Modern Technology for Safe Drinking Water Treatment
The project involved fully equipping a newly constructed water treatment plant—including a pre-pumping station—with electrical and automation systems. The goal was to further improve the treatment of water from the Ruhr River and ensure the long-term quality of drinking water. The task was technically challenging: In addition to the power supply provided by high-capacity transformers, extensive switchgear, automation technology, drives, sensors, cabling, and building services had to be integrated into a complex plant structure. Special challenges arose due to the large volumes of water required—which could only be supplied in close coordination with the water utility during commissioning—as well as the need to work in parallel with the plant construction. The installation of large transformers in confined spaces also placed high demands on planning, coordination, and execution.
Gefeba was responsible for the electrical, measurement, control, regulation, and automation systems for the water treatment plant and the preliminary pumping station. The scope of work ranged from planning, delivery, and installation through commissioning and testing to complete documentation and acceptance. For the power supply, the project included, among other things, two cast-resin transformers, a low-voltage main distribution panel, sub-distribution panels, UPS systems, and the equipotential bonding and grounding system. The feed-in to the low-voltage switchgear was implemented using a high-current busbar system.
A key component was the delivery and fabrication of the switchgear and automation cabinets. The low-voltage main distribution panel was configured with two feed-in switches and one interconnection switch and designed in 3B configuration. This allows for separate access to individual sections within the control cabinet, which improves protection against accidental contact and facilitates maintenance. In total, a comprehensive range of load feeders, automation cabinets, and control cabinet units were installed.
The existing Siemens PCS 7 process control system was expanded for process automation. Gefeba supplied and engineered automation stations, redundant S7-400H systems, ET200SP-HA remote I/O stations, PROFINET communication, and the associated network infrastructure. This included the automation software, signal connection, visualization, signal checks, and cold and warm commissioning. In addition, variable-frequency drives were integrated for pumps, flushing water pumps, and flushing air blowers. Numerous AUMA actuators with PROFINET connectivity were integrated to control the waterways.
The project also included complete cable routing planning and installation of power, control, and network cables; the integration of building systems, including lighting, emergency alarm, and fire alarm systems; as well as comprehensive testing, measurement, and CE documentation. The work was closely coordinated with the plant construction team, as electrical installation and mechanical plant construction took place simultaneously.
Thanks to the implemented EMSR and automation technology, the water treatment plant features a modern, structured, and maintainable system architecture designed for the long term. The combination of a high-performance power supply, redundantly designed automation, standardized PROFINET communication, and clearly documented control cabinet and software structures creates a stable foundation for the safe operation of the plant. At the same time, the technical design supports improved maintainability, a clear overview of the plant, and future expandability.
For the operator, this represents a significant contribution to reliable water treatment and to ensuring drinking water quality over the long term. In this project, gefeba was able to leverage its role as an experienced technical implementation partner for complex EMSR and automation projects in the critical infrastructure sector—from control cabinet manufacturing and automation to on-site commissioning.
Why Customers
Choose to Work with Us
We develop customized solutions—from analysis through the engineering phase to commissioning and support. Our focus is on maximum functionality, on-time delivery, and durability.
Our project work is supported by collaborations with leading technology partners such as Siemens, Rittal, B&R, and Proxmox, which provide the technological foundation for our project results and help expand them.
