-up stops when level measuring LC1902 detects
a level of more than ‘stop preparation’ setting.
Calculating the amount of flocculant powder to be dosed to make-up batch (DD1901)

Once unit has started the makepup of a new batch, every second the capacity of the dosing screw is
calculated. The formula is:
‘Calculated capacity setpoint dosing screw DD1901 [kg/h] ’ = A x B x 0,6 x C

Where:
A = ‘ Actual equalised tapwater flow FIS1901 [L/min.]’.
B = ‘Desired concentration flocculant batch [%]’
C = ‘Overdosing factor flocculant [x]’
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:
‘Actual concentration flocculant batch (%)’ = A / B

Where:
A = ‘Total powder quantity DD1901’
B = ‘Total water volume tap water FIS1901’
The make-up is designed to achieve the ‘desired concentration flocculant batch’. PLC control works
with two values around this setpoint.
1. ‘Concentration setpoint’ -/- ‘Lower offset to actual concentration setpoint’.

2. ‘Concentration setpoint’ + ‘Higher offset to actual concentration 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.
Water valve V1903

The water valve is opened, during entire make-up cycle, and approx. 5 seconds after stop level has
been detected. The water valve will close if failures occur to the dosing screw or any of the mixers, or
in case the powder compartment suffers from low level alarm. Same goes for the high level detection
alarm in third compartment, or any abnormality in water flow detection by FIS1901.
Dosing screw DD1901

Once make-up cycle starts, the dosing screw will not be started until at least the ‘on delay start dosing
screw’ timer has elapsed. From here on the start and stop of the dosing screw (as well as its
capacity/frequency) are dependent on the comparison with earlier explained calculated values.
Obviously the water valve must be opened, and there should not be any failure issue with mixers or
dosing screw.
When dosing screw is ran in manual/hand mode, the screw will run on a separate ‘frequency on hand’
setpoint.
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.
Mixers MX1901 and MX1902

Mixers are in operation during entire make-up cycle, except for the period that dosing screw is not yet
activated. 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 mixers’.
Flocculant hopper P1904

The transfer from big bag of powder-flocculant, is done by hopper P1904. To determine its start and
stop conditions, both level sensors in the powder-flocculant compartment of the make-up unit are used.
LS1901 is the lower level sensor, and LS1905 is the upper level sensor.
The start of hopper P1904 becomes active, when both level sensors are LOW (no detection of powder).
This hopper remains active, until upper level sensor LS1905 becomes HIGH (detection of powder).
Low level alarm powder compartment LS1901

The moment that lower level sensor does no longer detect powder, it should activate the hopper to fill
up the unit again. If this part works fine, there is no need to give a low level alarm on absence of LS1901
detection. This is why the alarm is delayed, as defined by setpoint ‘on delay low level alarm powder
section LS1901’. Alarm will only be activated once dosing screw in operation. In case of alarm, the
water valve closes, and make-up is interrupted. Operator reset is required to restart the make-up cycle.
Alarms related to level sensor LC1902

High level alarm is generated when level is above ‘high level alarm’ setpoint for a longer time than 5
seconds. Once activated, it will automatically reset, when level drop below ‘high level alarm’ setpoint
for a longer time than 10 seconds. During a high level alarm, the water valve V1903 will be stopped,
which automatically leads to the stop of entire make-up procedure. Make sure that high level setpoint
is set higher than the ‘stop preparation’ setpoint.
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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.
Alarms related to flow sensor FIS1901

While water valve is opened, the actual flow value (analogue 4…20mA signal) is checked for a minimum
and maximum value, that it should be inbetween. If value gets higher than ‘High flow alarm FIS1901’,
or less than ‘Low flow alarm FIS1901’ an alarm is generated. In both situations, there is a time-delay
before alarm is activated, both defined by the setpoint ‘On delay flow alarms FIS1901’. In case of either
alarm, the water valve closes, and make-up is interrupted. Operator reset is required to restart the
make-up cycle.
Settings
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Actual equalised tapwater flow flocculant make-up unit - FIS1901 (READ … L/min. n.a.
ONLY)
Desired concentration flocculant batch …% 0.00 - 999.99 %
K factor pulse contact water counter – FIS1901 (amount of litres per pulse) 10.0 0.0 – 9999.9 L/pulse
L/pulse
Overdosing factor flocculant, to compensate delayed start DD1901 (range 1.00 x 1.00 - 3.00 x
1.00-3.00 x)
Calculated capacity setpoint dosing screw DD1901 (READ ONLY) … Kg/h n.a.
Capacity dosing screw DD1901, at minimum frequency (setting 8) … Kg/h … Kg/h
Capacity dosing screw DD1901, at maximum frequency (setting 9) … Kg/h … Kg/h
Minimum frequency dosing screw DD1901 (READ ONLY) … Hz n.a.
Maximum frequency dosing screw DD1901 (READ ONLY) … Hz n.a.
Calculated frequency dosing screw DD1901, at actual capacity setpoint … Hz n.a.
(READ ONLY)
--- --- ---
Actual concentration flocculant batch (estimated calculation – READ ONLY) …% n.a.
Lower offset to actual concentration setpoint, to start dosing screw DD1901 …% 0.00 - 999.99 %
Higher offset to actual concentration setpoint, to stop dosing screw DD1901 …% 0.00 - 999.99 %
Total water volume detected by pulse contact water counter FIS1901 … Litres n.a.
(VERIFICATION ONLY)
Total water volume detected by integration of equalised tap water FIS1901 … Litres n.a.
(READ ONLY)
Total powder quantity dosed by dosing screw DD1901 (READ ONLY) … Grams n.a.
On delay start dosing screw DD1901 upon start of preparation … sec. 0.0 - 9999.9 sec.
Ripening time mixers MX1901 and MX1902 900.0 sec. 0.0 - 9999.9 sec.
On time vibrator M1901 1.0 sec. 0.0 - 9999.9 sec.
Off time vibrator M1901 10.0 sec. 0.0 - 9999.9 sec.
--- --- ---
High flow alarm on equalised tapwater flow value – FIS1901 … L/min. 0.0 – 9999.9 L/min.
Low flow alarm on equalised tapwater flow value – FIS1901 … L/min. 0.0 – 9999.9 L/min.
On delay flow alarms on equalised tapwater flow – FIS1901 … sec. 0.0 - 9999.9 sec.
Low level alarm flocculant make-up unit – LC1902 …% 0.0 - 9999.9 %
Low level flocculant make-up unit – LC1902 – Start preparation …% 0.0 - 9999.9 %
High level flocculant make-up unit – LC1902 – Stop preparation …% 0.0 - 9999.9 %
High level alarm flocculant make-up unit – LC1902 …% 0.0 - 9999.9 %
On delay low level alarm flocculant make-up unit – LC1902 … sec. 0.0 - 9999.9 sec.
On delay low level alarm powder section flocculant make-up unit – LS1901 … sec. 0.0 - 9999.9 sec.
Desired frequency dosing screw DD1901, when running on hand … Hz 0.0 - 9999.9 Hz
Alarms
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LC1902 High level alarm preparation section flocculant make-up unit T1901
LC1902 Wire break level measuring flocculant make-up unit T1901
FIS1901 Wire break flow measuring tap water flocculant make-up unit T1901
FIS1901 Low flow alarm tap water flocculant make-up unit T1901
FIS1901 High flow alarm tap water flocculant make-up unit T1901
MX1901 Failure running mixer 1 flocculant make-up unit T1901
MX1902 Failure running mixer 2 flocculant make-up unit T1901
DD1901 Failure running VSD dosing screw flocculant make-up unit T1901
LS1901 Low level alarm powder flocculant make-up unit T1901
Page 29 of 74
4 P&ID Sheet 3 – Pump pit T0101, Curved screen CS0501, Buffer tank T321 and flotation unit
FU2801

All equipment in this chapter, and therefore on P&ID sheet 3 are delivered under scope B. This has
been a separate project P000246. The physical location of the equipment is split up over two
locations.
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.
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
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.
removed by operator. In regards to the drain water of FU2801, it is returned to buffer tank T0321.
works:
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T0101 LC0101 Level sensor pump pit
T0101 P0101 Feed pump curved screen
CS0501 V0501 Flush valve spray bar curved screen
CS0501 V0502 Air valve spray bar curved screen
T0321 LC0321 Level measuring buffer tank
T0321 MX0321 Mixer buffer tank
T0321 P0321 Feed pump flotation unit
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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Cleaning cycle curved screen

Cleaning of the curved screen can be split up in two stage. First stage is during normal operation (feed
active), and second stage is the period after stop level (feed pump inactive). This second stage is
defined by the off-delay time 20K3, inside control panel P6.
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.

Setpoint relay 1 (E&H RIA 452) – Start curved screen CS0501 (*1) 30.0 % 0.0 - 999.9 %
Offset relay 1 (E&H RIA 452) – Start curved screen CS0501 (*1) 20.0 % 0.0 - 999.9 %
Setpoint relay 3 (E&H RIA 452) – High level alarm T0101 (*1) 85.0 % 0.0 - 999.9 %
Offset relay 3 (E&H RIA 452) – Reset high level alarm T0101 (*1) 5.0 % 0.0 - 999.9 %
Timer relay 20K1 – On delay start feed pump P0101 5 sec. Depending on time scale
Timer relay 20K3 – Off delay curved screen CS0501 3 min. Depending on time scale
Timer relay 21K1 (1) – Rising time spray arm curved screen – V0502 15 sec. Depending on time scale
Timer relay 21K1 (2) – Falling time spray arm curved screen – V0502 13 sec. Depending on time scale
Timer relay 21K4 (1) – On time spray valve curved screen – V0501 30 sec. Depending on time scale
Timer relay 21K4 (2) – Off time spray valve curved screen – V0501 5 min. Depending on time scale
*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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LC0101 High level alarm pump pit T0101
P0101 (General) Failure feed pump
White Control voltage Lack of white LED can indicate a number of internal failures (e.g. emergency stop,
LED on front panel P6 control voltage, main power, etc.
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).
4.3 Buffer tank T0321 – LC0321, MX0321 and P0321
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.
Settings

High level alarm buffer tank T0321 – LC0321 90.0 % 0.0 - 9999.9 %
Reset high level alarm buffer tank T0321 – LC0321 85.0 % 0.0 - 9999.9 %
Alarms
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LC0321 High level alarm buffer tank T0321
LC0321 Wire break level measuring buffer tank T0321
MX0321 Temperature failure mixer buffer tank
MX0321 Failure running mixer buffer tank
P0321 Temperature failure feed pump flotation unit FU2801
P0321 Failure running feed pump flotation unit FU2801
SC2801
Description
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
is allowed to be started.
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.
Recirculation pump
Aeration valve

alarm.
Page 34 of 74


Skimmer drive
Settings

Off delay recirculation pump P2801 with aeration valve V2813 (stop 30.0 sec. 0.0 - 9999.9 sec.
procedure phase 1)
Off delay recirculation pump P2801 (stop procedure phase 2) 150.0 sec. 0.0 - 9999.9 sec.
On delay failure running softstarter P2801 10.0 sec. 0.0 - 9999.9 sec.
On delay start feed pump P0321 on aeration valve V2813 90.0 sec. 0.0 - 9999.9 sec.
On delay stop feed pump P0321 on standstill skimmer drive SC2801 300.0 sec. 0.0 - 9999.9 sec.
On time (pulse) skimmer drive SC2801 120.0 sec. 0.0 - 9999.9 sec.
Off time (pause) skimmer drive SC2801 120.0 sec. 0.0 - 9999.9 sec.
Alarms
Page 35 of 74

Description
particles, along with water are drained back to Buffer tank T0321. To separate the sand and other
unit is in operation, otherwise DAF unit would be emptied. When there is a high level alarm in Buffer
Sand drain cycle

Sludge drain cycle

Settings
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On delay sand drain V2805 120.0 sec. 0.0 - 9999.9 sec.
On time sand drain V2805 3.0 sec. 0.0 - 9999.9 sec.
Off time sand drain V2805 60.0 min. 0.0 - 9999.9 min.
On delay sludge drains V2808A/B 240.0 sec. 0.0 - 9999.9 sec.
On time sludge drains V2808A/B 3.0 sec. 0.0 - 9999.9 sec.
Interval time sludge drains V2808A/B 120.0 sec. 0.0 - 9999.9 sec.
Off time sludge drains V2808A/B 60.0 min. 0.0 - 9999.9 min.
Alarms

LC0321 High level alarm buffer tank T0321
Description
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
Page 37 of 74

Start level sludge compartment LC2802 – Start sludge pump P2802 20.0 % 0.0 - 9999.9 %
Stop level sludge compartment LC2802 – Stop sludge pump P2802 15.0 % 0.0 - 9999.9 %
Alarms

Client Client not ready to receive sludge from FU2801
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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

The selector tank T2301 is a collection point for multiple water flows:
 Effluent water flotation unit FU2501
 Effluent water flotation unit FU2801
 Return sludge from flotation unit FU2601
 Return sludge from flotation unit FU2701
 Drain water from flotation units FU2601 and FU2701
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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works:

T2301 LC2301 Level measuring selector tank
T2301 QIC2301 pH measuring selector tank
T2301 MX2301 Mixer selector tank
T2301 P2301 Feed pump anoxic tank
T1501 LS1501 Level switch neutraliser buffer
T1501 P1501 Dosing pump neutraliser
T2401 LC2401 Level measuring anoxic tank
T2401 MX2401 Mixer anoxic tank
T2401 P2401 Feed pump aeration tank
T3001 LC3001 Level measuring aeration tank
T3001 QIC3001A Oxygen measuring aeration tank (Sensor A)
T3001 QIC3001B Oxygen measuring aeration tank (Sensor B)
T3001 P3002 Feed pump flotation unit FU2601
T3001 P3022 Feed pump flotation unit FU2701
BW3001 BW3001 Blower 1 aeration tank
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 additional condition for P2301 to run, is the absence of a high level alarm in the anoxic tank (defined
by LC2401).
Settings
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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 %
Start level feed pump anoxic tank P2301 – LC2301 50.0 % 0.0 - 9999.9 %
Stop level feed pump anoxic tank P2301 – LC2301 25.0 % 0.0 - 9999.9 %
High level alarm selector tank T2301 – LC2301 90.0 % 0.0 - 9999.9 %
Reset high level alarm selector tank T2301 – LC2301 85.0 % 0.0 - 9999.9 %
Alarms

LC2301 High level alarm selector tank T2301
LC2301 Wire break level measuring selector tank T2301
MX2301 Failure running mixer selector tank
P2301 Failure running feed pump anoxic tank
P2301 Temperature failure feed pump anoxic tank
LC2401 High level alarm anoxic tank T2401
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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The actual pH control can be done in 3 different ways:
PID control in automatic mode

Once the above-mentioned conditions are met, the dosing pump P1501 is started. During this period,
the dosing in PID controlled, based on the 10 settings related to PID pH controller QIC2301. The control
is permanently adjusted according P, I and D factors, 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 P1501, the PID controller starts with an on-delay. During this period, the output of the
dosing pump will be as defined by the initial value (unless set-up to be 0.0 L/h). In that last case, it will
restart with the value it was last stopped with. Only after the on-delay, the controlling is activated.
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.
PID control in manual mode

If the PID control mode is switched to manual (instead of automatic), the dosing pump does still follow
all start-conditions, but once running, it will always run on the value as defined under ‘capacity dosing
pump P1501, when running on hand or in manual PID mode’.
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 so-called ‘bucket-principle’

The bucket principle is based on the emptying of bucket of chemicals into the tank. Then await the
result, while mixing the chemicals into the water. After that, the system determines if another bucket is
required, or not.
The bucket is simulated by a pre-defined running time of the dosing pump, while running at a preset
capacity (so total amount of chemicals can be determined). This is the pulse time. After a waiting time,
with MX2301 in operation, it is determined if another batch of chemical dosing is necessary. This is the
pause time.
This option can be done by using the automatic, PID control mode, while min./max./initial output values
are restricted to the same value. This option can also be done, using the manual PID control mode.
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
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
QIC2301 – Control mode PID pH controller (*2) Manual or Automatic

mode
QIC2301 – Control action PID pH controller (*3) Acid or Caustic mode
*3 : In acid mode, the capacity output of dosing pump decreases, when measured pH value is below
setpoint. In caustic mode, the capacity output of dosing pump increases, when measured pH value is
below setpoint.
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Alarms

QIC2301 Wire break pH measuring selector tank
QIC2301 Low pH alarm selector tank
QIC2301 High pH alarm selector tank
P1501 Circuit breaker dosing pump neutraliser selector tank
LS1501 Low level alarm neutraliser buffer T1501
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.
in this tank, the feed to the anoxic tank is stopped.
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

Desired frequency feed pump aeration tank – P2401 50.0 Hz 0.0 - 9999.9 Hz
Start level feed pump aeration tank P2401 – LC2401 50.0 % 0.0 - 9999.9 %
Stop level feed pump aeration tank P2401 – LC2401 25.0 % 0.0 - 9999.9 %
High level alarm anoxic tank T2401 – LC2401 90.0 % 0.0 - 9999.9 %
Reset high level alarm anoxic tank T2401 – LC2401 85.0 % 0.0 - 9999.9 %
On delay failure running softstarter mixer MX2401 15.0 sec. 0.0 – 9999.9 sec.
Alarms
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LC2401 High level alarm anoxic tank T2401
LC2401 Wire break level measuring anoxic tank T2401
MX2401 Failure running softstarter mixer anoxic tank
P2401 Failure running VSD feed pump aeration tank
LC3001 High level alarm aeration tank T2401
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.
in this tank, the feed from the anoxic tank is stopped.
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
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Start level blowers BW30x1 and oxygen control QIC3001A/B – LC3001 30.0 % 0.0 - 9999.9 %
Stop level blowers BW30x1 and oxygen control QIC3001A/B – LC3001 20.0 % 0.0 - 9999.9 %
High level alarm aeration tank T3001 – LC3001 90.0 % 0.0 - 9999.9 %
Reset high level alarm aeration tank T3001 – LC3001 85.0 % 0.0 - 9999.9 %
--- --- ---
Interval time linear calculation frequency P3002, based on level LC3001 15.0 sec. 0.0 – 9999.9 sec.
Minimum level aeration tank, used for linear calculation frequency P3002 60.0 % 0.0 - 9999.9 %
Maximum level aeration tank, used for linear calculation frequency P3002 90.0 % 0.0 - 9999.9 %
Minimum frequency feed pump P3002, at maximum level aeration tank 40.0 Hz 0.0 - 9999.9 Hz
Maximum frequency feed pump P3002, at minimum level aeration tank 50.0 Hz 0.0 - 9999.9 Hz
Calculated frequency feed pump P3002, at actual level aeration tank (READ ... Hz n.a.
ONLY)
Desired frequency feed pump flotation unit FU2601, when running on hand – 50.0 Hz 0.0 - 9999.9 Hz
P3002
--- --- ---
Interval time linear calculation frequency P3022, based on level LC3001 15.0 sec. 0.0 – 9999.9 sec.
Minimum level aeration tank, used for linear calculation frequency P3022 60.0 % 0.0 - 9999.9 %
Maximum level aeration tank, used for linear calculation frequency P3022 90.0 % 0.0 - 9999.9 %
Minimum frequency feed pump P3022, at maximum level aeration tank 40.0 Hz 0 .0 - 9999.9 Hz
Maximum frequency feed pump P3022, at minimum level aeration tank 50.0 Hz 0.0 - 9999.9 Hz
Calculated frequency feed pump P3022, at actual level aeration tank (READ ... Hz n.a.
ONLY)
Desired frequency feed pump flotation unit FU2701, when running on hand – 50.0 Hz 0.0 - 9999.9 Hz
P3022
Alarms

LC3001 Wire break level measuring aeration tank T3001
P3002 Failure running VSD feed pump flotation unit FU2601
P3022 Failure running VSD feed pump flotation unit FU2701
HMI indication only Client not ready to receive effluent water from FU2601 / FU2701
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.
The start conditions for the oxygen control

 The oxygen measuring has detected a value less than the setpoint ‘oxygen start level – Start
blowers’, and the level may not yet have exceeded the setpoint ‘oxygen stop level – Stop
blowers – LC3001’.
 The level measuring in the aeration tank has detected a level above the setpoint ‘start level
blowers’, and this level may not yet have dropped below the setpoint ‘stop level blowers –
LC3001’.
 The unit switch of aeration tank is in automatic mode
PID control in automatic mode

Once the above-mentioned conditions are met, the blower control is activated, generally be starting the
VSD blower BW3041. During this period, the PID oxygen control is based on the 10 settings related to
PID oxygen controller QIC3001A/B. The control is permanently adjusted according P, I and D factors,
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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.
PID control in manual mode

If the PID control mode is switched to manual mode (instead of automatic), the blower(s) still follow all
start-conditions, but once running, they will always run on the value as defined under ‘desired frequency
blowers BW30x1, when running in manual PID mode’. Again, this value should be in the range of 25 to
180Hz.
When running blower BW3041 on hand, another setting is valid. Obviously, this setting can only contain
values in-between 25 and 60Hz.
Settings
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Oxygen start level QIC3001A and/or B (*1) – Start blowers BW30x1 1.5 mg/l 0.0 – 9999.9 mg/l
Oxygen start level QIC3001A and/or B (*1) – Stop blowers BW30x1 4.0 mg/l 0.0 – 9999.9 mg/l
On delay oxygen alarms QIC3001A and or B (*1) 180.0 sec. 0.0 – 9999.9 sec.
Low oxygen alarm QIC3001A and/or B (*1) 1.0 mg/l 0.0 – 9999.9 mg/l
High oxygen alarm QIC3001A and/or B (*1) 5.5 mg/l 0.0 – 9999.9 mg/l
Off time blowers BW30x1, above oxygen stop level QIC3001A and/or B 600.0 sec. 0.0 – 9999.9 sec.
(*1)
On time blowers BW30x1, above oxygen stop level QIC3001A and/or B 120.0 sec. 0.0 – 9999.9 sec.
(*1)
Minimum off time blowers BW30x1 300.0 sec. 0.0 – 9999.9 sec.
Minimum on time blowers BW30x1 120.0 sec. 0.0 – 9999.9 sec.
Starting time to prevent other blowers from starting simultaneously 30.0 sec. 0.0 – 9999.9 sec.
--- --- ---
On delay failure running signal softstarters blower BW3001 and 15.0 sec. 0.0 – 9999.9 sec.
BW3021
Output frequency blower BW3041, after splitter function (READ ONLY) … Hz n.a.
Desired frequency blower BW3041, when running on hand 25 Hz 25.0 – 60.0 Hz
Desired frequency blowers BW30x1, when running on manual PID … Hz 25.0 – 180.0 Hz
mode
Desired frequency blowers BW30x1, when running in pulse-pause mode … Hz 25.0 – 180.0 Hz
Calculated average value of QIC3001A and B (*1 - READ ONLY) … mg/l n.a.
Actual deviation between QIC3001A and B (READ ONLY) … mg/l n.a.
Maximum deviation between QIC3001A and B – Alarm activation 1.0 mg/l 0.0 – 9999.9 mg/l
Low temperature alarm aeration tank – QIC3001A/B 15.0 °C 0.0 – 9999.9 °C
High temperature alarm aeration tank – QIC3001A/B 60.0 °C 0.0 – 9999.9 °C
On delay temperature alarms aeration tank – QIC3001A/B 180.0 sec. 0.0 – 9999.9 sec.
--- --- ---
Setpoint PID oxygen controller aeration tank – Frequency control 3.0 mg/l 0.0 – 9999.9 mg/l
blowers BW30x1 – QIC3001A/B
On delay PID oxygen controller – QIC3001A/B 45.0 sec. 0.0 – 9999.9 sec.
Initial output PID oxygen controller, during on delay controller – 0.0 Hz 0.0 - 9999.9 Hz
QIC3001A/B (*2)
Proportional gain PID oxygen controller (P-factor) – QIC3001A/B 8.000 % 0.000 – 999.999 %
Integral action PID oxygen controller (I-factor) – QIC3001A/B 4.000 sec. 0.000 – 999.999 sec.
Derivative action PID oxygen controller (D-factor) – QIC3001A/B 0.000 sec. 0.000 – 999.999 sec.
Deadband PID oxygen controller – QIC3001A/B 0.2 mg/l 0.0 – 9999.9 mg/l
Minimum output value PID oxygen controller – QIC3001A/B 25.0 Hz 25.0 – 180.0 Hz
Maximum output value PID oxygen controller – QIC3001A/B 180.0 Hz 25.0 – 180.0 Hz
Actual output PID oxygen controller – Frequency blowers BW30x1 – … Hz n.a.
QIC3001A/B (READ ONLY)
*1 : The valid sensor is determined in the preference settings in the HMI. If both sensors are activated,
the average value is taken.
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QIC3001 – Control mode PID oxygen controller (*3) Manual or Automatic

mode
QIC3001 – Pulse/Pause control above oxygen stop level (*4) Disable or Enable
QIC3001A – Oxygen control QIC3001A (*5) Disable or Enable
QIC3001B – Oxygen control QIC3001B (*5) Disable or Enable
*4 : All blowers stop when the measured oxygen is above stop level. They will not be restarted before
oxygen measuring drops below oxygen start level. With this option disabled, none of the blower is
activated during this stop period. With this option enabled, there is a pulse-/pause start of the blower(s),
starting with pause. The amount of blowers during the pulse period, can be determined in the settings.
*5 : At least one of the oxygen sensors (A or B) should be activated. If not, an alarm is generated. If
only one sensor is selected, all controls will be based on the measurement of that sensor. In case both
sensors are enabled, the average value of both sensor A and B, are used for the controls.
Alarms

QIC3001A Wire break oxygen measuring 1 aeration tank
QIC3001A-T Wire break temperature measuring 1 aeration tank
QIC3001A-T Low temperature alarm 1 aeration tank
QIC3001A-T High temperature alarm 1 aeration tank
QIC3001B Wire break oxygen measuring 2 aeration tank
QIC3001B-T Wire break temperature measuring 2 aeration tank
QIC3001B-T Low temperature alarm 2 aeration tank
QIC3001B-T High temperature alarm 2 aeration tank
QIC3001A/B Low oxygen alarm aeration tank – QIC3001A or B (depending on setting)
QIC3001A/B High oxygen alarm aeration tank – QIC3001A or B (depending on setting)
QIC3001A/B Deviation between QIC3001A and QIC3001B too high
QIC3001A/B Both oxygen sensors aeration tank disabled – Activate at least one !
BW3001 Failure running softstarter blower 1 aeration tank
BW3021 Failure running softstarter blower 2 aeration tank
BW3041 Failure running VSD blower 3 aeration tank
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6 P&ID Sheet 4 (part 2 of 3) – Flocculant make-up unit T1821, Flocculator PF0901 and flotation unit
FU2601

The water of the aeration tank is discharged, but not without passing through a Nijhuis ‘Floc-Flot’ system
first. The flotation unit, uses the principle of Dissolved Air Flotation, and that is why it may also be
referred to as DAF unit. Due to the amount of water to be discharged, it is done over 2 separated
discharge line (FU2601 and FU2701 line).
Flocculant injection will be injected in a pre-engineered location. The amount of flocculant required, will
be determined by the commissioning engineer.
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.
works:
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FU2601 V2635 Excess sludge valve
FU2601 V2655 Sludge return valve to selector tank
FU2601 V2675 Sludge return valve to aeration tank
Description
explanation is the flocculant dosing pump P1821. The level in Aeration tank T3001 determines the start
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.
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
Settings
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On delay low flow alarm post dilution flocculant dosing pump P1821 180.0 sec. 0 – 9999.9 sec.
– FIS1822
Desired capacity dosing pump flocculant PF0901 – P1821 … L/h 0.0 - 9999.9 L/h
Alarms

LS1822 Low level alarm preparation section flocculant make-up unit T1821
SC2601
Description
The level inside Aeration tank T3001 determines the start and stop of flotation (DAF) unit FU2601.
Start procedure
Stop procedure
Client not ready for effluent contact

Control panel P1 allows client to control the effluent flow, coming from both FU2601 and FU2701. By
means of Volt-free contact 133K3 (Control panel P1 – Page 133), client is able to stop the feed pumps
of both flotation units. This can be of interest, when effluent water would e.g. be pumped to an effluent
channel, or effluent tank. In case this channel of buffer would suffer from a high level alarm, the signal
can be switched off (LOW), to stop both P3002 and P3022. This automatically means that signal should
be wire-bridged, if client does not wish to use this option.
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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
Aeration valve

alarm.


Skimmer drive
Settings
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procedure phase 1)
Alarms

Description
particles, along with water are drained back to Selector tank T2301. To separate the sand and other
unit is in operation, otherwise DAF unit would be emptied. When there is a high level alarm in Selector
Sand drain cycle

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Sludge drain cycle

Settings

Off time sand drain V2605 60.0 min. 0.0 – 9999.9 min.
Off time sludge drains V2608A/B 60.0 min. 0.0 – 9999.9 min.
Alarms

Description
The level is measured by a 4...20mA pressure sensor, installed near lowest point of this 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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 Sludge return valve to anoxic tank – Selection valve V2675
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 case excess sludge is active (V2635):

In case sludge return to selector tank is active (V2655):

There should not be a high level alarm in the selector tank
In case sludge return to anoxic/aeration tank is active (V2675):

There should not be a high level alarm in the aeration tank
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

Start level sludge compartment LC2602 – Start sludge pump P2602 20.0 % 0.0 - 9999.9 %
Stop level sludge compartment LC2602 – Stop sludge pump P2602 15.0 % 0.0 - 9999.9 %
Alarms

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V2675
Description
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.
Excess sludge valve V2635

There is only a specific amount of time, that sludge can be pumped to the client. The HMI allow for a
couple of settings to control this. First of all, there is a reset time (in hours and minutes). When real time
clock of PLC detects the actual time, to be the same as this ‘reset time excess sludge timer’, all ongoing
timers are reset to zero, and the system is restarted by allowing excess sludge. Another timer counts
the amount of time that sludge pump P2602 has performed sludge excess, and limits this for an
adjustable time. Actual timer is also visible in the HMI. Be aware that the counter is only active if V2635
is opened, and P2602 is actually in operation. By the time that maximum time is reached, both valve
and pump are stopped, and sludge can only be returned into the system (up till reset time becomes
valid again).
Valve V2635 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 V2635 detected to be open.
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.
Sludge return valve selector tank V2655

Once excess sludge valve is no longer active (maximum time reached, client not ready, or failure
opening V2635), the excess sludge is stopped, and sludge is return into the system. Where it is
returned, is based on the run condition of either feed pump P0301 or feed pump P0321 (both feeding
the selector tank). If at least one of the pumps is active, the sludge return will also be to the selector
tank.
General opening condition for this valve is also the absence of high level alarm in the selector tank.
Sludge return valve anoxic/aeration tank V2675

the selector tank). If both pumps are inactive, the sludge return will be to the anoxic/aeration tank. In
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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.
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

Start level sludge compartment LC2602 – Start sludge pump P2602 20.0 % 0.0 – 9999.9 sec.
Stop level sludge compartment LC2602 – Stop sludge pump P2602 15.0 % 0.0 – 9999.9 sec.
Off delay sludge valves – V2635, V2655 or V2675 10.0 sec. 0.0 – 9999.9 sec.
On delay failure opening/closing sludge valves – V2635, V2655 or V2675 15.0 sec. 0.0 – 9999.9 sec.
Maximum time per day to excess sludge – V2635/P2602 … min. 0.00 – 999.99 min.
Actual excess sludge time today – V2635/P2602 (READ ONLY) … min. n.a.
Reset time excess sludge timer – Hours 12 hh 0 - 23 hh
Reset time excess sludge timer - Minutes 00 mm 0 - 59 mm
Alarms

V2635 Failure opening excess sludge valve V2635
V2635 Failure closing excess sludge valve V2635
V2655 Failure opening sludge return valve to selector tank V2655
V2655 Failure closing sludge return valve to selector tank V2655
V2675 Failure opening sludge return valve to aeration tank V2655
V2675 Failure closing sludge return valve to aeration tank V2655
6.7 Flocculant make up-unit T821 – Various components
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.
The concerning equipment for this chapter is:

T1821 T1821 Flocculant make-up unit
T1821 V1823 Tap water supply flocculant make-up unit
T1821 FIS1821 Flow detection tap water supply flocculant make-up unit
T1821 MX1821 Mixer first compartment flocculant make-up unit
T1821 LC1821 Level measuring first compartment flocculant make-up unit
T1821 DD1821 Dosing screw flocculant make-up unit
T1821 HE1821 Heater dosing screw flocculant make-up unit
T1821 M1821 Vibrator flocculant make-up unit
T1821 P1822 Transfer pump flocculant make-up unit
T1821 LS1822 Low level detection powder compartment flocculant make-up unit
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.
The sequence of the flocculant make-up unit, follows 4 steps:
Step 1. <Filling> Preparation of a new batch in first compartment

The analogue level measuring in compartment 1 (LC1821), detects the level to have dropped below a
value as defined by ‘low level preparation section’. After a minor delay (couple of seconds), the water
valve V1821 opens, and the flow detection FIS1821 counts the amount of water that is filled during this
batch. The mixer MX1821 and dosing screw DD1821, will not start before the water level is above the
level that mixer can do his job properly. So, during new batch, the level has to rise until the value defined
by ‘minimum water volume for starting mixer and dosing screw’. Depending on the ‘desired
concentration of the batch’, the amount of powder to be added to the water is calculated. Upon every
pulse detection of FIS1821 (depending on K-factor; generally 10 litres per pulse), in combination with
opened water valve, you’ll see the ‘total running time dosing screw’ to be increasing. Once dosing screw
starts, you will simultaneously see it count-down to match the amount of flocculant of powder to actual
measured amount of water. The calculation itself, is explained a little further in this chapter.
During entire step, it is important that mixer MX1821 is in operation. Any alarms in regards to flocculant
make-up, may temporary stop the make-up cycle, and await operator’s reset.
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.
Step 2. <Ripening> Finishing the new batch by extended mixing

After water valve closes, the adjustable ‘ripening time MX1821’ defines the off-delay time for the mixer.
It is required that mixing remains active for at least another 15 minutes. Theoretically it is not common
to happen, but would step 4 be initiated before step 2 is finished, an alarm is generated. This is called
‘ripening time interrupted.
The Step 2 may be activated, based on amount of volume added in step 1. By the time the desired
amount of volume has been reached, there may be a remaining value in the ‘total on time dosing screw’.
This value will have to count-down to zero, before actual ripening starts.
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.
Step 3. <Waiting on LS> Waiting for low level in second compartment

After ripening time has finished, and powder has been properly mixed with the water, the unit will go
into standby mode, and await the level in the second compartment to drop below low level sensor
LS1822. An alarm is not yet generated for LS1822, and sequence will go to step 4 (likely a couple of
seconds delayed). Only if step 4 does not bring up the level in second compartment above LS1822, an
alarm is activated. This alarm delay is adjustable (on delay low level alarm LS1822).
During step 3, the water valve, the dosing screw, and the mixer are all off. Obviously, the amount of
time for the level to drop, is depending on the consume of flocculant in the flocculators PF0901 and
PF0921.
Step 4. <Transferring> Transfer from first to second compartment.

Pump P1822 is started, and the prepared flocculant in compartment 1 is pumped into storage
compartment 2. There is no high level detection in the second compartment, but the available amount
in compartment 1 could not overfill compartment 2. In the rare case of it would (e.g. sensor failure), it
will internally overfloat back into compartment 1.
The transfer remains active until level in compartment 1 drops below the ‘low level preparation section’
setpoint. Pump P1822, stops, and sequence goes back into step 1.
In regards to a low level alarm in this compartment, similar explanation is valid as earlier mentioned for
LS1822. The low level should be delay for such a long time, that the automatic control brings up the
level to acceptable value, before an alarm is generated. Adjustable value ‘On delay low level alarm
storage section LC1821’.
Capacity calculation dosing screw DD1821

Dosing screw DD1821 is started only during step 1, where it may run extended when desired amount
of water volume has been added to the make-up unit. The amount of run-time of the dosing screw is
depending on the amount of pulses, but also on another couple of settings.
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.
Flow measuring water supply FIS1821

The flow measurement in the water supply to the unit, is measured as:
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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.
Level measuring first compartment (preparation section) LC1821

The level measurement in the first component gives a 4…20mA signal to Nijhuis PLC, showing the
level in the preparation section of the flocculant make-up unit. Our commissioning engineer will make
sure that the shown value is properly calibrated, so an empty tank shows 0% and a nearly overfloating
tank shows 100%.
There is no direct connection between level in first and second compartment of this make-up unit.
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.
Level switch second compartment (storage section) LS1822

The second compartment of this unit, is where flocculant dosing pumps P1821 and P1841 withdraw
their flocculant from. To prevent the pumps from running dry, level switch LS1822 is used to stop these
pumps in time. Since level switch is also used to initiate step 4 of the make-up cycle, the actual low
level alarm must be delayed an adjustable amount of time (e.g. 30-45 seconds). This setting is defined
by ‘on delay low alarm storage section’. Low level alarm is automatically reset, when level has gone up.
Water valve V1823

The water valve is opened, during entire make-up cycle (step 1). The water valve will close if failures
occur to the dosing screw or the mixer, or in case there is a filling speed alarm on FIS1821.
Dosing screw DD1821
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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’.
Transfer pump P1822

Transfer pump P1822 is in operation during the transfer phase of the make-up unit (step 4). The only
limitation for P1822, is the low level detection in the preparation compartment (LC1821).
Settings
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Desired concentration flocculant batch …% 0.0 – 9999.9 %
Capacity dosing screw DD1821 … gr/min. 0.0 – 9999.9 gr./min.
K factor pulse contact water counter – FIS1821 (amount of litres per pulse) 10.0 0.0 – 9999.9 L/pulse
L/pulse
On delay low level alarm preparation and storage sections – LC1821 and 30.0 sec. 0.0 - 9999.9 sec.
LS1822
Actual status T1821 (READ ONLY) …. <Text indication of actual status> … n.a.
Actual water volume flocculant make-up unit – FIS1822 (READ ONLY) … Litres n.a.
Maximum water volume flocculant make-up unit, for one batch – FIS1822 … Litres 0.0 – 9999.9 Litres
Minimum water volume for starting mixer MX1821 and dosing screw … Litres 0.0 – 9999.9 Litres
DD1821
Ripening time mixer MX1821 900.0 sec. 0.0 - 9999.9 sec.
Calculated on time dosing screw DD1821 on every pulse FIS1822 (READ … sec. n.a.
ONLY)
--- --- ---
Total running time dosing screw DD1821 (READ ONLY) … sec. n.a.
Minimum on time dosing screw DD1821 … sec. 0 - 9999.9 sec.
On time vibrator M1821 1.0 sec. 0 - 9999.9 sec.
Off time vibrator M1821 10.0 sec. 0 - 9999.9 sec.
Measuring period filling speed alarms FIS1821 60.0 sec. 0 - 9999.9 sec.
Filling speed too low alarm FIS1821 … Litres 0.0 – 9999.9 Litres
Filling speed too high alarm FIS1821 … Litres 0.0 – 9999.9 Litres
Actual filling speed measuring – FIS1821 (READ ONLY) … Litres n.a.
Low level preparation section – LC1821 – Start preparation and low level 20.0 % 0.0 - 9999.9 %
alarm (delayed)
High level alarm preparation section flocculant make-up unit – LC1821 90.0 % 0.0 - 9999.9 %
Alarms

LC1821 High level alarm preparation section flocculant make-up unit T1821
LC1821 Wire break level measuring flocculant make-up unit T1821
LS1822 Low level alarm storage section flocculant make-up unit T1821
FIS1821 Low filling speed alarm flocculant make-up unit T1821
FIS1821 High filling speed alarm flocculant make-up unit T1821
MX1821 Failure running mixer flocculant make-up unit T1821
M1821 Circuit breaker vibrator flocculant make-up unit T1821
DD1821 Failure running dosing screw flocculant make-up unit T1821
P1822 Failure running transfer pump flocculant make-up unit T1821
MX1821 Ripening time interrupted flocculant make-up unit T1821
Page 65 of 74
7 P&ID Sheet 4 (part 3 of 3) – Flocculator PF0921 and flotation unit FU2701

The water of the aeration tank is discharged, but not without passing through a Nijhuis ‘Floc-Flot’ system
first. The flotation unit, uses the principle of Dissolved Air Flotation, and that is why it may also be
referred to as DAF unit. Due to the amount of water to be discharged, it is done over 2 separated
discharge line (FU2601 and FU2701 line).
Flocculant injection will be injected in a pre-engineered location. The amount of flocculant required, will
be determined by the commissioning engineer.
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.
works:
Page 66 of 74

FU2701 V2735 Excess sludge valve
FU2701 V2755 Sludge return valve to selector tank
FU2701 V2775 Sludge return valve to aeration tank
Description
explanation is the flocculant dosing pump P1841. The level in Aeration tank T3001 determines the start
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.
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
Settings
Page 67 of 74

On delay low flow alarm post dilution flocculant dosing pump P1841 180.0 sec. 0.0 – 9999.9 sec.
– FIS1842
Desired capacity dosing pump flocculant PF0921 – P1841 … L/h 0.0 - 9999.9 L/h
Alarms

LS1822 Low level alarm preparation section flocculant make-up unit T1821
SC2701
Description
The level inside Aeration tank T3001 determines the start and stop of flotation (DAF) unit FU2701.
Start procedure
Stop procedure
Client not ready for effluent contact

Control panel P1 allows client to control the effluent flow, coming from both FU2601 and FU2701. By
means of Volt-free contact 133K3 (Control panel P1 – Page 133), client is able to stop the feed pumps
of both flotation units. This can be of interest, when effluent water would e.g. be pumped to an effluent
channel, or effluent tank. In case this channel of buffer would suffer from a high level alarm, the signal
can be switched off (LOW), to stop both P3002 and P3022. This automatically means that signal should
be wire-bridged, if client does not wish to use this option.
Page 68 of 74
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
Aeration valve

alarm.


Skimmer drive
Settings
Page 69 of 74

procedure phase 1)
High level alarm sludge compartment – LC2702 90.0 % 0 - 999.9 %
Reset high level alarm sludge compartment – LC2702 85.0 % 0 - 999.9 %
Alarms

Description
particles, along with water are drained back to Selector tank T2301. To separate the sand and other
unit is in operation, otherwise DAF unit would be emptied. When there is a high level alarm in Selector
Sand drain cycle

Page 70 of 74
Sludge drain cycle

Settings

Off time sand drain V2705 60.0 Min. 0.0 – 9999.9 min.
Off time sludge drains V2708A/B 60.0 Min. 0.0 – 9999.9 min.
Alarms

Description
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
Page 71 of 74
 Sludge return valve to anoxic tank – Selection valve V2775
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 case excess sludge is active (V2735):

In case sludge return to selector tank is active (V2755):

There should not be a high level alarm in the selector tank
In case sludge return to anoxic/aeration tank is active (V2775):

There should not be a high level alarm in the aeration tank
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

Start level sludge compartment LC2702 – Start sludge pump P2702 20.0 % 0.0 – 9999.9 %
Stop level sludge compartment LC2702 – Stop sludge pump P2702 15.0 % 0.0 – 9999.9 %
High level alarm sludge compartment – LC2702 90.0 % 0.0 – 9999.9 %
Reset high level alarm sludge compartment – LC2702 85.0 % 0.0 – 9999.9 %
Alarms

Page 72 of 74
V2775
Description
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.
Excess sludge valve V2735

There is only a specific amount of time, that sludge can be pumped to the client. The HMI allow for a
couple of settings to control this. First of all, there is a reset time (in hours and minutes). When real time
clock of PLC detects the actual time, to be the same as this ‘reset time excess sludge timer’, all ongoing
timers are reset to zero, and the system is restarted by allowing excess sludge. Another timer counts
the amount of time that sludge pump P2702 has performed sludge excess, and limits this for an
adjustable time. Actual timer is also visible in the HMI. Be aware that the counter is only active if V2735
is opened, and P2702 is actually in operation. By the time that maximum time is reached, both valve
and pump are stopped, and sludge can only be returned into the system (up till reset time becomes
valid again).
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.
Sludge return valve selector tank V2755

the selector tank). If at least one of the pumps is active, the sludge return will also be to the selector
tank.
General opening condition for this valve is also the absence of high level alarm in the selector tank.
Sludge return valve anoxic/aeration tank V2775

the selector tank). If both pumps are inactive, the sludge return will be to the anoxic/aeration tank. In
Page 73 of 74
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.
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

Start level sludge compartment LC2702 – Start sludge pump P2702 20.0 % 0.0 – 9999.9 %
Stop level sludge compartment LC2702 – Stop sludge pump P2702 15.0 % 0.0 – 9999.9 %
Off delay sludge valves – V2735, V2755 or V2775 10.0 sec. 0.0 – 9999.9 %
On delay failure opening/closing sludge valves – V2735, V2755 or V2775 15.0 sec. 0.0 – 9999.9 %
Maximum time per day to excess sludge – V2735/P2702 … min. 0.00 – 999.99 min.
Actual excess sludge time today – V2735/P2702 (READ ONLY) … min. n.a.
Reset time excess sludge timer - Hours 12 hh 0 - 23 hh
Reset time excess sludge timer - Minutes 00 mm 0 - 59 mm
Alarms

V2735 Failure opening excess sludge valve V2735
V2735 Failure closing excess sludge valve V2735
V2755 Failure opening sludge return valve to selector tank V2755
V2755 Failure closing sludge return valve to selector tank V2755
V2775 Failure opening sludge return valve to aeration tank V2755
V2775 Failure closing sludge return valve to aeration tank V2755
Page 74 of 74

P000245-FDS-RevA As Built

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P000245-FDS-RevA As Built

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Process control and functional description

P000245-FDS-RevA (As Built)

1 General introduction on functional design specification ...................................................................5

1 General introduction on functional design specification

1.1 General introduction

Sheets 1, 2 and 4 cover the project P000245, also referred to as Scope A + C.

1.2 Manual – Off – Auto switches

Switches may also be referred to as H-O-A switches, where H refers to Hand.

Manual mode (Hand)

WARNING: Do NOT use off mode for service or maintenance!

1.3 NWT standard HMI panels

1.4 Measurement failures

1.5 Other remarks regarding PLC control

All LC/FIC/QIC/PC/TIC measurements are analogue 4-20mA measurement signals.

1.6 Unit and trigger switches

1.7 General failures, commonly used

2 P&ID Sheet 1 - Decanters, Reduction Units and Transfer tank T0301

2.1 General introduction

Plant Tag No Item ref Plant Description

 Feed pump is free of failures and equipment is in AUTO mode

Setting Typical Adjustable range

Component tag Description

Setting Typical Adjustable range

FIC34x1 – Control mode PID flow controller (*2) Manual or Automatic

Component tag Description

Setting Typical Adjustable range

Component tag Description

2.5 Reduction unit – RU33x1

Setting Typical Adjustable range

Component tag Description

2.6 Transport screw decanters – TS4601

Setting Typical Adjustable range

Component tag Description

2.7 Transfer tank T0301 – LC0301, MX0301 and P0301

Setting Typical Adjustable range

Component tag Description

3.1 General introduction

Plant Tag No Item ref Plant Description

Setting Typical Adjustable range

Component tag Description

Pressure switch PIS2501

Pressure switch PIS2502

Air flow switch FIS2501

Setting Typical Adjustable range

Component tag Description

Sand drain cycle

Sludge drain cycle

Setting Typical Adjustable range

Component tag Description

3.5 Flotation unit FU2501 – Sludge compartment – LC2502 and P2502

Setting Typical Adjustable range

Component tag Description

3.6 Flocculant make up-unit T1901 – Various components

The concerning equipment for this chapter is:

Plant Tag No Item ref Plant Description

Flow measuring tapwater supply FIS1901

Level measuring third compartment (preparation section) LC1902

 Low level flocculant make-up unit, to start preparation of a new batch

Calculating the amount of flocculant powder to be dosed to make-up batch (DD1901)

‘Calculated capacity setpoint dosing screw DD1901 [kg/h] ’ = A x B x 0,6 x C

‘Actual concentration flocculant batch (%)’ = A / B

1. ‘Concentration setpoint’ -/- ‘Lower offset to actual concentration setpoint’.

Water valve V1903