Reading Samples 8027892

Energy optimisation in water and
wastewater treatment plants
EDS®
Water Management
Workbook
With CD-ROM
Festo Didactic
8027892 en
12/2013 R1.0
Order No.: 8027892
Status: 12/2013
Authors: Martina Groß, Peter Maurer*, Yvonne Salazar, Thomas Schwab**, Johannes Strittmatter
Graphics: Doris Schwarzenberger
Layout: 01/2014, Frank Ebel
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2014
Internet: www.festo-didactic.com
E-mail: [email protected]
* Stuttgart University
Institute for Sanitary Engineering, Water Quality and Solid Waste Management (ISWA)
Bandtäle 2
70569 Stuttgart
Federal Republic of Germany
** ADIRO Automatisierungstechnik GmbH

Limburgstrasse 40
73734 Esslingen
Federal Republic of Germany
The purchaser shall receive a single right of use which is non-exclusive, non-time-limited and limited
geographically to use at the purchaser's site/location as follows.
The purchaser shall be entitled to use the work to train his/her staff at the purchaser's site/location and
shall also be entitled to use parts of the copyright material as the basis for the production of his/her own
training documentation for the training of his/her staff at the purchaser's site/location with
acknowledgement of source and to make copies for this purpose. In the case of schools/technical colleges
and training centres, the right of use shall also include use by school and college students and trainees at
the purchaser's site/location for teaching purposes.
The right of use shall in all cases exclude the right to publish the copyright material or to make this available
for use on intranet, Internet and LMS platforms and databases such as Moodle, which allow access by a
wide variety of users, including those outside of the purchaser's site/location.
Entitlement to other rights relating to reproductions, copies, adaptations, translations, microfilming and
transfer to and storage and processing in electronic systems, no matter whether in whole or in part, shall
require the prior consent of Festo Didactic GmbH & Co. KG.
Contents
EDS® Water Management __________________________________________________________________ V

Description ______________________________________________________________________________ V
EDS® systems data ________________________________________________________________________ VI
The four systems of the EDS® Water Management _____________________________________________ VII
Piping and instrumentation diagrams ________________________________________________________ VIII
Correlating the exercises with the EDS® Water Management systems _______________________________ IX
Appropriate use and disclaimer ____________________________________________________________ XII
Notes for the trainer/instructor _____________________________________________________________ XIII
Structure of the exercises _________________________________________________________________ XIII
Exercises and solutions
1 Energy optimisation in water and wastewater treatment plants _____________________________3

1.1 The training equipment ______________________________________________________________3
1.2 The most important P&I symbols used for the EDS® Water Management _______________________5
1.3 Learning outcomes correlated with exercises _____________________________________________6
1.4 Introduction to the learning module “Energy optimisation in water and
wastewater treatment plants” _________________________________________________________8
1.4.1 Reduction of the energy consumption___________________________________________________8
1.4.2 Increase of the energy generation ______________________________________________________9
1.4.3 Introduction of energy management ____________________________________________________9
2 Energy consumption and power generation ___________________________________________ 10

2.1 Fundamentals ____________________________________________________________________ 10
2.1.1 Primary energy consumption ________________________________________________________ 10
2.1.2 Problems of energy generation ______________________________________________________ 12
2.2 Exercises ________________________________________________________________________ 14
2.2.1 Consumption of primary energy______________________________________________________ 14
2.2.2 Energy saving in daily life ___________________________________________________________ 16
2.2.3 Energy consumption in facilities for water- and wastewater treatment ______________________ 17
2.2.4 Assessment of electrical energy consumption in a wastewater treatment plant _______________ 21
3 Forms of energy, efficiency and power ________________________________________________ 25

3.1 Fundamentals ____________________________________________________________________ 25
3.1.1 Forms of energy __________________________________________________________________ 25
3.1.2 Power __________________________________________________________________________ 25
3.1.3 Efficiency ________________________________________________________________________ 26
© Festo Didactic GmbH & Co. KG 8027892 III

Contents
3.2 Exercises ________________________________________________________________________ 27

3.2.1 Examine the electrical energy consumption of the EDS® Water Management _________________ 27
3.2.2 Forms of energy __________________________________________________________________ 32
3.2.3 Efficiency of the pump _____________________________________________________________ 35
3.2.4 Energy monitoring of the solenoid valve _______________________________________________ 43
4 Interference and water supply ______________________________________________________ 44

4.1 Fundamentals ____________________________________________________________________ 44
4.2 Exercise _________________________________________________________________________ 44
4.2.1 Effects of interference in the piping system ____________________________________________ 44
5 Energy optimisation of pumping using closed-loop control technology_____________________ 47

5.1 Fundamentals ____________________________________________________________________ 47
5.2 Exercises ________________________________________________________________________ 47
5.2.1 Optimising energy consumption in fill level control ______________________________________ 47
5.2.2 Optimising flow control ____________________________________________________________ 51
6 Energy optimisation of aeration and costs ____________________________________________ 54

6.1 Fundamentals ____________________________________________________________________ 54
6.2 Exercises ________________________________________________________________________ 56
6.2.1 Energy consumption of the air blower at different power settings __________________________ 60
6.2.2 Controlling the oxygen concentration using a two-step controller __________________________ 61
6.2.3 Controlling the oxygen concentration using a continuous controller ________________________ 63
6.2.4 Energy consumption of aeration _____________________________________________________ 65
6.2.5 Calculating aeration cost ___________________________________________________________ 66
7 Causes for waste of energy _________________________________________________________ 68

7.1 Fundamentals ____________________________________________________________________ 68
7.2 Exercise _________________________________________________________________________ 69
7.2.1 Excessive energy consumption and counter measures ___________________________________ 69
8 Energy management ______________________________________________________________ 71

8.1 Fundamentals ____________________________________________________________________ 71
8.2 Exercises ________________________________________________________________________ 71
8.2.1 Permanent control of the measures and energy optimisation ______________________________ 71
8.2.2 Cost optimisation _________________________________________________________________ 73
9 Energy production in wastewater plants ______________________________________________ 75

9.1 Fundamentals ____________________________________________________________________ 75
9.2 Exercise _________________________________________________________________________ 76
9.2.1 Estimate the power generation ______________________________________________________ 76
Appendix ______________________________________________________________________________ 79
Safety instructions _______________________________________________________________________ 79
Components ____________________________________________________________________________ 81
Abbreviations ___________________________________________________________________________ 84
IV © Festo Didactic GmbH & Co. KG 8027892

EDS® Water Management
Description
The EDS® (Environmental Discovery System) Water Management is designed to simulate the entire cycle of
human water use. This starts with water catchment by pumping from groundwater, springs or surface water
and includes subsequent storage and purification. It also covers the distribution of water to consumers and
its use– which causes water to become wastewater. Further on wastewater transport together with rain
runoffs and wastewater treatment are reproduced.
In a real wastewater treatment plant the final effluent is discharged into surface water, normally rivers.
Direct reuse is not common, but the effluent now is part of natural water bodies which again feeds the
sources of water extraction. The water cycle in the EDS® Water Management is completed by reusing the
final effluent as input water into the system.
The EDS® Water Management training equipment vividly simulates this “man-made” water cycle with its
four systems:
1. Water Treatment
2. Water Supply
3. Wastewater Disposal
4. Wastewater Treatment
Processes such as pumping, storage, flocculation, disinfection and distribution of water can be learnt
through practical exercises. After adding solid matter, we follow the stream of wastewater and discover
processes such as sedimentation, aeration and sludge recirculation.
Comprehensive documentation with theoretical input additionally promotes the learning success. Four of
the workbooks correspond directly to the systems, whereas two overarching workbooks additionally deliver
a sound introduction into closed-loop control technology and energy efficiency.
The following workbooks are available:

1. Water treatment
2. Water supply
3. Wastewater disposal
4. Wastewater treatment
5. Monitoring, controlling and optimising operations
6. Energy optimisation in water and wastewater treatment plants
Each system can be used as stand-alone training equipment for an individual learning module. The training
equipment can be modified individually as piping and sensors use are flexible. If the four systems are
connected they form an integrated training equipment that covers all of the processes and exercises
described in the workbooks. Using the systems together allows students to see how individual process
steps interact as well as how a measure taken in one area affects one or more of the other systems.
© Festo Didactic GmbH & Co. KG 8027892 V

As in the real world, the processes interact. The wastewater treatment plant, for example, has to process the
amount and composition of wastewater delivered by the sewer system. Similarly, the single systems of the
training equipment are connected only by pipes, which transport the water. Whereas the control process is
separate for each system. So EDS® Water Management invites students to ‘try things out’ and even simulate
problems, using different settings and system states. This experimentation can be done without incurring
costs or causing damage, something not possible in a real water or wastewater treatment plant.
After completion of the learning modules described in the workbooks, the student’s expertise will be
significantly increased. The strong practical orientation helps to transfer the knowledge and skills acquired
during the training directly to their work environment. Professional training actively contributes to safe and
efficient operation of treatment plants and improves the availability of clean drinking water.
EDS® systems data
Dimensions of the EDS® Water Management without main storage tank, worktable and PC desk
 Width: 2660 mm (minimum); 3500 mm (optimum)
 Depth: 400 mm
 Height: 1150 mm from table top
The EDS® Water Management training equipment with all four systems
VI © Festo Didactic GmbH & Co. KG 8027892

The four systems of the EDS® Water Management
Water Treatment
The System has been designed for use in the learning modules:
 Water treatment
 Monitoring, controlling and optimising operations
 Energy optimisation in water and wastewater treatment plants
Conducting the exercises on the Water Treatment System, students learn the principles, function and
operation of a variety of water purification processes. Subsequently, they apply the acquired skills to create
an environmentally safe effluent on one side and to ensure drinking water purification on the other side.
Water Supply
The system has been designed for use in the learning modules:
 Water supply
As the system is used in three learning modules, its range of applications is wide and students perform
many exercises on it. The learning module “Water Supply” pumps are one of the main topics, other
exercises deal with control technologies in water transport to achieve the optimum distribution of drinking
water to the consumer. In addition, the flow of water from the source to the public is examined.
Wastewater Disposal
 Wastewater disposal
Using the system in the learning module “Wastewater Disposal”, students are familiarised with control
technologies of wastewater removal and the related processes. The flow of wastewater from urban
settlements to the wastewater plant is examined.
© Festo Didactic GmbH & Co. KG 8027892 VII

Wastewater Treatment
 Wastewater treatment
In the learning module “Wastewater Treatment”, the system is used to illustrate the principles of
wastewater treatment processes focused on sedimentation, biological treatment and sludge recirculation. In
learning module “Energy Optimisation” the system illustrates processes and measures related to energy
efficiency in the water and wastewater treatment, especially aeration. For the module “Monitoring,
controlling and optimising operations” the topics flow control, aeration and fill level control can be treated.
Piping and instrumentation diagrams
The Water Treatment system and the Water Supply system
VIII © Festo Didactic GmbH & Co. KG 8027892

The Wastewater Disposal system and the Wastewater Treatment system
Correlating the exercises with the EDS® Water Management systems

The table below shows which of the EDS® systems can be used for which exercise. The systems concerned
are marked with “X”. If there is no “X” in a line, the respective exercise is knowledge driven and none of the
EDS® systems is required. “(X)” means that it is possible to conduct the exercise with this system. However
the systems marked with “X” are to be preferred.
W- W- WW- WW-
Correlation of the exercises with the EDS® Water Management systems PUR SUP TRA TRE
Getting started
The “Getting started” also includes exercises for the commissioning of electronic X X X X
sensors, pumps and valves.
Workbook “Water treatment”
2. Precipitation and Flocculation
2.2.1 Iron flocculation using iron hydroxide X
3. Chlorine dosing and disinfection
3.2.1 Chlorine dosage and measurement of chlorine concentration X
W-PUR: Water Treatment System

W-SUP: Water Supply System
WW-TRA: Wastewater Disposal System
WW-TRE: Wastewater Treatment System
© Festo Didactic GmbH & Co. KG 8027892 IX

W- W- WW- WW-
Workbook “Water supply”
3. Operation of pumps
3.2.1 Setting up the pump (X) X (X) (X)
3.2.2 Pressure measurement X
3.2.3 Flow measurement X (X) X (X)
3.2.4 Controlling water supply using hand valves X (X) X (X)
4. Water transport to high tower
4.2.1 Control of the filling level while simultaneously withdrawing water X
4.2.2 Manual control of the filling level using 2-way ball valve with pneumatic actuator X
5. Water supply to different pressure zones
5.2.1 Simulation of two settlement zones located on different altitudes X and X

(both systems are used)
6. Water loss
6.2.1 Identification of water loss X
Workbook “Wastewater disposal”
2. Principles of water flow in pipes
2.2.1 Wastewater disposal in gravity sewers – Hydraulic capacity, impounding and X

backwater
3. Transport of solids
3.2.1 Transport of solids in sewers with varying flow rates X
4. Operation of sewer systems
4.2.1 Flow control simulating a rain overflow basin X
4.2.2 Drain Control – closed loop control using the proportional media valve X
Workbook “Wastewater treatment”
2. Sedimentation
2.2.1 Analysis of factors affecting sedimentation
2.2.2 Simulation of the sedimentation of sludge (granulate) X
2.2.3 Analysis of flow rates X
2.2.4 Influence of solids load on sedimentation X
3. Biological treatment (activated sludge)
3.2.1 Keeping solids concentration in the aeration tank high X
3.2.2 Aeration X

X © Festo Didactic GmbH & Co. KG 8027892

W- W- WW- WW-
Workbook “Monitoring, controlling and optimising operations”
2. Closed loop control technology: Pump
2.2.1 Controlling the fill level using a two-step controller X
2.2.2 Controlling the fill level using a continuous controller X
2.2.3 Flow control using a proportional-integral controller X X X
3. Closed loop control technology: Proportional media valve
3.2.1 Volumetric Flow Control X
3.2.2 Drain Control X
4. Closed loop control technology: Aeration
4.2.1 Controlling the oxygen concentration using a two-step controller X
4.2.2 Controlling the oxygen concentration using a continuous controller X
Workbook “Energy optimisation in water and wastewater treatment plants”
2. Energy consumption and power generation
2.2.1 Consumption of primary energy
2.2.2 Energy saving in daily life
2.2.3 Energy consumption in facilities for water- and wastewater treatment
2.2.4 Assessment of electrical energy consumption in a wastewater treatment plant
3. Forms of energy, efficiency and power
3.2.1 Examination of electrical energy consumption

X X X X
of the EDS® Water Management
3.2.2 Forms of energy
3.2.3 Efficiency of the pump X X X X
3.2.4 Energy monitoring of the solenoid valve X X X
4. Interference and water supply
4.2.1 Effects of interference in the piping system X X X X
5. Energy optimisation of pumping: closed-loop control
5.2.1 Optimising energy consumption in fill level control X
5.2.2 Optimising flow control X X X

© Festo Didactic GmbH & Co. KG 8027892 XI

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6. Energy optimisation of aeration and costs
6.2.1 Energy consumption of the air blower at different power settings X
6.2.4 Energy consumption of aeration X
6.2.5 Calculation of aeration cost
7. Causes for waste of energy
7.2.1 Excessive energy consumption and counter measures
8. Energy management
8.2.1 Permanent control of the measures and energy optimisation
8.2.2 Cost optimisation
9. Energy generation in wastewater plants
9.2.1 Estimate the power generation

WW-TRP: Wastewater Disposal System
Appropriate use and disclaimer

The EDS® Water Management may only be used:
 For its intended purpose in teaching and training applications
 When its safety functions are in flawless condition
The components included in the training equipment have been designed in accordance with the latest
technology, as well as recognised safety rules. However, life and limb of the user and third parties may be
endangered, and the safe functioning of the components may be impaired, if they are used improperly.
The EDS® Water Management has been developed and manufactured exclusively for technical and
vocational education and training (TVET). The respective educational institutions and their instructors must
ensure that all students observe the safety precautions described in this workbook.
Festo Didactic hereby excludes any and all liability for damages suffered by students, the educational
institution and/or any third parties, which occur during use of the training equipment in situations which
serve any purpose other than education and training, unless such damages have been caused by Festo
Didactic due to malicious intent or gross negligence.
XII © Festo Didactic GmbH & Co. KG 8027892

Notes for the trainer/instructor

 Please observe the specifications in the data sheets for the individual components carefully and in
particular all safety instructions in the previous chapter. Before the exercises are conducted, please
assess their possible hazards to avoid accidents and emergency situations.
 Electrical components are pre-wired at the factory, and are mounted onto an H-rail for direct attachment
to the rectangular profile. Alternatively, they can be shipped unwired as a kit. In either case, wiring work
must only be carried out by qualified personnel.
 Like all training products of Festo Didactic, the learning systems of the EDS® are strongly practice
focussed. Their prime objective is to increase the professional competence of students by giving them
tasks and challenges that reflect actual work conditions. During the training the instructor should
strictly focus on the learning outcomes and design the learning process in a way that at the end the
learning outcomes are achieved.
 As the EDS® Water Management training equipment simulates real processes, it represents an ideal tool
to deliver relevant and state-of-the-art know-how and skills to the students. Consequently, the
conduction of the exercises should form the core of the learning process. Theoretical explanations and
presentations should only be used to support the knowledge and skill transfer resulting from the
exercises.
 Since the knowledge of students usually differs, the degree how in depth the contents of the learning
module should be treated might vary considerably. Thus, there is no concrete recommendation
concerning the duration of a learning module. Generally, the instructor should plan and conduct the
learning module in a way that the students have enough time to execute the exercises, ask questions
and share their experience and knowledge.
Structure of the exercises

The training equipment and workbooks of Festo Didactic facilitate a didactic approach that is oriented
towards hands-on learning. To support the practice-driven approach of the learning process, the exercises
play a crucial role. They reflect real work challenges and problems. Therefore it is important that they are
always explained in the context of work. Consequently, the exercises are composed of the following
structural elements:
 Problem description
The problem description creates a scenario from the work place and places the students into a work
environment.
 Layout
Sometimes an instruction is given on how to prepare an exercise, which materials are needed and how
to assemble the EDS® Water Management System that is used for the respective task(s).
 Learning outcomes
The learning outcomes allow evaluating student’s learning success and giving employers an orientation
of the student’s competence level. Moreover they are guidelines for the learning process.
© Festo Didactic GmbH & Co. KG 8027892 XIII

 Tasks
Tasks contain a short and precise task description and give a clear explanation of what has to be done,
to be solved or achieved.
 Training notes
Training notes give additional tips or information that help the students to successfully work on the
tasks. A description of software tools for calculation, measuring, etc., which are useful for the solution
of the tasks, might also be included.
 Training notes for the trainer / instructor
The trainer / instructor notes provide further recommendations, suggestions and information to
professionally execute the training and support students effectively in their learning.
XIV © Festo Didactic GmbH & Co. KG 8027892



2.1 Fundamentals ____________________________________________________________________ 10
2.2 Exercises ________________________________________________________________________ 14

3.1 Fundamentals ____________________________________________________________________ 25
3.1.1 Forms of energy __________________________________________________________________ 25
3.1.2 Power __________________________________________________________________________ 25
3.1.3 Efficiency ________________________________________________________________________ 26
3.2 Exercises ________________________________________________________________________ 27
3.2.2 Forms of energy __________________________________________________________________ 32

4.1 Fundamentals ____________________________________________________________________ 44
4.2 Exercise _________________________________________________________________________ 44

5.1 Fundamentals ____________________________________________________________________ 47
5.2 Exercises ________________________________________________________________________ 47
© Festo Didactic GmbH & Co. KG 8027892 1


6.1 Fundamentals ____________________________________________________________________ 54
6.2 Exercises ________________________________________________________________________ 56

7.1 Fundamentals ____________________________________________________________________ 68
7.2 Exercise _________________________________________________________________________ 69

8.1 Fundamentals ____________________________________________________________________ 71
8.2 Exercises ________________________________________________________________________ 71

9.1 Fundamentals ____________________________________________________________________ 75
9.2 Exercise _________________________________________________________________________ 76
Appendix ______________________________________________________________________________ 79
Components ____________________________________________________________________________ 81
Abbreviations ___________________________________________________________________________ 84
2 © Festo Didactic GmbH & Co. KG 8027892

1 Energy optimisation in water and wastewater treatment plants
1.1 The training equipment

The four systems have been designed for the use in the learning module Energy optimisation in water and
wastewater treatment plants.
In learning module “Energy optimisation” the system illustrates processes and measures related to energy
efficiency in the water and wastewater treatment, especially aeration.
Picture of the Water Treatment system Picture of the Water Supply system
Picture of the Wastewater Disposal system Picture of the Wastewater Treatment system

are marked with “X”.
W- W- WW- WW-

X X X X


1.2 The most important P&I symbols used for the EDS® Water Management
Piping and Instrumentation (P&I) diagrams show the functional layout of a plant or facility. P&I diagrams
contain different symbols for sensors, valves, actuators, motors, pumps, tanks and pipes. The P&I diagrams
in this workbook are based on EN 62424 respectively EN 10628. To keep the diagrams easy to read, a
simplified form is used.
Symbol Meaning
Pump with electric motor
Tank (sedimentation tank shape)
Filter
Pipe
Branching pipe
Actuator (general symbol)
Manual actuator
Manual valve
Sensor
Top: FIC means flow sensor (F) which shows the current value (I) and can be used
for closed loop control (C)
Bottom: numbering
Further explanation of the characters in the top of the symbol: see table below
Symbols – Examples from the EDS® systems

First character Following character(s)
F Flow A Alarm
L Level C Controller
P Pressure I Instantaneous value
Q Quality O Optical signal
T Temperature R Registration
D Difference +/- Threshold
Denomination of sensors
1.3 Learning outcomes correlated with exercises

With exercise 2.2.1 “Consumption of primary energy” the student can:
 name the main sources of primary energy in his or her own country / region
 outline the ecological implications connected with the use of different energy sources.
In exercise 2.2.2 “Energy saving in daily life” the students are invited to discuss the topic and reflect their
own potentials for energy saving.
With exercise 2.2.3 “Energy consumption in facilities for water- and wastewater treatment” the student can:
 list the types of energy consumed in the plant
 assess the ecological implications of the types of energy
 set the basis for an energy management system
 find cases of energy waste and excessive energy consumption
 develop first ideas for energy saving.
With exercise 2.2.4 “Assessment of electrical energy consumption in a wastewater treatment plant” the
student can:
 document the electricity consumption of the plant
 identify potentials for energy saving by using benchmark.
With exercise 3.2.1 “Examine the electrical energy consumption of the EDS® Water Management” the
student can:
 define the terms energy, power and efficiency
 calculate efficiency using the related basic formula
 conduct initial analysis with energy monitoring software
 name the various forms of energy used by the system.
With exercise 3.2.2 “Forms of energy” the student can:

 calculate potential energy of a liquid in an elevated tank
 name energy conversion and potential energy losses of a system
 assign different forms of energy to components of the training equipment.

With exercise 3.2.3 “Efficiency of the pump” the student can:

 find the optimum voltage to operate a pump
 compare different pumps and access their efficiency
 measure and calculate the efficiency of a pump.
By measuring the energy consumption of a device in exercise 3.2.4 “Energy monitoring of the solenoid
valve” the student can check the manufacturer’s or seller’s specifications.
With exercise 4.2.1 “Effects of interference in the piping system” the student can:
 identify the difference in energy consumption between the free and the narrowed system.
With exercise 5.2.1 “Optimising energy consumption in fill level control” the student can:
 compare and interpret different control strategies of closed-loop control regarding their energy demand.
With exercise 5.2.2 “Optimising flow control” the student can:

 determine control settings of closed-loop control to optimise energy consumption.
With exercises 6.2.1 to 6.2.4

“Controlling the oxygen concentration using a two-step controller”,
“Controlling the oxygen concentration using a continuous controller” and
“Measure energy consumption of aeration” the student can:
 control a slow reacting system - aeration
 choose the optimum control scheme for aeration processes
 measure energy consumption of the air blower
 estimate costs of aeration.
With exercise 6.2.4 “Calculation of aeration cost” the student can:

 calculate the electricity cost of aeration
 describe the effect of efficiency on the cost of the aeration process.
With exercise 7.2.1 “Excessive energy consumption and counter measures” the student can:
 systematically analyse deficits in energy consumption
 find possible reasons
 develop counter measures
 name data necessarily needed to allow a successful evaluation.

With exercise 8.2.1 “Permanent control of the measures and energy optimisation” the student can:
 evaluate measures for energy saving
 develop key indicators to control the effectiveness of his measures
 describe the structure and methods of energy management.
With exercise 8.2.2 “Cost optimisation” the student can:

 check and optimise the conditions of purchasing electricity for a facility.
With exercise 9.2.1 “Estimate the power generation” the student can:
 name the total energy demand of different sludge stabilisation technologies for a given wastewater
treatment plant
 calculate the gas production possible in litres and in kWh
 calculate how much electricity could be generated out of it
 determine the total reduction of electrical energy demand.
1.4 Introduction to the learning module “Energy optimisation in water and wastewater treatment plants”
Water and wastewater treatment plants are energy-intensive and account for up to 35 percent of municipal
energy consumption. Particularly pumps and aeration consume a significant portion of energy in water and
wastewater plants and should therefore be a special focus. In many cases water and wastewater treatment
plants are operated without optimised devices or measures for processes optimisation. However, an
optimised system consumes less electrical power, results in reduced maintenance work and increased life
time of the operational units. A detailed study of the energy consumption should be executed in order to
determine the optimisation potential. As a result, the most potent measures can be determined for the
particular plant.
1.4.1 Reduction of the energy consumption

Strict and regular maintenance measures are an efficient way to cut energy consumption as these measures
provide smooth and trouble-free operation of pumps and other machines. Outdated and poorly
synchronised systems are subject to malfunctions and consume relatively much energy. When new plants
are built or existing ones modernised, significant amounts of energy can be saved by implementing an
appropriate design and selecting energy-efficient components. In day to day plant operation, well-qualified
staff, optimum system settings and control parameters play an essential role for energy saving.
Regularly measuring the performance of the machines is another important measure for energy saving as
the resulting data deliver valuable information about the efficiency of the machines and may detect
malfunctions.

1.4.2 Increase of the energy generation

Sludge gas resulting from wastewater treatment can be used to generate heat and electricity. To produce
sludge gas, wastewater treatment plants must be equipped with a sludge gas digester. The energy delivered
by sludge gas might cover up to 70% of the energy consumption of a wastewater treatment plant. In some
cases, the gas is fed into the public gas supply and used by natural gas filling stations or in households for
heating.
1.4.3 Introduction of energy management

Water and wastewater treatment plants can reduce their consumption of electrical and heating energy by
introducing an energy management system which supervises and controls all machines and devices which
affect the energy consumption of the respective plant. Using energy management tools, an overall energy
concept of the plant can be prepared which includes measurable targets and concrete measures.
The basis for the implementation of an energy management system is a well-qualified and motivated staff,
who are aware of the importance of energy saving and are willing to carry out all required measures for cost
effectiveness in the plant.

Exercises and worksheets


2.1 Fundamentals ____________________________________________________________________ 10
2.2 Exercises ________________________________________________________________________ 14

3.1 Fundamentals ____________________________________________________________________ 25
3.1.1 Forms of energy __________________________________________________________________ 25
3.1.2 Power __________________________________________________________________________ 25
3.1.3 Efficiency ________________________________________________________________________ 26
3.2 Exercises ________________________________________________________________________ 27
3.2.2 Forms of energy __________________________________________________________________ 32

4.1 Fundamentals ____________________________________________________________________ 44
4.2 Exercise _________________________________________________________________________ 44

5.1 Fundamentals ____________________________________________________________________ 47
5.2 Exercises ________________________________________________________________________ 47

Exercises and worksheets

6.1 Fundamentals ____________________________________________________________________ 54
6.2 Exercises ________________________________________________________________________ 56

7.1 Fundamentals ____________________________________________________________________ 68
7.2 Exercise _________________________________________________________________________ 69

8.1 Fundamentals ____________________________________________________________________ 71
8.2 Exercises ________________________________________________________________________ 71

9.1 Fundamentals ____________________________________________________________________ 75
9.2 Exercise _________________________________________________________________________ 76
Appendix ______________________________________________________________________________ 79
Components ____________________________________________________________________________ 81
Abbreviations ___________________________________________________________________________ 84

1.1 The training equipment

The four systems have been designed for the use in the learning module Energy optimisation in water and
wastewater treatment plants.
In learning module “Energy optimisation” the system illustrates processes and measures related to energy
efficiency in the water and wastewater treatment, especially aeration.
Picture of the Water Treatment system Picture of the Water Supply system
Picture of the Wastewater Disposal system Picture of the Wastewater Treatment system
© Festo Didactic GmbH & Co. KG 8027892 Name: __________________________________ Date: ____________ 3
are marked with “X”.
W- W- WW- WW-

X X X X

4 Name: __________________________________ Date: ____________ © Festo Didactic GmbH & Co. KG 8027892
1.2 The most important P&I symbols used for the EDS® Water Management
Piping and Instrumentation (P&I) diagrams show the functional layout of a plant or facility. P&I diagrams
contain different symbols for sensors, valves, actuators, motors, pumps, tanks and pipes. The P&I diagrams
in this workbook are based on EN 62424 respectively EN 10628. To keep the diagrams easy to read, a
simplified form is used.
Symbol Meaning
Pump with electric motor
Tank (sedimentation tank shape)
Filter
Pipe
Branching pipe
Actuator (general symbol)
Manual actuator
Manual valve
Sensor
Top: FIC means flow sensor (F) which shows the current value (I) and can be used
for closed loop control (C)
Bottom: numbering
Further explanation of the characters in the top of the symbol: see table below
Symbols – Examples from the EDS® systems
First character Following character(s)
F Flow A Alarm
L Level C Controller
P Pressure I Instantaneous value
Q Quality O Optical signal
T Temperature R Registration
D Difference +/- Threshold
Denomination of sensors
1.3 Learning outcomes correlated with exercises

With exercise 2.2.1 “Consumption of primary energy” the student can:
 name the main sources of primary energy in his or her own country / region
 outline the ecological implications connected with the use of different energy sources.
In exercise 2.2.2 “Energy saving in daily life” the students are invited to discuss the topic and reflect their
own potentials for energy saving.
With exercise 2.2.3 “Energy consumption in facilities for water- and wastewater treatment” the student can:
 list the types of energy consumed in the plant
 assess the ecological implications of the types of energy
 set the basis for an energy management system
 find cases of energy waste and excessive energy consumption
 develop first ideas for energy saving.
With exercise 2.2.4 “Assessment of electrical energy consumption in a wastewater treatment plant” the
student can:
 document the electricity consumption of the plant
 identify potentials for energy saving by using benchmark.
With exercise 3.2.1 “Examine the electrical energy consumption of the EDS® Water Management” the
student can:
 define the terms energy, power and efficiency
 calculate efficiency using the related basic formula
 conduct initial analysis with energy monitoring software
 name the various forms of energy used by the system.
With exercise 3.2.2 “Forms of energy” the student can:

 calculate potential energy of a liquid in an elevated tank
 name energy conversion and potential energy losses of a system
 assign different forms of energy to components of the training equipment.
With exercise 3.2.3 “Efficiency of the pump” the student can:

 find the optimum voltage to operate a pump
 compare different pumps and access their efficiency
 measure and calculate the efficiency of a pump.
By measuring the energy consumption of a device in exercise 3.2.4 “Energy monitoring of the solenoid
valve” the student can check the manufacturer’s or seller’s specifications.
With exercise 4.2.1 “Effects of interference in the piping system” the student can:
 identify the difference in energy consumption between the free and the narrowed system.
With exercise 5.2.1 “Optimising energy consumption in fill level control” the student can:
 compare and interpret different control strategies of closed-loop control regarding their energy demand.
With exercise 5.2.2 “Optimising flow control” the student can:

 determine control settings of closed-loop control to optimise energy consumption.
With exercises 6.2.1 to 6.2.4

“Controlling the oxygen concentration using a two-step controller”,
“Controlling the oxygen concentration using a continuous controller” and
“Measure energy consumption of aeration” the student can:
 control a slow reacting system - aeration
 choose the optimum control scheme for aeration processes
 measure energy consumption of the air blower
 estimate costs of aeration.
With exercise 6.2.4 “Calculation of aeration cost” the student can:

 calculate the electricity cost of aeration
 describe the effect of efficiency on the cost of the aeration process.
With exercise 7.2.1 “Excessive energy consumption and counter measures” the student can:
 systematically analyse deficits in energy consumption
 find possible reasons
 develop counter measures
 name data necessarily needed to allow a successful evaluation.
With exercise 8.2.1 “Permanent control of the measures and energy optimisation” the student can:
 evaluate measures for energy saving
 develop key indicators to control the effectiveness of his measures
 describe the structure and methods of energy management.
With exercise 8.2.2 “Cost optimisation” the student can:

 check and optimise the conditions of purchasing electricity for a facility.
With exercise 9.2.1 “Estimate the power generation” the student can:
 name the total energy demand of different sludge stabilisation technologies for a given wastewater
treatment plant
 calculate the gas production possible in litres and in kWh
 calculate how much electricity could be generated out of it
 determine the total reduction of electrical energy demand.
1.4 Introduction to the learning module “Energy optimisation in water and wastewater treatment plants”
Water and wastewater treatment plants are energy-intensive and account for up to 35 percent of municipal
energy consumption. Particularly pumps and aeration consume a significant portion of energy in water and
wastewater plants and should therefore be a special focus. In many cases water and wastewater treatment
plants are operated without optimised devices or measures for processes optimisation. However, an
optimised system consumes less electrical power, results in reduced maintenance work and increased life
time of the operational units. A detailed study of the energy consumption should be executed in order to
determine the optimisation potential. As a result, the most potent measures can be determined for the
particular plant.
Following steps to reduce the energy costs in water and wastewater treatment plants.
1.4.1 Reduction of the energy consumption

Strict and regular maintenance measures are an efficient way to cut energy consumption as these measures
provide smooth and trouble-free operation of pumps and other machines. Outdated and poorly
synchronised systems are subject to malfunctions and consume relatively much energy. When new plants
are built or existing ones modernised, significant amounts of energy can be saved by implementing an
appropriate design and selecting energy-efficient components. In day to day plant operation, well-qualified
staff, optimum system settings and control parameters play an essential role for energy saving.
Regularly measuring the performance of the machines is another important measure for energy saving as
the resulting data deliver valuable information about the efficiency of the machines and may detect
malfunctions.
1.4.2 Increase of the energy generation

Sludge gas resulting from wastewater treatment can be used to generate heat and electricity. To produce
sludge gas, wastewater treatment plants must be equipped with a sludge gas digester. The energy delivered
by sludge gas might cover up to 70% of the energy consumption of a wastewater treatment plant. In some
cases, the gas is fed into the public gas supply and used by natural gas filling stations or in households for
heating.
1.4.3 Introduction of energy management

Water and wastewater treatment plants can reduce their consumption of electrical and heating energy by
introducing an energy management system which supervises and controls all machines and devices which
affect the energy consumption of the respective plant. Using energy management tools, an overall energy
concept of the plant can be prepared which includes measurable targets and concrete measures.
The basis for the implementation of an energy management system is a well-qualified and motivated staff,
who are aware of the importance of energy saving and are willing to carry out all required measures for cost
effectiveness in the plant.

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Energy optimisation in water and

wastewater treatment plants

** ADIRO Automatisierungstechnik GmbH

EDS® Water Management __________________________________________________________________ V

Exercises and solutions

1 Energy optimisation in water and wastewater treatment plants _____________________________3

2 Energy consumption and power generation ___________________________________________ 10

3 Forms of energy, efficiency and power ________________________________________________ 25

© Festo Didactic GmbH & Co. KG 8027892 III

3.2 Exercises ________________________________________________________________________ 27

4 Interference and water supply ______________________________________________________ 44

5 Energy optimisation of pumping using closed-loop control technology_____________________ 47

6 Energy optimisation of aeration and costs ____________________________________________ 54

7 Causes for waste of energy _________________________________________________________ 68

8 Energy management ______________________________________________________________ 71

9 Energy production in wastewater plants ______________________________________________ 75

IV © Festo Didactic GmbH & Co. KG 8027892

The following workbooks are available:

© Festo Didactic GmbH & Co. KG 8027892 V

EDS® systems data

VI © Festo Didactic GmbH & Co. KG 8027892

The four systems of the EDS® Water Management

© Festo Didactic GmbH & Co. KG 8027892 VII

Piping and instrumentation diagrams

The Water Treatment system and the Water Supply system

VIII © Festo Didactic GmbH & Co. KG 8027892

The Wastewater Disposal system and the Wastewater Treatment system

Correlating the exercises with the EDS® Water Management systems

Workbook “Water treatment”

2. Precipitation and Flocculation

2.2.1 Iron flocculation using iron hydroxide X

3. Chlorine dosing and disinfection

3.2.1 Chlorine dosage and measurement of chlorine concentration X

W-PUR: Water Treatment System

© Festo Didactic GmbH & Co. KG 8027892 IX

Workbook “Water supply”

3.2.1 Setting up the pump (X) X (X) (X)

3.2.2 Pressure measurement X

3.2.3 Flow measurement X (X) X (X)

3.2.4 Controlling water supply using hand valves X (X) X (X)

4. Water transport to high tower

4.2.1 Control of the filling level while simultaneously withdrawing water X

5. Water supply to different pressure zones

5.2.1 Simulation of two settlement zones located on different altitudes X and X

6.2.1 Identification of water loss X

Workbook “Wastewater disposal”

2. Principles of water flow in pipes

2.2.1 Wastewater disposal in gravity sewers – Hydraulic capacity, impounding and X

3.2.1 Transport of solids in sewers with varying flow rates X

4. Operation of sewer systems

4.2.1 Flow control simulating a rain overflow basin X

Workbook “Wastewater treatment”

2.2.1 Analysis of factors affecting sedimentation

2.2.2 Simulation of the sedimentation of sludge (granulate) X

2.2.3 Analysis of flow rates X

2.2.4 Influence of solids load on sedimentation X

3. Biological treatment (activated sludge)

3.2.1 Keeping solids concentration in the aeration tank high X

W-PUR: Water Treatment System