Project Overview

In Prosselsheim, a small town northeast of Würzburg, Germany, a 30-year-old wastewater treatment plant (WWTP) serving 1,500 residents has undergone a groundbreaking modernization. Partnering with Siemens and water utility provider SüdWasser, the municipality replaced outdated systems with an AI-driven control solution, achieving daily energy savings of 500 kWh and streamlining operations.

Key Upgrades

Intelligent Monitoring & Remote Control

• Radar Level Meters: Real-time monitoring of pump station levels, integrated with the SIMATIC WinCC Unified control system.
• Web-Based Access: Operators adjust pump settings remotely via browser—even from home.
• Secure Connectivity: VPN and cellular networks link remote stations (e.g., stormwater tanks) to the central system.

One-Day Modernization Miracle

• Replaced legacy control cabinets within 24 hours during ongoing operations.
• Standardized components enable seamless replication for similar small-scale plants.

Automated Compliance & Reporting

• PM-ANALYZE Add-On: Digitally replaces paper logs; generates DWA (German Water Association) reports with one click, slashing annual reporting time from 3 days to 5 hours.
• SENTRON PAC Devices: Track energy consumption for transparency and optimization.

Operational Benefits

Efficiency Boost:

• Intuitive interface requires no training—consistent across PCs, tablets, and control panels.
• Automatic SMS alerts for anomalies (e.g., equipment failures), soon enhanced by Siemens’ Alarm Control Center app.

Cost & Energy Savings:

• 500 kWh/day reduction in energy use—praised by local officials.
• Extended equipment lifespan through predictive maintenance.

Process Optimization:

• Trend analysis via SIMATIC WinCC Unified enables real-time adjustments to treatment strategies.
• Data-driven insights empower operators to test new efficiency tactics confidently.

Industry Impact

This project demonstrates:

✅ Feasibility of Small-Plant Modernization: Cost-effective upgrades for aging infrastructure.

✅ Scalable Solutions: Blueprint for 1,500–5,000 population-equivalent WWTPs.

✅ Digital Transformation: Remote monitoring bridges staffing gaps in rural municipalities.

Future Outlook

Prosselsheim plans to upgrade remaining remote stations, with Siemens positioned as a key partner. As engineer Michael Werner notes: “The new system doesn’t just run the plant—it teaches us how to run it better.”