Effluent Treatment Plant Control Integration: Achieving Sustainability & Efficiency for Wisconsin Paper Manufacturer
Wunderlich-Malec Engineering, a leader in industrial control systems integration, recently completed a groundbreaking project at a Wisconsin paper board manufacturing facility. This unique project integrates an advanced Effluent Treatment Plant (ETP) with existing systems to create a fully circular reclaimed water operation, setting a new benchmark for environmental performance and operational efficiency.
A leading Wisconsin Paper Board Manufacturer installed a first-of-its-kind, circular reclaimed water system, in the state of Wisconsin. The unique reclaimed water treatment system allows the mill to operate with the water it needs without discharging a single drop of wastewater into the Fox River. The customer relied on WM to provide best in class system integration services to integrate all aspects of this reclaimed water treatment system and associated Effluent Treatment Plant (ETP) with the Balance of Plant (BOP) system to insure an integrated plant operation.
Background & Customer Needs/Requirements
The paper board manufacturer added an Effluent Treatment Plant that required a Rockwell PlantPAx distributed control system integrated with the existing plants Balance of Plant Rockwell system. The new ETP system required:
- Hardware components to add over 400 I/O points for the ETP plant.
- Design, fabricate and test one power supply panel and two remote I/O cabinets.
- Program and integrate the new system to control the ETP plant and integrate with the existing BOP control system per the design criteria.
- Collaborate with the customer to design and program existing BOP HMI screens to incorporate the ETP system.
- Commission and test the installed ETP system to achieve he functional performance requirements.
- Coach and train the plant operations personnel on the new ETP system integrated with existing BOP system.
The customer required the new ETP control system integrated with the existing BOP system to become fully operational with minimal disruption or any downtime scheduled for the existing plant operations.
WM ’s Approach & Solutions
- Collaboration and Coordination with Customer’s Team:
- WM Project Manager and Lead Engineer integrate and participate in design and scheduling meetings.
- Review, consult and incorporate design documents into control system design and programming.
- Engineer, Procure Equipment and Fabricate Panels:
- Incorporate the ETP control equipment requirements into the WM panel design, procure equipment and build to UL standards.
- Panels provided with redundant power supplies and fully tested prior to shipment.
- Control System Programming:
- Customer Plant standards in the BOP system were utilized in the ETP system programing to ensure complete continuity in the ETP system look-and-feel and its documentation.
- Additional programming was required of the existing BOP control system to ensure operational integration of plant production processes with the new ETP.
- Simulation, Commissioning, Start-up and Training:
- Complete system created virtually and functionally tested to ensure functional designs are achieved and reduce site commissioning.
- WM engineers collaborated with customer contractors to successful ETP commissioning and turnover with no downtime of plant operations.
- During start-up and following WM trained plant personnel.
Why Choose Wunderlich-Malec Engineering?
WME’s industry-leading automation and controls team has a proven record of engineering and delivering water treatment control systems with minimal disruption to plant operations. We integrate advanced control solutions with proven methodologies and provide unparalleled customer support that ensures long-term reliability and operational excellence.
📞 Contact us today to learn how WME can optimize your energy plant’s automation!
Customer Benefits
Challenge: Produce Quality Products & Discharge Clean Wastewater
WME Solution: WM provided Integrated Control System for a new discharge water ETP system
Customer Benefit: Eliminate wastewater discharge and achieve plants sustainability goal
Challenge: Integrate ETP control system into plants existing network and control system.
WME Solution: WM designed and fabricated control panels and engineers’ program new ETP system.
Customer Benefit: Customer has seamless integrated plant control system including ETP system.
Challenge: Provide control operators with new similar HMI screens
WME Solution: Program screens to enhance operator adaption of ETP points
Customer Benefit: HMI control room with integrated ETP SCADA function
Challenge: Install & initiate new system with minimal plant downtime
WME Solution: Pre-planning, simulation testing & coordination
Customer Benefit: Minimal plant outage to integrate new ETP process
Challenge: Minimize maintenance costs
WME Solution: Matched ETP system with existing plant control system
Customer Benefit: Lower equipment replacement troubleshooting costs
✓ Control System ensures ETP elimination of wastewater discharge.
✓ Integrate new ETP Control system with existing network and BOP system.
✓ Operational personnel easily adapt & integrate new points into HMI.
✓ Minimal Downtime & Seamless Transition of new ETP system
✓ Reduce Maintenance Costs & Increase Efficiency