Createch Control Platform

The CREA® platform, developed by the Spanish company Createch Solutions S.L. and represented in Italy by WATERSPIN Srl, is an advanced optimization and control system for wastewater treatment plants that helps improve process performance while minimizing associated operating costs.

The main features of the platform, which will be described in more detail in this document, are:

• Support for multiple technologies – CREA® supports all types of PLCs and probes/analyzers available on the market.
• Predictive diagnostics for instrument maintenance – CREA® allows verification of the proper functioning of installed instruments.
• Real-time control of nitrogen and dissolved oxygen (DO) – CREA® enables constant monitoring of all key parameters in the biological treatment section.
• Data archiving – CREA® enables the creation, transmission, and storage of data.
• Alarm generation – CREA® allows for the creation and transmission of customized alarms.
• Historical trend creation – CREA® enables the creation and customization of trends for all recorded parameters.
• Report generation – CREA® allows the creation, customization, and transmission of reports.
• Password and username access – CREA® grants access to users with credentials and configurable permission levels.
• Task scheduling – CREA® allows the creation, customization, and scheduling of maintenance and monitoring tasks for probes, instruments, and electromechanical components.

The five main products developed by Createch Solutions S.L. are:

• CREApro – A tailor-made and self-customizable platform for medium to large-sized plants, offering process optimization through cutting-edge, customized control solutions aimed at achieving maximum performance.
• CREAlite – A customized platform with plug & play control solutions, suitable for small to medium-sized facilities.
• CREAcompaq – A tailored platform with ad hoc communication and plug & play control solutions for small-scale sites.
• CREAmaster – A smart cloud-based platform for integrating data from multiple CREA platforms, designed for integrated and efficient management of multiple wastewater treatment facilities.
• CREAsmart – A fully customized smart platform for the efficient monitoring of consumption (water, gas, energy, etc.) in industrial plants.

Createch Solutions S.L.

Createch Solutions S.L. is a company specializing in advanced process control systems designed to optimize the management of wastewater treatment plants and reduce their energy consumption.

The company has built its expertise over the years through more than 100 installations. This experience, combined with deep knowledge in the wastewater treatment sector and communications engineering, gives Createch Solutions S.L. a unique know-how in the field and allows it to provide the best operational solutions for any type and configuration of wastewater treatment plant.

Specifically, Createch Solutions S.L. has developed the advanced and intelligent control platform CREA®, which can be installed in both municipal and industrial plants.

The CREA® platform is a high-tech management software offering the following advantages:

• Real-time data monitoring;
• Advanced and intelligent control of the wastewater treatment process;
• Optimization of operating parameters;
• Effective and unambiguous interpretation of large volumes of data and information;
• High process robustness and reliability;
• Flexibility and adaptability to any type of wastewater treatment system;
• Intuitive and user-friendly control interface;
• Easily accessible via web service;
• Remote control capabilities.

The following table presents some references to existing plants where the CREA® control platform has been implemented in recent years:

Introduction to the CREA® Platform

The CREA® platform represents an evolution of classical RTC systems, being part of the so-called “smart RTCs” or iRTC, which integrate constant monitoring of quality parameters with the ability to achieve significant energy savings. This is achieved through real-time processing of flexible control strategies to better manage the plant.

Compared to a classical RTC, this goal is achieved by CREA® through a combination of:

• Mathematical models
• Advanced control logics (fuzzy logic)
• Predictive/adaptive models
• “Case-Based-Reasoning” algorithms
• “Rules-Based-Systems” algorithms

Among the key strengths of the CREA® technology compared to traditional RTC systems are:

• ADAPTABILITY: The CREA® platform doesn’t just apply a standardized control; it adapts to the specific features of the installation, considering the characteristics and peculiarities of the plant in its logic. For example, in the aerobic section, its control is not limited to the processing of a simple dynamic setpoint of dissolved oxygen based on nitrogen concentrations in and out, but also takes into account the trends in concentration profiles over time, the location of measuring instruments, the shape of the tanks, the type and model of diffusers and blowers, etc. The resulting solution is tailor-made for the specific wastewater treatment plant, thus providing a fast and effective response to any change.
• FLEXIBILITY: Traditional RTC systems are rigidly linked to the compartment where specific control instruments (probes, analyzers, etc.) are installed, and they are limited to optimizing only that part of the plant. If the operator wants to expand control to another section, a new RTC system must be purchased. The CREA® platform allows for simultaneous control and optimization of multiple sections, and if the operator wants to change the operation logic or expand the system, CREA® makes it easy to integrate any modifications or expansions. The CREA® platform can be seen as a suit that changes shape depending on the changes over time in what it fits.It is also noteworthy that CREA®, unlike many control systems tied to a specific supplier, can work with machinery and instruments of any type or brand.
• EXTENDED CONTROL: Traditional RTC systems don’t have direct control of machinery but merely indicate an optimal value of dissolved oxygen, flow rate, etc. It is up to the customer to program the PLC to achieve the desired value. The CREA® platform, however, directly controls the machinery (pumps, blowers, mixers, etc.) and components (automated actuating valves) installed within the treatment plant, allowing for significant energy savings and a quick response to changes.
• CUSTOMIZATION: Unlike traditional RTC systems, which have a rigid structure, the CREA® platform allows for the customization of the control modules, even incorporating the operator’s past operational experience. This enables intelligent monitoring of the entire process, generating additional operational savings (both in terms of energy consumption and reagents). Moreover, the operator can tailor alarms, reporting, and event scheduling (such as maintenance) to the specific needs of the plant.
• SELF-CORRECTIVE ACTIONS: In traditional RTC systems, the diagnostic function of measuring instruments is limited to creating and sending alerts regarding necessary maintenance actions and reporting the functionality of each sensor. The CREA® platform’s diagnostic and control module, however, doesn’t just notify the operator of the problem; it can automatically select an equivalent signal to control and manage the process, or, if this is not possible, autonomously apply corrective actions to minimize the effects of poor signal quality.

In addition to the above-mentioned features, this control system can be implemented to account for different tariff bands through the so-called “time zone strategy.” By operating the CREA® platform in this mode—considering the unit cost variation of kWh in different time slots—it is possible to further increase cost savings by shifting consumption peaks to hours when the kWh cost is lower.

Regarding the system’s computational capabilities, the uniqueness of the CREA® platform lies in its intrinsic ability to handle large volumes of real-time data through a software solution specifically developed for this purpose.

The combination of these advanced algorithms and the flexibility to exploit different tariff bands allows for significant energy savings, with results reaching up to a 40% reduction in aeration-related consumption and up to a 20% reduction in total energy consumption.

2. INSTALLATION CHARACTERISTICS

The CREA® platform is accessible from any device (desktop and laptop computers, tablets, and smartphones) with an Internet connection and/or access to the local network of the water treatment plant where the platform is installed. Each authorized user has a personal username and access password defined by Createch360°’s IT technicians according to the client’s requirements. Specific permissions are defined for each user category.

Installation Components

The CREA® platform installation typically includes both hardware and software components:

HARDWARE:

• OPC Server
• All-in-One Visualization Terminal

SOFTWARE:

The CREA® platform consists of various control modules, which may or may not be integrated into the dedicated plant solution depending on specific needs and following a careful cost/benefit analysis for the end customer. Communication between the CREA® platform and the field (machines and instruments) occurs through existing PLCs using a virtual switch.

Standard General Modules

Each CREA® platform is equipped with the following standard general modules to support plant management and control:

Data Acquisition, Collection, and Management Module

1. Data transfer from the field (instruments, probes, and analyzers) to the platform’s historical archives;
2. Data filtering to detect and remove inputs considered erroneous;
3. Information management: ability to represent historical data in tables and graphs, highlight KPI trends (key performance indicators), and export all data to Excel files.

Energy Management Module

1. Energy consumption recording – the consumption of CREA®-controlled machines is continuously monitored and saved to a specific database;
2. Data processing: display of consumption data in tables and graphs with Excel export capability.

Reporting Module

Plant managers can configure customized reports of process data (in Excel spreadsheets and/or graphs), which are sent via email at a user-defined frequency to the email addresses listed in the corresponding mailing list.

Event and Alarm Notification Module

1. Create custom alarms: Plant managers can create alarms (selecting specific parameters, setting activation/deactivation thresholds) that, when triggered, display a pop-up on the platform screen and send an email to a preset list;
2. Create events: ability to insert system notes indicating specific events (e.g., maintenance, equipment failures, influent quality issues).

The control modules can be further customized by CREATECH SOLUTIONS SL if the client wants to introduce specific control loops (e.g., the ability to flush diffusers with air for cleaning).

Customized Control Panel (DASHBOARD)

The dashboard (Figure 2) is the user interface where all process information collected and processed by the CREA® platform is displayed in an easy and intuitive manner. The dashboard’s layout—what information is shown (process parameters, effluent pollutant values, energy consumption, etc.) and how it is displayed (graphs, tables, live values, etc.)—is fully customizable (each user designs their own dashboard as desired). This setup offers a comprehensive overview of the plant’s status and operations tailored to the specific user’s needs.

The data shown on the dashboard is continuously updated, reflecting real-time measurements without any user intervention.

Specific Modules for Wastewater Treatment Plant Control

This section primarily addresses water line control modes. Additional modules can always be added to an already installed and configured platform based on the operator’s specific needs.

The water line control solution aims to achieve the following objectives:

• Ensure continuous compliance with discharge limits according to current regulations;
• Provide an advanced analysis tool for process control, diagnostics, and field instrumentation supervision;
• Optimize equalization tank drainage based on the most energy-efficient time slots and real biological performance;
• Optimize nitrogen and phosphorus removal efficiency while minimizing energy consumption;
• Apply and optimize an intermittent aeration control logic that alternates aerobic and anoxic phases across the biological lines independently;
• Maximize biological phosphorus removal;
• Minimize air pressure requirements in the biological line’s compressed air system (and related pressure losses) by keeping air regulation valves at maximum openness according to actual biological line performance;
• Control blower performance to optimize air production and distribution across the biological tanks;
• Optimize chemical dosing for phosphorus removal;
• Optimize TSS concentration and SRT values in the biological section.

Water Line

The proposed CREA® platform configuration for the water line control of the plant includes the following modules:

Buffer Control

This module manages the equalization tank by intelligently controlling the pumps—maximizing flow to the biological stage when online performance is better and energy costs are lower. Effluent transfer from equalization to the biological process also depends on hydraulic level measurements in the biological tanks.

The aeration system control module, based on the plant’s specific process needs (discharge limits, influent loads, process specifications, air supply system configuration) and real-time measurements of key process parameters (e.g., Dissolved Oxygen, Ammonium, Nitrates, Oxidation-Reduction Potential), controls and manages the aeration process with the following goals:

• Optimize nutrient removal processes;
• Minimize energy consumption associated with the air production and distribution system.

N – Control

Optimize the parameters of the biological nutrient removal process using:nepis.epa.gov

• Dynamic DO Set Point (Dynamic DO SP): Based on direct online measurements (NH₄⁺, NO₃⁻, DO) independently for each individual line, to promote either nitrification or denitrification processes depending on effluent quality. The dissolved oxygen set point in each biological reactor is adjusted based on effluent quality (ammonium and nitrate). Therefore, the dissolved oxygen set point is continuously adapted to the real-time oxygen demand of the process. Each reactor is individually controlled to provide optimized performance. The dissolved oxygen set point is lowered when effluent quality is at optimal levels (to reduce aeration energy consumption) and increased when the system’s nitrification capacity needs to be enhanced to maintain proper effluent quality. This strategy aims to minimize the energy consumption required by the system to optimally conduct this biological degradation process.
• Nitrification/Denitrification Cycle Control Strategy: Based on the effluent quality of each biological tank (measuring NH₄⁺ and NO₃⁻ parameters). This control logic induces denitrification phases (aeration shutdown/minimum aeration setting – mixer activation) in aerobic compartments. In other words, it introduces intermittent aeration control, imposing sequential anoxic phases in different reactors based on the treated flow and effluent quality. When effluent ammonium reaches sufficiently low levels (set point established by the operator), introducing anoxic phases (periods of anoxia achieved by interrupting air supply) enhances the denitrification capacity of the bioreactor, leading to significant savings in process air production and distribution costs without compromising effluent quality.
• Advanced Blower Control and Management: Based on frequency and flow rate to achieve the set dissolved oxygen concentration in each aeration tank with minimal energy consumption. The control considers the energy efficiency of each blower to utilize them based on energy cost, load to be reduced, and daily rotation schedule.
• Time Zone Strategy: Optimize part of the pollutant removal during time slots when energy costs are lower.

Note: The N-Control module can regulate nitrification and denitrification cycles in reactors without the need to install mixers. It is possible to program minimum aeration cycles to allow denitrification and prevent sludge sedimentation in biological tanks by performing so-called pulsed aeration. However, installing mixers reduces the air requirement for this function and avoids relying on sludge sedimentability to limit the DN phase when necessary.

MOV Control – Maximum Valve Opening

The Most Open Valve (MOV) strategy is the advanced management of the degree of opening of modulating air line control valves. This strategy works in conjunction with the Dynamic Pressure Strategy, which references the dynamic pressure measured in the main air distribution manifold. The air distribution system is forced to operate at any time at the maximum possible opening degree of each valve, facilitating the air production system to work at the minimum pressure regulation point.

The valve opening degree is adjusted to meet the set dissolved oxygen in each reactor, which can be automatically set by the platform or manually defined by the user.

Sludge Retention Time (SRT) Supervision Module

This module supervises the evolution of the sludge retention time (SRT). The platform acquires temperature data and biomass concentration values in the biological/membrane compartment and verifies nitrification and denitrification performance by measuring values provided by probes and analyzers, comparing them with historical plant data.

The control strategy adjusts the wasting flow to maintain an optimal concentration of solids in the aerated mixture and SRT in the biological system, acting based on field-measured SST concentration data and HRT, returning the calculation of the optimal sludge residence time that the biological reactor should adopt based on temperature and season.

The module enables overall process performance improvement, increased nutrient removal efficiency, optimization of energy consumption associated with oxygen demand, better sludge sedimentability, and reduced risk of issues related to biological sludge quality.

From the reprocessing of the above data, the platform suggests how to modify the frequency and amount of wasted sludge to balance purification performance and optimal operation of the biological compartment with reduced excess sludge production.

P-Control Module

Advanced chemical dosing control module (for phosphorus removal and/or emergency SST reduction) that automatically regulates the dosing of the selected chemical based on online measured concentrations of PO₄, TP, and SST and turbidity, aiming to meet the required standard with minimal reagent consumption.

RASe Control Module

Advanced external recirculation control module based on influent flow rate, online measured SST value in the biological reactor, SST in the recirculation pipe, and sludge level in each secondary clarifier. This module optimizes the operation of recirculation pumps, appropriately managing the amount of sludge in the system, always ensuring the correct SST concentration needed to achieve the best removal performance.

RASi Control Module

Advanced internal recirculation flow control module based on treated flow and NO₃ concentrations in the biological reactor and TN in the effluent, aiming to improve the denitrification process while minimizing the lifted flow and corresponding energy consumption. This module optimizes the operation of internal recirculation pumps, appropriately managing the delivered flow based on online measured values.

Sludge Line

The sludge line of a treatment plant can also be optimized by introducing a process control platform. In this case, the modules with which the CREA® platform is proposed to be configured are as follows:

• Thickening Control Module: Designed to optimize the performance of the sludge thickening section
  • Gravity Thickening
  • Advanced Excess Sludge Control: The excess sludge flow from each thickener is automatically and independently managed by the platform based on SST measurements in the thickening compartment, SST in the pump discharge pipe, and delivered flow. The system automatically performs a mass balance to identify the correct volume of sludge to be extracted from each thickening unit.
  • Dynamic Thickening
  • Advanced Polyelectrolyte Dosing Control: The chemical dosing is adjusted based on the flow rate and SST concentration of each thickening line, analyzing both the individual mass balance and that of the entire dynamic thickening section.

DSS Module – Anaerobic Digestion Control

The DSS (Decision Support System) module is an intelligent control solution capable of optimizing the performance of the anaerobic digestion process 24/7, ensuring maximum stability. Monitoring critical parameters and analyzing their trends over time allow the control platform to perform advanced diagnostics, offering the operator indications on how to maintain the efficiency of the anaerobic digestion process. The control module incorporates various algorithms for managing incoming information and can anticipate potential deviations in the anaerobic process by signaling them to the operator through intelligent data analysis.

For controlling the KPIs of the process, a special dashboard is provided, clearly and simply displaying the key operational parameters of the process. The main objectives of this control module are as follows:

• Define the process state in real-time by assigning it a degree (normal/unstable/destabilized)
• Provide the operator with indications regarding possible process deviations
• Provide alarms in case of malfunction
• Identify potential causes of malfunction
• Propose preventive and corrective actions to resolve the anomaly

DW-Control Module

Module for intelligent dewatering control and optimization of related phases.

The reliability of measuring the SST content in the centrate stream produced by the dewatering unit is improved through the introduction of CREAbox, a device developed by Createch Solution srl, consisting of a sampling cell where the measuring probe is housed. This cell is designed to minimize turbulence inside and ensure stable measurement: the cell is equipped with automatic inlet and outlet valves governed by the control platform, allowing the entry and exit of the water/sludge stream.

The DW Control module utilizes three control logics aimed at minimizing operational costs:

• Advanced Polyelectrolyte Dosing Control: Optimizes chemical dosing based on the SST load at the centrifuge inlet and the SST level in the supernatant (centrate) to ensure the desired centrate quality. This control operates independently on different dosing lines, optimizing each based on the actual dewatering performance.

Advanced Sludge Feed Control Module

This module regulates the sludge feed flow to each centrifuge, adjusting the mass load of each dewatering unit based on machine performance, the quality of the centrate, and the actual dosing rate of the poly-electrolyte. To optimize the operation of this module, all operational limits specified by the machine manufacturer are loaded into the system, along with those related to the maximum allowable load based on expected yields and/or pilot tests conducted, as well as the levels of the stabilized sludge tanks.

Advanced Dewatering Unit Control Module

This module controls the differential speed of each centrifuge to maximize motor performance, thereby achieving the highest percentage of dry solids in the sludge and the best quality of the centrate with the minimum poly-electrolyte consumption.

Together, these three control systems can correct and optimize the overall performance of the dewatering section to maximize the dry solids produced at the lowest operational cost.

Automatic Cogeneration Section Control Module

This module automatically controls the cogeneration section present in the plant to maximize electricity production based on the following input variables:

• Actual internal energy demand for the treatment plant;
• Biogas production and level in the gasometer;
• Energy price for the period;
• Presence of other installed energy production sources in the plant (e.g., solar panels).

The control strategy of this module aims to maximize profit from the produced electricity, thereby increasing the overall efficiency of the treatment plant.

IDM Module – Field Instrumentation Diagnosis and Control

This module validates the information provided by field measurement instruments: through verification algorithms, in case of malfunction and based on cross-checks, the system can verify the reliability of the received data and determine if the information is consistent.

It analyzes all data received from field instrumentation to:

1. Diagnose the reliability of instruments by detecting any drifts: it analyzes and compares signals from all probes for a specific substance (e.g., NH4+) present in different zones of the same biological degradation line and those from probes installed in other biological degradation lines, determining the reliability of each probe’s signal. Each signal is assigned a percentage value indicating its reliability;
2. Inform the operator when a probe or instrument provides unreliable readings;
3. Study the operational modes of the plant.

If the CREA® platform detects poor functioning of a probe or low-quality signal, the system may decide to discard that signal and:

1. Report the issue to the operator (popup on dashboard and email notification);
2. Automatically select an equivalent signal to control and manage the process;
3. If option 2 is not feasible, apply corrective actions to minimize the effects of the poor-quality signal.

This diagnostic tool will also be used to evaluate the performance of blowers and automatically actuated valves by checking any discrepancies between the command sent to the machinery and the received signal. In this way, malfunctions can be anticipated and immediately communicated to operators via email and/or SMS.

CREAlab Module – Automatic Laboratory Data Archiving

This module digitizes laboratory analysis data and performs the following activities:

1. Online reprocessing of data to define plant performance through specific KPI control or by generating graphs to compare historical and current data;
2. Cross-verification of data reliability produced by probes and analyzers present in the field. Laboratory data, typically more reliable than field data from probes, are used by the IDM module as additional verification of the reliability of field signals.

System Architecture

The physical installation of the OPC Server, where the platform resides, typically occurs at the treatment plant itself (in the control room). Therefore, the CREA® technology is not cloud-based; the algorithms reside on the server at the plant. The server is then connected to an operator interface (screen, keyboard, mouse) that allows monitoring of plant performance, modification of process parameters, management of historical data, and interaction with the system.

Figure 3 presents a diagram summarizing the typical architecture of the control system.

Advantages of the Proposed Configuration

The choice of this communication architecture should be further explained and compared with alternative solutions provided by other suppliers to understand the greater potential of the solution proposed by Createch Solutions S.L.

A key feature of the CREA® installation is that it interfaces with the control system developed for the PLC without modifying it in any way.

CREA® is installed in parallel with the plant’s SCADA system and directly controls the machines and electromechanical components connected to it (blowers, pumps, valves, etc.), managing their operation based on specific process needs and optimizing their performance to achieve the defined discharge parameters with the lowest possible energy consumption. This goal is achieved through the use of predictive and adaptive algorithms, and when the volume of collected data is significant, artificial intelligence algorithms that do not require intervention from the process logic implemented in the existing SCADA system. Traditional RTC systems, on the other hand, collect data from the field, analyze and process it, and then send a signal to the SCADA defining the set-point to apply (e.g., dissolved oxygen), allowing the treatment process to be regulated by the SCADA. In other words, traditional RTCs do not act directly on the active components that regulate the treatment process but simply define a set-point to which the SCADA logic refers to manage the treatment process.

With the CREA® system, SCADA maintains its independence and is always available: this approach provides greater security for the operator, who can choose at any time whether to manage the plant with the advanced control platform, thereby generating energy savings, or use the control system developed with traditional control logic installed on the PLC.

In case of a control platform failure, the plant will automatically switch to the existing SCADA management.

The interface between the traditional control system and the advanced control system is achieved by creating a virtual switch in the PLC code. PLC signals can thus be acquired by the OPC server where the CREA® platform is installed, allowing it to communicate with the machines and instruments installed in the field through the PLC. In this way, the operator can decide at any time whether to control the plant through SCADA or manage the parts subject to advanced process control with the CREA® platform.

Signal duplication means, for example, that set-points initialized by the operator within the traditional control system (e.g., the O2 set-point in the oxidation tank) are not overwritten or modified and remain unchanged, effectively constituting a backup.

In the unlikely event of communication errors between the OPC server and the PLC(s), the security protocol developed by Createch Solutions S.L. allows automatic switching from CREA® management to the system’s management based on traditional logic control installed in the PLC.

Other solutions available on the market, instead, acquire probe signals directly through the RTC control module, which means that in the event of communication errors, information related to the monitoring of direct parameters risks being lost. Furthermore, these architectures may involve modifications to the setpoints of the traditional control system, resulting in less secure plant management.

An important aspect to highlight is that the CREA® platform is able to interface with all PLC models and probes available on the market, as Createch Solutions S.L. is not tied to any specific manufacturer.

Through a secure access protocol (VPN – Virtual Private Network), it is possible to connect to the server remotely. This function is typically used to allow the transmission of information about the plant’s operation.

Remote access also allows Createch Solutions S.L. technicians to provide continuous support to the operator. With the operator’s prior authorization, they can intervene to optimize the platform’s performance during commissioning and provide support after installation.

In summary, the proposed architecture offers significant advantages for the plant operator. In short:

1. The installation of CREA® does not alter the architecture of the traditional control system (PLC + SCADA), which remains essentially in “stand-by” and functions normally as a backup;
2. The operator can always choose whether to manage the plant using the CREA® advanced control platform or through a control system based on traditional logic;
3. Communication protocols to/from the PLC can be fully adapted to the customer’s needs (Profibus, Ethernet, etc.);
4. The CREA® platform is compatible with any brand of instrumentation and/or PLC installed;
5. Remote access allows real-time troubleshooting and problem resolution.