29.09.2006
Dr. B. Wiebusch

10th Japanese-German Workshop on Water Technology
Berlin, October 9 - 10, 2006

Development of a Technical Controlling and Energy Management
System within the Wupperverband – an Interim Report
Dr.-Ing. Bernd Wiebusch

1 Introduction
In view of the globalization of industry on the one hand and the growing debts of public bodies
on the other hand, public bodies operating water and wastewater systems are increasingly
adopting entrepreneurial management approaches and ways of thinking.
One of the objectives of modern management systems is to provide management with steeringand decision-making tools. By developing a technical and economic controlling system including
appropriate reports, it is possible to counteract the growing pressure on costs.
A further step is to consider significant operating cost items such as energy, consumables(precipitants and flocculants), repair and maintenance separately and to develop dedicatedmanagement systems for these items with a view to reducing expenditure. As regards energy,
the objective of cost reduction is combined with the ecological objective of cutting emissions of
the greenhouse gas carbon dioxide.
All system operators participate in this general development process in accordance with theirsize and their specific tasks. On the basis of general strategic goals, the main challenge isalways to develop specific operational tasks and projects adapted to the size of the organization
concerned and the resources available.
This presentation gives an interim report on the development of a technical controlling andenergy management system at the Wupperverband.

2 The Wupperverband as an operator of water and wastewater facilities in thecatchment area of the Wupper
The Wupperverband is one of the water associations of North Rhine-Westphalia, operating as apublic body under a special statute. The association is responsible for the river basin of the
Wupper, with a total area of 814 km². The River Wupper is about 114 km long, drains thenorthern part of the Bergisches Land region and flows into the Rhine near Cologne. Annual
precipitation in the catchment area varies from 700 to 1400 mm and about 900,000 people livein the area.
Within the catchment area, the Wupperverband is primarily responsible for river maintenance,
low water replenishment and flood management. In this connection, it operates nine reservoirs(one drinking water and eight industrial water reservoirs) and is responsible for waste waterdisposal and treatment in part of the catchment area.
The Wupperverband operates 70 stormwater tanks – the last tanks upstream from the waste
water treatment plants, 60 km of sewers, 11 waste water treatment plants and a sewage sludge
incineration plant. The population equivalent connected to these systems is about 1.1 million.
The association has a workforce of 380 and receives contribution revenue totalling some 100
million euros.
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3 Elements of technical controlling
A technical controlling system determines at regular intervals key figures which are madeavailable to company management for steering purposes.
The prerequisites for the development of a technical controlling system are as follows:xxxx

Initially, a central process data system of adequate performance is needed.
Then, the technical data must be linked with commercial data from the accounting
system.
A reporting system must be established to present key technical and commercial data;andA system for the determination of key operating data must be introduced.

3.1 Modernization of central process data system
In 2004, the Wupperverband launched a project for the renewal of its central process datasystem. The old system is based on MS Access and was developed within the association stepby-step over a period of 16 years. On the one hand, this system features data selection
mechanisms developed in accordance with operating experience. On the other hand, thesystem is entirely overloaded.
The new system is to represent an improvement and to meet the following criteria:
x Complete central process data system for the wastewater sector, allowing thesimultaneous processing of continuous and laboratory data and integrating all data fromprocessing plants, stormwater tanks, sewers, the central laboratory and external sources
x Easy-to-use evaluation tool with graphics modules designed to reach a large number of
employeesx Capabilities for the rapid analysis of operating conditions for operational optimizationx Standard solution available on the marketplace with standard interfaces to external
programs
x Rapid development and production of standard reports to support the reporting systemand technical controlling.
The project, which was divided into three phases, is currently in progress and implementation is
expected to take about one year for each phase (see Table 1). Phase I includes the selection ofa consultant, the description of the actual situation, the definition of requirements in a working
group throughout the association and obtaining budget proposals to give an indication of thetotal cost. Phase II includes the preparation of a tender specification and the official tendering
procedure (in accordance with VOL, the standard conditions of contract for services to beprovided for public bodies in Germany). As of 15 September 2006, this phase had been
completed and the contract had been awarded. Phase III will now include the installation andcommissioning of the system.
One interesting result of the tendering process was that the system required by the
Wupperverband was not available on the market as a complete unit. The systems available
could only meet about 80% of the specified requirements. Potential contractors considered theapproach for laboratory data selection and evaluation adopted in the old system to be highly
innovative. As a result, suppliers were prepared to invest in this aspect or to waive royalties witha view to making their own products more attractive.
The positive result of these developments for the Wupperverband was that the final price wasabout 70% below the price indicated in budget proposals. This clearly indicates that it can pay
to work intensively on the design and tendering of a system of this type. The total cost breaks
down into about 45% for system design and 55% for the system itself.

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Table 1:

Project milestones for the replacement of the central process data system

Phase Project milestones

Time frame

Project definition and selection of consultat

I3-4/2004

Description of the status quo of the various existing data system,
preparation of the catalogue of requirements / Development of
the product specification with consultant and internal working
group

7/2004 - 6/2005

Presentation of potential bidders and budget proposals

II

5/2005Preparation of detailed tender specifications describing therequirement catalogue

7/2005-4/2006

Call for tenders

5-9/2006

Installation of the adapted standard system

10/2006 - 3/2007

III
Scheduled commissioning

5/2007

Table 1 shows the time schedule for the various phases of the project.
Standard reports

Generalrequirements

Simulators

Configurable
reports

reports

Excel

Web presentation
External- tools

TimeView
Graph presentation
Plant diagrams

Graphic
evaluation

Calculation formulaeDataevaluation

User/rights
administration

Statisticalevaluation

Data manipulation

File export

Compression stages

InterfacesDataadministration

Data backup
strategy

Operating dataacquisition system

Data to external storage

Updating/
configuration

Key wastewater data
Value status

Data
exportAvailability

Plausibility checks

Data
interchange

Depth of archiving
Manual/automatic
Downloading/
uploadingLaboratory data
Properties

Transfer(Precipitation) event

Continuous
data

Messages

Data sources

Resolution
Minimum/maximum/average values

Alarm signals

Fig. 1: Functional requirements for the design of the new central process data system(LeiKon, 2005)

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Fig. 1 gives an overview of the general functional requirements to be met by the new central
process data system.
3.2 Development of a reporting system
The reporting system for wastewater operations developed since 2003 has a three-stage
structure. Monthly reports in accordance with DWA code of practice M 260 are generated by theprocess control systems of the waste water treatment plants and are used as a management
tool by plant management.
On the basis of these monthly reports, two-page quarterly reports are produced for eachtreatment plant, using Excel. These reports cover the following items:x

Master data of treatment plantxDigestion performancex

Human resources data (working times,
absences, overtime worked)x

Key sludge treatment datax

Calculated population equivalentsx

Key energy datax

Water flow rates, concentrations,pollution loadsx

Precipitants and flocculantsx

Nutrient conditionsx

Wastewater accepted for treatmentx

Key data of activated sludge processx

Disposal of residual materials and wastexEffluent plots

These quarterly reports contain key technical data but no information on cost. The
Wupperverband is currently working on the expansion of these reports to include cost
information.
Once each year, a more comprehensive status report with about 100 pages is produced. This
covers current and historic development of key technical and financial data. The association
uses this report as a basis for its main wastewater business processes over the following year.
The Wupperverband sees potential for automating the reporting system within the new processdata system, in the definition and annual updating of key technical and economic indicators for
management and budgeting and in linking the technical process data system with thecommercial data system. The Wupperverband already uses a presentation software package
developed by MIK AG on the basis of SAP. In future, technical data from the operating datasystem are to be supplied to this package.
3.3 Participation in national benchmarking projects
As regards the conceptual design of an indicator system for wastewater treatment, theWupperverband has accessed work carried out by 10 major German waste water treatment
plant operators via service contracts. These utilities have established a service company,
aquabench GmbH, which uses and develops a benchmarking process for waste water
treatment plants together with its customers.
The main objective of these projects is to make business processes comparable for allconcerned and to determine and compare key cost figures for each indicator of a sub-process.
The benchmark is always the best value of a subprocess and not necessarily the lowest value(Fig. 2). Within the project, the resulting deviations must be analysed and any measuresrequired must be defined.
The objective of this approach is to supplement the expertise developed within the associationby the know-how available in the sector and to use it for cost optimization.

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For the second time now, the association is using the existing treatment plant operation moduleand has already carried out benchmarking exercises on five waste water treatment plants. The
measures resulting from the first project, which covered Burg and Hückeswagen waste water
treatment plants, are currently being implemented and no final results of the project areavailable as yet. Other operators report average savings of up to 5% as a result ofbenchmarking.
For corporate benchmarking, the association also uses a method already developed forcomparing key balance sheet indicators of similar companies.
For the projects “analysis and monitoring of indirect discharges" and “reservoirs”, theassociation is participating in the development of methods and will then carry out a comparisonof key figures. In this way, the Wupperverband is actively involved in further development within
the sector.
Fig. 2 shows the system and procedure for benchmarking projects. With annual datacompilation, benchmarking can be used as a controlling tool. For this purpose, it is important tocompile and evaluate the data automatically using an online portal.

Comparison of
key figures(sh ort,(k urz-/mm ed iuitte
m l-un/land glon
frisgtig-te) rm )Deviation

A n a lys iso f ca u s es

N o n -quan tifiab le m ea su res

P o te n tial

(s till to b e inves tig ated o r
still req uiring e xp la natio n)

C a n no t b e chan ge d

Determination of
deviations
from benchmark

Determination of
key figures

Q ua ntifiable/specific m easures

Start offollow-up survey

Controllingbybenchmarking

Implementationof measures

Analysis ofcausesPlan of action

B e s t va lu e A c tu a l va lu eDivision into quantifiable andnon-quantifiable measures

Fig. 2: System and procedure for benchmarking projects

4 Elements of energy management
One of the key challenges faced by manufacturing industry today is to secure energy supplies
at economically acceptable conditions. Attempts by government in 1999 to liberalize the former
quasi-monopoly situation in the energy industry only led to a reduction in energy costs for alimited period of time. Energy prices have now reached a very high level. The reasons are thegeneral global increase in energy consumption on the one hand and the shortage of energy
resources (for example, on the oil market) on the other hand. In Germany, taxes (levies under
the Renewable Energy and CHP Acts, eco-tax and value added tax also account for a relatively
large proportion of the price of energy.
The Wupperverband therefore decided to introduce energy management as a matrix process
covering all the functional units of the association.
The objectives of the energy management process are to reduce energy costs on the one hand
and to minimize carbon dioxide emissions (greenhouse effect) on the other hand.
The operational tasks resulting from the process are as follows:

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x
x
x
x
x
x

Transparent tracking and presentation of energy consumption and energy costs within
the Wupperverband,
Brief presentation of energy policy and legal developments,
Further development of energy purchasing methods and contract systems,
Proposal of measures to reduce energy consumption and costs at individual plants,
Proposals concerning the expansion and optimization of power generation fromrenewable energy sources (CHP and hydropower plants),
Development of innovative projects to reduce energy consumption.

4.1 Energy consumption and power generation
The Wupperverband uses 56.8 million kWh of energy per year. Of this figure, 40.4 million kWh
are purchased from external sources. This energy includes electric power, fuel oil, natural gas
and district heat. Table 2 below shows the percentage breakdown of energy consumption by thevarious sources of energy.
Table 2:

Energy used by the Wupperverband

EnergyConsumption WV per year

kWh / aPower (external)

approx. 25.6 Mio. kWh/a

25,600,188

45%Power (internal)

approx. 16.3 Mio. kWh/a

16,348,818

29%

Fuel oilapprox. 1.22 Mio. l/a

12,792,497

23%

Natural gas andpropaneapprox. 132,000 m3/a

1,200,000

2%

District heatapprox. 820,000 kWh/a

820,000

1%

56,761,503

100%

Share

Energy expenses account for approx. 10% of the cost of materials used and approx. 50% of thecost of raw materials and consumables.
Since 2000, energy expenses have risen by an average of about 5 % per year. Among otherthings, this is a result of the expansion of waste water treatment plants to provide more effective
treatment. In addition, the cost of electric power in 2007 will increase by about 25 % comparedwith 2005 if consumption remains constant.
The Wupperverband uses approx. 16.3 million kWh of power generated by the association itself
using packaged CHP plants, hydropower plants and one steam turbine. In addition, theassociation’s hydropower plants generate about 8.7 million kWh of power which is fed directly tothe public grid. The association therefore generates power corresponding to about 60 % of its
own requirements from renewable sources! In addition, the above table shows that electric
power accounts for two-thirds of the energy used by the association.
4.2 Development of an energy data management (EDM) system
The purpose of an energy data management system is to record the energy consumption dataof individual plants and power generated by the association itself almost on a real-time basis.
Initially, the project launched in July 2005 records power purchased from external sources for
17 power use points with special contracts in a central database as a load plot on the basis of
15-minute values. The data is presented using visualization software.

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In the next stage of the project, there are plans to record the power generated by CHP andhydropower plants as well as power purchased under general tariffs. It is also planned to export
the data to the future operating data system.
Using the EDM system, it is possible to create updated reports on energy consumption, loadand power generated by the association’s own plants. Where necessary, periods with highenergy consumption (e.g. load peaks) will require more intensive analysis.
Fig. 3 shows the structure of the energy data management (EDM) system.

Variouspower users

Ethernet

WAN

TCP/IP

TCP/IPODBC interface

Various
workplaces

FTP server
Buchenhofen STP
Headquarters

Field office

Sewage treatment
plant
Klärwerk
Calibrated power
meter with effective
power, reactive
power and 15-min.
pulse signals

Export
of
.csv
files

Web application via
intranet

TCP/IP

Data logger withinstallation housing

Ethernet and 230 V
cable: withconnection to
distribution
assembly

Operating datasystem server
Headquarters

Fig. 3: Structure of an energy data management system for the Wupperverband

Reactive power
0.1%

Demand charge
13.7%
Eco-tax
20.8%

Renewable
Energy Act levy
5.1%

Commodity
charge45.1%

CHP levy
0.7%
Meter rental
0.6%
Value added tax
13.8%

Fig. 4: Breakdown of electric power costs into energy components, taxes and levies

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4.3 Purchasing of electric power
In 2004 and 2006, the Wupperverband issued calls for tenders for the supply of electric powerin accordance with VOL. The contract was concluded on the basis of supply to the point of use.
In other words, the power supplier concludes a contract with the network operator concerned
and invoices the demand and commodity charges as well as network utilization fees. The term
selected for the contract in both cases was two years.
The tendering process has brought definite benefits. Firstly, all 17 points of use with special
contract now have a simple, standardized power supply contract. Secondly, the increase inelectric power expenses was not as severe as expected, as a result of competition between
suppliers. The association had to accept a 15% increase in electric power cost as of 1 January2005 and a 25% increase as of 1 January 2007.
The price structure of these contracts indicates that the demand and commodity charges
account for 59% and taxes and levies (Renewable Energy Act and CHP levies, electric power
and value added taxes) for 41% of the price of electric power (see Fig. 4).
The association is now in the process of launching investigations concerning the applicability of
new purchasing methods (“timetable purchasing”) in cooperation with a power supplier. This
involves the use of a forecast load curve to be covered by the power purchased. Any excess
quantities purchased or deficits are balanced by the power supplier within a separate balancing
account.
The unbundling of power suppliers has led to the establishment of separate companies for
power sales and network operation. If this structure were reflected by power supply contracts, itwould be necessary to conclude separate network connection and network utilization contracts.
Contracts with network operators would cover the monopoly market of network utilization, while
only the supply of electric power would be included in calls for tenders. This approach could
have an advantage, in that more tenders would be received, especially from energy traders. As
a disadvantage, there would be a slight increase in administration expenses.
The configuration of power supply contracts can have a significant effect on external power
costs.
Average price in ct/kWh (Medium Voltage 10 kV)
Price level: July 2004

Regression analysis of 427 power use points

Duration of use [ h ]xWupper Water Association

Fig. 5: Average price as a function of duration of use of supply points, for delivery and meteringin the medium-voltage range (Specht, 2004)

Fig. 5 shows the relationship between the price of electric power and duration of use [h]. For
this purpose “duration of use” is defined as the power consumption in [kWh] divided by theannual peak load [kW]. If electric power is taken at absolutely the same load figure over theentire year, the “duration of use” is 8,760 hours, corresponding to the number of hours in theyear.
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Waste water treatment plants with relatively even power consumption normally have a highduration of use in excess of 5,000 hours, while the duration of use of pumping stations is often
below 1,000 hours. As the hours of use increase, the average price of electric power falls.
Power suppliers reward relatively constant consumption as the peak load capacity to be madeavailable is reduced and the load on power supply systems is more evenly distributed.
Load peaks have a greater detrimental impact on energy expenses with an annual demandcharge than if a monthly demand charge has been agreed,
Another point to be considered is the feeding of power generated by the association fromrenewable sources to the public grid under EEG – the Renewable Energy Act. Consideration of
the energy situation at Buchenhofen waste water treatment plant indicates a revenue potentialof about € 100,000 per year. Since the end of May 2006, the compact CHP plants at
Buchenhofen have been feeding power “virtually” to the public grid. However, it will benecessary to carry out a new viability analysis as a result of the severe increase in power prices
from 1 January 2007.
Under the Oil Tax Act (MinöStG), Section 25 (exemption, reimbursement or tax credits in the tax
area), there is a possibility of tax reimbursements if plants for the combined generation of heatand power have an annual degree of utilization of at least 70%.
This possibility of reimbursement has been used at the sewage sludge incineration plant forsome time.
4.4 Optimization of energy consumption
Standardized energy analyses in accordance with the energy manual for North RhineWestphalia published by the State Ministry of Environmental Protection, Nature Conservation,
Agriculture and Consumer Protection are a key tool for optimizing energy consumption. The
state subsidized these analyses for many years and the Wupperverband has already analysed
six waste water treatment plants. Although the subsidy program has been suspended, thecontinuation of these analyses is regarded as beneficial.
As a result of these analyses, measures are proposed and a general viability assessment ismade. For a more detailed assessment and implementation if appropriate, the proposals areforwarded to the operating departments concerned.
Table 3:

Savings potential as a result of energy analyses and realization

Total(without wwtp Odenthal)
Population equivalent: 191,376
Savings potential determined

Energy(power and heat)

Share inenergy[kWh/a][%]Costdifferential (AB
- AC)
[€/a]

Share incost[%]

2,492,692

100%

96,352100%

1,368,767

55%

85,313

89%

Realization with expansion /modifcation

983,727

39%

-499

-1%

Realization not feasible

31,565

1%

1,217

1%

Other items (clarification required)

108,633

4%

10,323

11%

Of which:
Already realized

Abbreviations: AB = Annual Benefit, AC = Annual Cost, wwtp = waste water treatment plant

Table 3 shows that 55% of the savings potential indicated by energy analyses conducted since1999 in terms of energy savings and 89% in terms of cost savings have already been realized.
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39% of the energy savings potential indicated will be realized in the long term in connection withmodifications and expansions.
The connection between power supply contract, peak loads, duration of use and power cost or
average power cost was already mentioned above.
The targeted shut-down or turning-down of individual units as part of a load management
strategy may help in reducing peak loads and the resulting demand charges (see Figure 6).
Where this is economically viable, an automated load management system is normally used.
450
400
350

P [kW]

300
250
200
150
100
50
0
1.1.

31.1.

1.3.

31.3.

Fig. 4: Sample load curve for a waste water treatment plant (for a population equivalent of
50,000) showing load peaks
The Wupperverband is currently conducting studies to determine whether it will be economically
viable to introduce automated load management systems at individual plants. Initial results
show that such systems would have a cost:benefit ratio approaching 1 as a result of the monthly
demand charge provisions. If load management at the plants is not automated, it will benecessary to manage loads manually using the energy data management system. This will only
be possible in connection with a retrospective analysis of the data collected. The experienceobtained could then be considered when selecting future modes of operation.
Table 4:

Overview of studies concerning the feasibility of automated load management
systems for the Wupperverband
wwtp

Annual hours ofuseFeasibility
Study

Base year

2003

Buchenhofen

5,702

5,131

Amortisationin 7.5 years

Hückeswagen

3,699

3,660

C/B = 0.8

Radevormwald

4,083

2,665

C/B = 0.9

Schwelm

2,699

2,415

C/B = 1.1

Burg

4,319

3,340

In progress

2005

Installation

2003
Feeding into network inaccordance withRenewable Energy Act
Together with themodifiation of the wwtp
After expansion of
wwtp
No installation

Abbreviations: C = Cost, B = Benefit, wwtp = waste water treatment plant

In addition, benchmarking projects include a technical and economic assessment of the energy
situation. However, the technical assessment is very rough and is no substitute for an energy
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analysis. An important addition by the benchmarking method is the economic assessment
based on the determination of specific consumption costs and, in the case of packaged CHP
plant operation, specific production costs.
4.5 Increasing the share of renewable energy
In order to ensure greater independence from the rising cost of energy purchased from externalsources, it is necessary to increase the share of energy generated by the Wupperverband itself
from renewable sources. In this connection, the Wupperverband can tap potential in thefollowing areas:x Construction and operation of further hydroelectric power plants on the reservoirs
operated by the Wupperverband
x Increase in digestion gas production for power generation by the cofermentation oforganic materials, using vacant capacities in digesters
x Installation of solar power facilities on the association’s buildings
In future, depending on network transmission charges and electric power prices, it may become
viable for the Wupperverband to transmit hydropower to its own waste water treatment plants
for use at those plants instead of feeding it to the public power grid.

5 Conclusion and outlook
The basic structures of a technical controlling and energy management system have beendeveloped within the Wupperverband since 2003. The current technical controlling tasks at
Wupperverband are operating data processing, reporting of key technical and economic dataand participation in external benchmarking projects.
Technical controlling activities in future will include the definition of key technical and economic
indicators and integration in reporting for the management of operating processes and forbudget planning.
Energy management, which will be a matrix process at Wupperverband in future, will have theenvironmental objective of reducing carbon dioxide emissions and the economic objective of
cutting costs. The methods used for achieving these objectives will be the development of apurchasing and contract system adapted to energy markets, the central recording of all energy
data on a real-time basis as part of the reporting system, the use of load management system
to ensure even load factors and energy analyses to optimize energy consumption.
Although the Wupperverband already covers 60% of its energy requirements from renewablesources, there is still potential for increasing this share. In general terms, the power generated
by hydropower facilities could be increased and greater use could be made of organic materials
for cofermentation in the association’s fermentation basins. A review of this potential is currently
in progress.

6 Acknowledgements
The author wishes to thank his colleagues at the Emschergenossenschaft/Lippeverband andRuhrverband for the constructive exchange of ideas and the impetus which they have given to
his work.

7 Sources
Specht, 2004:
Support for the purchasing of electric power (call for tenders in accordance with VOL) by
Ingenieurbüro für Energiewirtschaft und –technik Dr. Specht, Müden

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LeiKon, 2005:
Specification for the project “Betriebliche Informationsverarbeitung T1/T2“ (operating dataprocessing, parts 1/2) of Wupperverband, July 2005, Ingenieurbüro LeiKon, Herzogenrath
WIW, 2004
Report on load management for the wwtp Hückeswagen of the Wupperverband,
Wupperverbandsgesellschaft für Integrale Wasserwirtschaft (WIW), Wuppertal

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- 85 -

www.WUPPERVERBAND.de

Catchment Area 814 km²
Wupper Length 114 km,
all rivers in total ca. 2300 km
Precipitation up to 1400 mm yearly,
Population: ca. 1 Mio. people

The Wupper Water Association

www.WUPPERVERBAND.de

Dr. Bernd Wiebusch

Development of aTechnical Controlling and Energy Management
System within the Wupperverband- an Interim Report -10th Japanese-German Workshop on Water Technology
Berlin, October 9- 10, 2006

www.WUPPERVERBAND.de

CologneWupper Catchment Area

The Wupperverband /Wupper Water Association

www.WUPPERVERBAND.de

11 waste water treatment plants
in total 1,1 Mio. population equivalents

The Wupper Water Association

Rhein – Catchment Area

- 86 Energy Management (since 2005)• Energy consumption and power production• Energy Data Management• Centralised purchase of energy (power)• Optimisation of the energy consumption• Management of power load peaks

 Collection and storage of water for the drinking

 Waste water collection and treatment

 River maintenance

www.WUPPERVERBAND.decatchment area data Collection and evaluation of river and Regulation of the river flow

www.WUPPERVERBAND.de• Central Process Data System• Reporting System• Benchmarking

water supply

Technical Controlling (since 2003)

Issueswww.WUPPERVERBAND.de

11 waste water treatment plants,
in total 1,1 Mio. population equivalents,
70 storm water tanks,
60 km large sewer pipes for waste
water transportation

The Wupper Water Association

Responsibilities

www.WUPPERVERBAND.de

11 waste water treatment plants,
in total 1,1 Mio. population equivalents,
70 storm water tanks

The Wupper Water Association

- 87 -

Costs approx. 275 T€

Run-time of the project: 3 years

Scheduled commissioning

Installation of the adapted standard system

Call for tenders

Preparation of detailed tender specifications describing therequirement catalogue

Presentation of potential bidders and budget proposals

www.WUPPERVERBAND.de

III

II

I

Description of the status quo of the various existing data system,
preparation of the catalogue of requirements / Development of
the product specification with consultant and internal working
group

Project definition and selection of consultat

Phase Project milestones

5/2007

10/2006 - 3/2007

5-9/2006

7/2005-4/2006

5/20057/2004 - 6/2005

3-4/2004

Time frame

Central Process Data System [CPDS] - (2)www.WUPPERVERBAND.de

Technical Controlling within the
Wupperverband

Graphic
evaluation

reports

Alarm signals(Precipitation) event

Downloading/
uploading

Availability

Continuous
data

Laboratory data

Dez 05
1.152
38
0,0
3,3

Okt 0534.05927.57443.532

Okt 05
123
24,3
0,036
0,21
0,58

Okt 053,51,8

Nov 05
123
20,6
0,025
0,42
0,80

Nov 052,82,2

Nov 05554.273
265
97
4,0
26,0
3.958
1.518
64
400

Nov 0532.98425.29336.407Dez 05
133
18,4
0,04
0,04
0,55

Dez 054,2
1,6

Dez 05875.407
166
35
2,5
16,0
5.434
1.350
83
554

Dez 0545.28022.50050.392

4
3,5
3
2,5
2
1,5
1
0,5
0

01.10.05

70
60
50
40
30
20
10
0

21.10.05

21.10.05

30.11.05
CSB Bescheid

10.11.05

10.11.05

30.11.05

Hückeswagen 4.Quartal Pges

mg/l CSB hom_

Hückeswagen 4.Quartal CSB

20.12.05

CSB erklärt

20.12.05

Ablauf Klärwerk (Ablaufganglinien der Überwachungswerte CSB, Pges, NH4-N, Nanorg)

ISV
tTS
BTS
ß- Wert Biologie
ß- Wert Flockungsfiltration

3.4 Kennwerte Belebung[ml/g][d][kgBSB5/(kgTS*d)][mol Me/ mol P][mol Me/ mol P]

3.3 Nährstoffverhältnis Zulauf Belebung
CSB / BSB5
BSB5 / Nges

Nov 05
1.382
32
3,8
2,2

[d]

Okt 05

www.WUPPERVERBAND.de

mg/l Pges_

24h- MP; 2h- MP; qualif. Stichprobe

01.10.05

Pges Bescheid

ISV

Nov 05ISV

Nov 05

Nov 05[EW][E]

21.10.05

mg/l NH4-N[mg/l][mg/l][mg/l][mg/l][mg/l][mg/l][µg/l][µg/l][µg/l][µg/l][µg/l][µg/l][µg/l]

30.11.05

Dez 05

Nanorg erklärt

20.12.05

1
5
50
50
50
100
100
** einzuhalten 1.5. - 31.10.

0

2

4

6

8

mg/l NH4-N
10§ 6 AbwAG § 4(5)
AbwAG
60
60
15
18
18
7
0,5
0,5

Bescheid

NH4-N Bescheid

Nanorg Bescheid

10.11.05

Dez 05Dez 05BTS[kg BSB5/ (kg TS*d)]
0,048
0,044
0,040
0,036
0,032
0,028
0,024
0,020
0,016
0,012
0,008
0,004
0,000

48.00033.864

ß-Wert Filter

Hückeswagen 4.Quartal Nanorg und NH4-N

Okt 05

NanorgtTS

Ausbaugrösse
Einwohner

ß-Wert Biologie

Okt 05CSB
BSB5Nanorg **NH4-N *Pges
oPO4-P
Hg
Cd
Cr
Ni
Pb
Cu
AOX
* einzuhalten bei > 7°C

01.10.05

0

5

10

15

mg/l Nanorg
20

200
150
100
50
0

[ml/g]

0,0

0,2

0,4

0,6

0,8

1,0

[mol Me/ mol P]

50,0
45,0
40,0
35,0
30,0
25,0
20,0
15,0
10,0
5,0
0,0

Tel.: 02192 / 1630
Fax: 02192 / 931347
Mail: gro @wupperverband.de* bezogen auf Summe aus geleistete Std + Krankheits-Std

3.2 Wassermengen / Zulaufkonzentrationen / Zulauffrachten
Okt 05
Wassermenge[m³/Monat]
501.623
CSB (24h- MP)[mg/ l]240
BSB5 (24h- MP)[mg/ l]99
Pges (24h- MP)[mg/ l]4,0Nges (24h- MP)[mg/ l]26,0CSB [Fracht][kg/ d]4.087
BSB5 [Fracht][kg/ d]1.654
Pges [Fracht][kg/ d]67
Nges [Fracht][kg/ d]479

3.1 Anschlusswerte berechnet
ccc
EW (CSB) Monatsmittel[EW]
EW (BSB5) Monatsmittel[EW]
EW (N) Monatsmittel[EW]
EW (CSB) 85 Quantil[EW]
EW (BSB5) 85 Quantil[EW]
EW (N) 85 Quantil[EW]

3 Verfahren

Gesamtstunden[Std/ Monat]Überstunden[Std/ Monat]
spezifische Krankenstunden [%]spezifische Überstunden*[%]

Okt 05
1.068
45
12,2
3,7

1 Name und Anschrift des Klärwerkes
Gruppenklärwerk Hückeswagen
Corneliusweg 442499 Hückeswagen

Stunden, Ausfälle, Überzeiten

2 Personal(approx. 100 pages / MS Word)
Current and historic development of key technical and financial data

• Yearly Status Report

Minimum/maximum/average values

Resolution

Properties

Automation in the CPDS

Data sources

Datainterchange

Updating/
configuration(2 pages / MS Excel)- Master data of wwtp,- HR data (working times, absences, overtime)- Calculated population equivalents- Water flow rates, concentrations, pollution loads- Nutrient relations,- Key data of activated sludge process- Effluent plots- Treatment efficiency- Key sludge treatment data
- Key energy data
- Precipitants and flocculants- Wastewater accepted for treatment- Disposal of residual materials and waste• Monthly Reports• Quarterly Reports

Reporting System

Messages

Transfer

Plausibility checks
Manual/automatic

www.WUPPERVERBAND.de

Depth of archiving

Value status

Key wastewater data

Data to external storage

Data
exportInterfaces

Data backup
strategy

Operating dataacquisition system

Excel
TimeView

File export

Statisticalevaluation

Calculation formulae

External- tools

Simulators

Compression stages

Dataevaluation

Web presentation

Data manipulationDataadministration

Plant diagrams

Graph presentation

Configurable
reports

Standard reports

User/rights
administration

Generalrequirements

Modernisation of the central process data collection and evaluation in
the waste water treatment department

Central Process Data System [CPDS] - (1)- 88 -

Gesamtaufwand je angeschlossenen EW CSB120 (85%-Wert)[€/EW CSB120 (85%-Wert)]

A n alysis
o f c au ses

KA 30310.000

KA 306EW CSB 120 (85%-Wert)

KA 304100.000

KA 305

KA 310

KA 307
KA 302

KA 308KA 301

Costs / PECSB120,85% <> Size of the Plant

www.WUPPERVERBAND.de

0,00
1.000

2,00

4,00

6,00

8,00

10,00

12,00

14,00

16,00

18,00

20,00

C a n n o t b e cha n ge d(s till to be inves tigated o r
still req uiring e xpla natio n)

N o n -q ua n tifiab le m ea s u re s

KA 311

Gesamtaufwand TP mechanische Reinigung je angeschlossenen EW CSB120 (85%-Wert)
Erhebungsjahr: 2003

Benchmarking: KPI´s

www.WUPPERVERBAND.de

B e s t va lu e A c tu a l va lu e

Deviation(sh ort,(k urz-/mm edium
ittel-und/langlongfris tig)-te rm )Q ua ntifiable/specific m easures

Comparison of Key Performance Indicators (KPI)

Benchmarking

1.000.000

KA 309P o ten tial

Process part
Sub Prozess

Gas flare

M ittle re Ab w eic h u n g

K o ste n In sta nd h.
(= 551 /5 52 +5 47 1+ 54 72+ 5 43 b
+ 54 9)/ a ng e. E inw . (C S B 85P erc.-W ert)

L öhn e un d G e hä lter (55 ) ink l.
externe D L Instand h. (547 1)/
an ge . E in w . (C S B 8 5-P e rc.W e rt)

K o sten E n erg ie (54 0)/ a ng e.
E inw . (C S B 8 5-P erc.-W e rt)

B e trieb sau fw and / a ng e. E inw .
(C S B 8 5-P e rc.-W e rt)

K en n zah l

www.WUPPERVERBAND.de

4

3

2

1

lfd .
N r.

€ pro E W

€ pro E W

€ pro E W

€ pro E W

E in h eit
K en n zah l< 10 0.0 00 E W C S B 1 20 (8 5% -W e rt)

0 ,87

1 ,02

3 ,13

5 ,23

Ist- W ert

0 ,46

0 ,73

1 ,98

4 ,01

Z ielw ert

U rs a c h e n a n a lys e B io lo g is c h e R e in ig u n g
Group
301
A n la g e :D aten stan d: 1 4 .1 0 .2 0 0 4

Flood water
pumps

Laboratory

Workshops

1,06

1,26

2,16

4,40

Ø -W ert

0,41

0,29

1,15

1,22

Ab w . zu m
Z ielw ert
ab s.

54,3%

8 9,1 %

3 9,7 %

5 8,1 %

3 0,4 %

g g f. Ab w .
zu m
Z ielw ert in%

letzte T e xtä nd erun g: 1 4 .1 0 .2 0 0 4

All

Benchmarking: Cause Analysis

www.WUPPERVERBAND.de

AssociatedZugehörige
buildings
GebäudeWith P-removal

AssociatedZugehörige
building
GebäudeCover
Abdeckung
Odour Treatment*

Waste water
pumps

Digestion gas
storage

Surplus sludge
pumps

Precipitation

Storage
Lager
Water Supply

Sludgestabilisation

Return Sludge
pumps
pumpwerk

Disposal of sandand screenings
AssociatedZugehörige
Buildings
GebäudeAssociatedZugehörige
Buildings
GebäudeOther buildings

Odour
Treatment

Reuse / Disposal/ Dumping

TrocknungDryingMembrane
Reactor-

Odour
AbluftTreatment
behandlung

behälterSludge storage

After thickening

AssociatedZugehörige
Buildings
GebäudeFinal clarifyer

Prim. sludge pumps
pumpwerk

Installations
pipes

Infrastructure

OthersIntermediate
Clarifyer

Entwässerung
Dewatering

Transport
Transport zur
Entsorgung

SludgedisposalPrimary
Tank
Vorklärung

Faulbehälter
Digester

PreVoreindicker
thickening

Sludgestabilisation

Puffer lake

Filtration

Advanced
Treatment

6,7%-17,9%-19,0%

44,9%

18,9%

g g f. Ab w .
zu m
M ittelw ert
in %Others

Grit Sandfang
chamber

Biological
Biologischer
Reactor*Reaktor*1

BiologicalTreatment

Sludge Path

Aeration
SystemScreens

MechanicalTreatment

Water Path

Process Modell

- 89 -

Schlammstabilisi Nutzung des zweiten Faulbehälters
erung(Testprojekt! Siehe Energieanalyse)

17

X

X

X

X
X

www.WUPPERVERBAND.de

Implementationof measures

Start offollow-up survey

Controllingbybenchmarking

Plan of action

Analysis ofcausesDetermination of
deviations
from benchmark

Zuständiger Betriebsingenieur muß ein
Zeitkontingent für dieses Projekt
Reduzierung der Stromkosten
haben.
Zuständiger Betriebsingenieur muß ein
Zeitkontingent für dieses Projekt
Reduzierung der Stromkosten
haben.
Gasmessung muß überprüft und ggf.
in Ordnung gebracht sein. Zuständiger
Reduzierung der Energiekosten /Betriebsingenieur muß ein
Gewinnung von Wärme
Zeitkontingent für dieses Projekt
haben.

Division into quantifiable andnon-quantifiable measures

Determination of
key figures

Comparison of
key figures

Nutzung der Rührwerke als
Ersatzaggregate, d.h. Reduzierung
von Instandhaltungsaufwand

W a s s o ll m it d ie s e r M a ß n a h m e
b e w irkt w e rd e n ?

Z ie ls e tzu n g

Probeweise Installation eines FU´s zur
stufenweisen Herunterregelung bei
gleichzeitiger Erfassung desReduzierung der Stromkosten
Mischergebnisses Keine Nachrüstung
von FU´s. Sondern Betrieb von nur 1
Rührwerk und zwar wechselnd.

keine

erw arte teerw artete
W e lch e B e d in g u n g e n m ü sse n e rfü llt se in ,E insparun g läss t E insp aru ng läs stu m d ie s e M a ß n a h m e n u m s e tze n zu
sic h konk re t insich nicht
können?
E U R benen nenb eziffern

V o ra u s s e tzu n g e n

Target: The Benchmarking - Loop

www.WUPPERVERBAND.de

540

Absenkung des Schlammalters in der biol. Stufe(s. Energieanalyse)

biol. Reinigung

16

540

540

Optimierung des Rückführverhältnisses (s.
Energieanalyse)

biol. Reinigung

15

0

540

Überprüfung des Rührwerkbetriebes in den
Denitrifikationszonen

biol. Reinigung

14

18

5472

Stillegung / Ausbau von 10 (?) Rührwerken(siehe Energieanalyse)(N r. aus
(B en ennung d er M aß nahm e die a ngedac ht ist.
E rhe bungsD iese S p alte w ird autom atisc h aus de n F o lges eiten ge fü llt) bo gen kfm .
K e nngröß en)q u a n tifizie rb a r
k fm . K e n n (B itte zu tre ffe n d e sg rö ß e n
a n k re u ze n )jan e inbiol. Reinigung(M ec h., B io. etc.)

R e in ig u n g s M aßnahm es tu fe13

N r.

Benchmarking: Plan of Actions
WWTP VII -> 2 wwtp with 170 TPE(Project type: moderated)aquabench GmbH

Yearly data collection in the framework of theOnline-Benchmarking System

www.WUPPERVERBAND.de

The Energy Management System
within the Wupperverband

www.WUPPERVERBAND.de• Target:indicators)• 2005/06: Company benchmarking (balance sheet

Pilot project: Central and de-central waste
water laboratory• 2005/06: Water reservoirs -> Pilot project: 2 WR
• 2005/06: Analysis and Monitoring of Indirect Discharger(Project type: Moderated with OnlineDatabase)• 2005/06: WWTP VIII -> 3 wwtp with 87 TPE• Partner:• 2004:

Benchmarking: Time Schedule- 90 -

approx. 16.3 Mio. kWh/aapprox. 1.22 Mio. l/aPower (external)

Power (internal)

Fuel oilapprox. 820,000 kWh/aDistrict heat

Biogas Power75%

Steam Power11%

kWh / a1%
100%

820,000

www.WUPPERVERBAND.de

Operating datasystem server
Headquarters

www.WUPPERVERBAND.de

Ethernet and 230 V
cable: withconnection to
distribution
assembly

Ethernet and 230 V
cable: withconnection to
distribution
assembly

Calibrated power
meter with effective
power, reactive
power and 15-min.
pulse signals

Sewage treatment
plant
Klärwerk

TCP/IP

Operating datasystem server
Headquarters

Export
of
.csv
files

FTP server
Buchenhofen STP

TCP/IP

Data logger withinstallation housing

TCP/IP

Field office

Web application via
intranet

Headquarters

Variouspower users

Ethernet

Various

Field office

Web application via
intranet

Headquarters

workplaces
TCP/IPODBC interface

WAN

Steam power (internal generation)

www.WUPPERVERBAND.de

Hydro power (internal generation)

Biogas power (internal generation)

25.600.188 kWh;62%

Electric power (external sources)

2.258.310 kWh;5%

12.254.832 kWh;29%

1.835.676 kWh;4%

Total Power Consumption 2005: 41.949.006 kWh- Purchasing of electric power and power generated by the Wupperverband -Data logger withinstallation housing

Export
of
.csv
files

FTP server
Buchenhofen STP

workplaces
TCP/IPODBC interface

TCP/IP

Various

WAN

Ethernet

Calibrated power
meter with effective
power, reactive
power and 15-min.
pulse signals

Sewage treatment
plant
Klärwerk

Variouspower users

2%

23%

29%

45%

Share

56,761,503

1,200,000

12,792,497

16,348,818

25,600,188

Structure of an energy data management (EDM) system

www.WUPPERVERBAND.de

Hydro Power
14%

Electricity produktion of the Wupperverband

approx. 132,000 m /aNatural gas and propane

3

Consumption WV per year

approx. 25.6 Mio. kWh/a

EnergyEnergy consumption, power production

- 91 -

supplier

13,147 €

36,672 €Services

In total

www.WUPPERVERBAND.de•

Wupper Water Association

Duration of use [ h ]Regression analysis of 427 power use points

Price level: July 2004

Average price in ct/kWh (Medium Voltage 10 kV)

Annual duration of use and average power costwww.WUPPERVERBAND.de

2.821 € / power consumer
18 data logger: approx. 2.241 € / power consumer

8,796 €

14,729 €Total cost(gros)

SoftwareHardware and other materials

Cost type• Optimisation and flexibility of the energy purchasing

billing and the reporting• Automatically evaluation of the power consumption, thewww.WUPPERVERBAND.de

Commodity
charge45.1%

Reactive power
0.1%

Value added tax
13.8%

Demand charge
13.7%

Meter rental
0.6%

CHP levy
0.7%

Renewable
Energy Act levy
5.1%

Eco-tax
20.8%

Elements of the power costs in Germany (2005)

www.WUPPERVERBAND.depurchase in relation to the power load curve.

• Investigation of new procurement methods, like scheduledutilisation• Separated contracts for network access and network

Delivery period: 2007/08 +1 +1
Delivery quantity: 21.5 Mio. kWh
Delivery „All inclusive“
5 charges, 19 offers = 3 – 5 offers per charge• Second call for tenders with 13 power consumers in 2006

Delivery period: 2005/06 +1 + 1
Delivery quantity : 27.7 Mio. kWh
18 power consumers
Delivery „All inclusive“
10 charges, 24 offers = 2 - 3 offers per charge• First Call for tenders for Power purchase in 2004:

Targets of the EDM:

• Quick availability of data in a consistent format,• Transparency of data, independence from the power

Power Procurement

Targets and cost of the Energy Data Management

- 92 -

3,699

4,083

2,699

4,319

Hückeswagen

Radevormwald

Schwelm

Burg

3,340

2,415

2,665

3,660

5,131

In progress

C/B = 1.1

C/B = 0.9

C/B = 0.8

Amortisationin 7.5 years

2003

Installation

11%

1%

-1%

89%

100%

No installation

After expansion of wwtp

Feeding into network inaccordance withRenewable Energy Act
Together with themodifiation of the wwtp

10,323

1,217

-499

85,31396,352[%]

Share incost

www.WUPPERVERBAND.dechallenge• Investigation of more wwtp´s• Implementation and Adaptation is a big operational

Abbreviations: C = Cost, B = Benefit, wwtp = waste water treatment plant

5,702

4%

108,633[€/a]

Cost differential(AB - AC)

Feasibility Study

1%

39%

55%

100%

[%]

Share inenergy31,565

983,727

1,368,767

2,492,692[kWh/a]Annual hours of
use
2003
2005

Buchenhofen

Base year

WWTP

Load Management

www.WUPPERVERBAND.deAbbreviations: AB = Annual Benefit, AC = Annual Cost

Other items (clarification required)

Realization not feasible

Detailed analysis

Detailed analysis

Detailed analysis

Rough Estimation Analysis

Detailed analysis

Detailed analysis

Rough Estimation Analysis

Analysis

Energy(power and heat)

90,01639,00732,500Realization with expansion / modifcation

Already realized

Of which:

Savings potential determined

Population equivalent: 191,376

Total(without wwtp Odenthal)

Burg

Mrz 06

2,143

Dhünn

Odenthal

Nov 01

Hückeswagen

Schwelm

Mrz 01

Feb 02

13,500Marienheide

Nov 04

12,700Wermelskirchen

Apr 99Feb 01

15,010PE

WWTP

Completion

Energy Analysis acc. to the “Manual NRW“

31.1.

1.3.

31.3.

www.WUPPERVERBAND.de

new task in the business. It is using the online data transfer fromlocal plants and is focusing on the collection and presentation of
the power load curve. It will support the purchasing andconsumption of electric power actively.

• The development of an Energy Data Management System is avarious business processes intensely. The aim of the process
benchmarking of wwtp´s is to generate the key performanceindicators on an online platform once a year
(www.aquabench.de).

• The Wupperverband is using the Benchmarking – Method in

the Wupperverband is developed and is available for the
management. It needs – however – optimisation, especially forthe use of technical and economical Key Performance
Indicators.

• The Reporting System for the waste water treatment plants of

the Wupperverband gets a modern, flexible and user-friendly tool
for process optimisation and technical controlling.

Conclusion and outlook (1)• With the installation of the new Central Process Data System

www.WUPPERVERBAND.de

0
1.1.

50

100

150

200

250

300

350

400

450

Load Managment

P [kW]

- 93 -

www.WUPPERVERBAND.de

reduce energy costs. It is difficult to find a balance between
power load reduction and an efficient waste water treatment
process. The Wupperverband is not using automatic load
management systems yet but will – however – install them undinvestigate further waste water treatment systems.

• Automatic Load Management Systems are an effective tool toAnalysis of the Manual NRW is successful and will be
continued.

• The reduction of power consumption by carrying out Energy

in terms of the market conditions - influenced by the European
Energy Exchange (EEX) - difficult and seems not to beeconomical.
It is important to look at new methods which are on the one side
faster and more flexible but have on the other side a limited risk
and fulfil the regulations for purchasing by public companies.

• The Purchase of Electric Power with fixed tender processes is

Conclusion and outlook (2)www.WUPPERVERBAND.de

your attention !

“Domo Arigato” for