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Software-sustainability through open, standardized interfaces

Project: Waste water Kitzingen
Customer: Stadt Kitzingen, Jürgen Orth, 09321-34378
System Integrator: Elektro Hofmockel, Karl Weber, 09876-9790-17
 Process control system, Remote control system
 Waste water


The sewage treatment plant of Kitzingen is a design capacity of 85,000 inhabitants by far the largest in the district.

The wastewater treatment is carried out by one of the activated sludge plant connected further purification with anaerobic sludge treatment. In the catchment area there are 22 stormwater overflows, 10 pumping stations and 6 measuring stations. The plant was built in 1980 and expanded in 1990 and 1999. Currently the restoration of all system components takes place.

The remote control and process control technology has been completely renovated in 2011. "In selecting the new system was us especially an open and modern technology with a focus on industrial standard interfaces important," says Jürgen Orth, the head of the treatment plant of the town of Kitzingen. Not again wanted to go through proprietary hardware or software depending on a manufacturer. Furthermore, the process creating images should be taken over by their own employees. Prerequisite was a development environment, which can be used completely without programming knowledge. After an extensive market analysis then the choice fell on the remote control and process control of FlowChief.

The company Hofmockel, Rohr at Nuremberg - System Integrator for FlowChief products - has been commissioned to install and implement the system. In parallel, the employees of the wastewater treatment plant have been trained to use and process pictures intensively directly at the company FlowChief. So now the entire system was visualized by its own employees. Nonetheless, the issue is thus not completed for Mr. Orth: "The annual software updates bring a lot of innovation in the system" so Orth, who also regularly participates in training sessions update the company FlowChief.

Facts FlowChief:

  • Process control system 10,000 process variables running as a hot standby redundancy
  • 30 RTUs via GPRS (manufacturer Siemens S7-300)
  • Online coupling (manufacturer Siemens S7-300 and S7-1500)
  • Engineering by end customer - about 100 process images
  • Operating log for DWA (automatic data transfer from FlowChief)
  • Web-based reports for relief structures (RSB) for submission to the water authority
  • Maintenance Management

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Energy management e-Gem across locations

Project: Energy management Schott AG
Customer: Schott AG, Dipl.-Ing. Lothar Kretschmer,
Leiter Energiewirtschaft Schott, 06131-66 101 66
Product: e-Gem
sector: Industry

SCHOTT is an international technology group with more than 130 years experience in the areas of specialty glasses and materials and advanced technologies. SCHOTT is one of the leaders in high-quality glass production for a variety of industries and is committed to sustainability in the fields of environment and energy consumption.

Since 2011, SCHOTT relies on the ISO 50001 certified energy data management system e-Gem of FlowChief. The existing software solution to date was replaced train to train while retaining the measurement infrastructure. The consumption data is collected across locations with U160x Summators from Gossen Metrawatt. FlowChief developed to a driver, the field side ECL, a proprietary system language of GMC, speaks and behaves according to the brim as a standard OPC Server. In addition to online consumption data while also archive values, system data and bus characteristics for monitoring infrastructure are recognized.

In Group 50 employees work in the future with the system and access via browser without installing any additional software on the application. This was, according to Mr. Lothar Kretschmer - line energy industry - also a major reason for the change. "The expense was just too great. Few people had access to the system and were increasingly busy to send their consumption data to third parties. A prerequisite for a new system was therefore a non-discriminatory, consistent access via a web browser. "

The centralized management structure of the Group is continuously synchronized with e-Gem. The result is an organization tree, which is historically accurate displayed by the application. Measuring points are absolutely, partially or virtually organized as metering points in the tree. Next there is a assignment to media and tariffs.

e-Gem acts as a data hub in the company. Energy planning, peak demand management, accounting and technical services access constantly back to the data and use this for your individual areas of responsibility.

Facts FlowChief:

  • e-Gem with 5,000 metering points
  • Hot Standby redundancy solution in its own data center (On Premise)
  • Automated synchronization with enterprise Master Data
  • Driver development for ECL incl Gossen Metrawatt U160x incl. archive handling and bus monitoring
  • Fully automatic synchronization points of consumption based on the dynamic configurations U1600
  • Multi-tenant structure and company-wide access via a web of more than 50 employees
  • Archive up to 10 years available Online (1-minute raster data volumes up to 1,000 GB)

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Central SCADA Application in a large Corporation

Project: Process control system SKF Schweinfurt
Customer: SKF GmbH, Wolfgang Voith, 09721-56026026
System Integrator: ACTEMIUM, Manuel Demling, 09721-75 746 15
Product: Process control system
Sector: Industry

SKF is a Swedish company with a broad product and service range around the areas of bearings, seals, lubrication, mechatronics and related services. At the Schweinfurt location - the headquarters of SKF Germany - are currently working about 4,400 people. Schweinfurt, making it the largest production base of the SKF Group worldwide. When monitoring and data collection of the supply systems in the production SKF relies on central process control. Tied in addition to the fluid, water, compressed air, ventilation and electrical infrastructure and the building control system of work 1 (administration building).

2012 decision to modernize the in the tooths Repas AEG control system was adopted. When choosing the new system, FlowChief sat among others in an assessment center to the current competitors through. Decisive per FlowChief process control system was, according to Mr. Voith - Head of Electrical Engineering at SKF in Schweinfurt - the uniquely integrated overall concept. Thus, besides the FlowChief process control system no product on the market that an innovative and free web visualization plugin offers powerful historicizing, reporting and full emergency service functionality in an application.

Facts FlowChief:

  • When completed, over 100,000 PV
  • Parallel access of up to 100 users via a web browser
  • Multi-tenant structure - structuring according to areas of activity (electrical, media, environment, ...)
  • Data sources:
    - Up to 350 controllers manufacturer Siemens and Beckhoff
    - Alphanumeric data from suppliers
  • Visualization with approximately 450 process graphics incl. zoom level dependent representation
  • Hot-standby redundancy (access through Load Balancer)
  • Archive data retention period:
    Online data currently 400 days raw data / messages (Outsourced 5 years)

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Network control technology with FlowChief in the canton Schwyz

Project: EBS Schwyz
Customer: Elektrizitätswerk des Bezirks Schwyz AG
Jürg Heinzer,
System Integrator: ERTECH Elektronik AG
Michael Bickel,
Product: Process control system
Sector: Energy & Energynetwork


The power station in the district of Schwyz (EBS) is a leader in the energy supply. EBS produces and transmits energy and also offers its customers services. The company arranges the environment a high priority, account economic, ecological and social aspects. A key task of the EES is to convert the hydropower the Muota into usable electricity and to provide customers in the supply area safe disposal. This EBS operates five hydropower plants along the Muota - the Muotakraftwerke. These were built 1956-1970 and annually produce around 220 million kilowatt hours of electricity. Thus, they cover about 70% of electricity needs in their own supply area.

Since 2011 EBS monitors the network infrastructure to producers and customers with process control of FlowChief. Planning and implementation was carried out by the Ertech Electronics AG Studen - General Distributor and system integrator for FlowChief software in Switzerland. "There was no central monitoring for the network system. Only small controllers and panels were installed on site for operation and fault signaling. EBS was particularly impressed the concept of centralization. The underlying server client architecture simplifies operation and the evaluation and processing of data considerably ", says project manager Michael Bickel of Ertech.

The connection of external control systems, protection devices or transformer monitoring is carried out via IEC 60870 and telecontrol components from SAE IT-systems. The telecontrol perfectly mastered the interplay of transmission media like GSM, dial-up connections (each 60870-5-101) and pure TCP / IP routes as fiber-optic technology (60870-5-104).

FlowChief visualized, monitors and manages network components such as circuit breakers, protective devices or transformer monitoring the power levels 6,3kV, 15kV and 50kV. In addition, data will be analyzed from the power plant control systems.

Critical operating conditions or disorders of the components are automatically forwarded to the Pickett service via voice call.

Meanwhile, in addition to the transformer stations, already 6 substations recorded. "This was initially not provided by EBS" said Mr. Bickel.

For Ertech the Electricity Schwyz were the first project in this complex perimeter with the software of FlowChief. Meanwhile, some more have been implemented with a similar range of tasks.

Facts FlowChief:

  • Process control 15 000 process variables (On Premise)
  • SAE connection telecontrol via IEC 60870-5-104 (Ethernet, fiber optic) and IEC 60870-5-101 (dial-up, GSM)
  • Visualization and monitoring of different nets, substations and circuit breakers
  • Discontinuation of switching commands
  • Alerting via language (Landline)
  • Leitvorgangsarchivierung - detailed record of relevant user interactions
  • Long-term archiving of messages (states) and measured values

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Process control including maintenance management for district heating networks

Project: District heating Marktoberdorf 
Customer: Fernwärme Marktoberdorf GmbH
Markus Hacker, 08342 4203 105,
System Integrator: Zach Elektroanlagen GmbH & Co. KG,
Tobias Zach, 08622-9881 330,
Product: Process control system, HMI
Sector: Energy & Energynetworks


Lack of continuity in terms of energy and raw materials mean that many municipalities for years dreamed of independence and predictability. The city lies in the Allgäu Alps Marktoberdorf is there a step further. Already since 2009 operates the district heating Marktoberdorf GmbH its own district heating network. The goal is a sustainable, environmentally friendly and economical heat supply of parts of the city and its citizens. Are powered public buildings such as Hall and indoor swimming pool as well as many private households.

At first the heat was purchased from local industrial plants, the operating company began to build in 2012's, perfectly matched to the demand characteristics of the customer care systems. In the expansion and the decision was made, to be monitored by a central process control system to operate the plant. "The system selection FlowChief convinced right away." So Mr. Markus Hacker - Head of Technology at the district Marktoberdorf GmbH. "FlowChief fulfilled not only the central tasks required of us as visualization, alerting or historicizing. We use the integrated maintenance and service management also functions that are not available on the range of current process control systems usually. "

With the implementation of FlowChief system integrator Zach was commissioned electrical equipment. The first task was the interfaces of the generation systems, heat meters, water meters and transfer stations and their protocols M-Bus, Modbus, Profibus and BAC-Net to bring to a common denominator. These decentralized controller Beckhoff were installed. These serve as a protocol converter and communicate to the brim with over Ethernet FlowChief.

Important decentralized locations were also equipped with a HMI solution from FlowChief. If the central control is not available, so suburb are still accessible to the process. "The engineering for this has already been run on the server. Process images and variable configuration had to be only copied "as Tobias brings Zach - Head of Automation Technology at Zach electrical equipment - a significant advantage to the point. By the way the end user uses identical user interfaces in the central and suburban.

Facts FlowChief:

  • Process Control System 25.000 process variables
  • Steadily growing heating network can be expanded by operators in the visualization of a button
  • 2 FlowChief HMI decentralized suburban stations
  • Alarm and Escalation Management (Dynamic alerting via SMS)
  • Online coupling of 6 Beckhoff controllers that serve as a protocol converter
  • Management with FlowChief maintenance management

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Intercommunal portal solution for water supplies

Project: Water supply Bayerischer Wald
Customer: Wasserversorgung Bayerischer Wald, 
Dipl.-Ing. Hermann Gruber, 0991-29 64 0,
Product: Process control system, Remote control system, Portal solutions, FlowChief VPN-Portal
Project expression: 6 Process control systems
Sector: Water supply

The water supply Bayerischer Wald (waldwasser) is a special purpose association with headquarters in lower Bavaria Deggendorf. Supplies Founded in November 1963 waldwasser today large parts of eastern Bavaria, approximately 10 percent of the area of ​​Bavaria, with a high quality drinking water. Approximately 200 communities lined up into the tree water community. waldwasser established itself as an inter-municipal administrative structure, the regional water supply from hand safely and is mainly for the sustainable use of the food no. 1, the drinking water. The Association sets since 2004. System-wide functions in monitoring, data collection and analysis on successful software solutions FlowChief. The private service area a clustered Process Control System for network operation in Deggendorf, Moos and Flanitz is operated so far. A hot-standby redundancy is in the drinking water treatment plant in Flanitz in use. 2014 took place the launch of a new waterworks with water softener at the site Moos.
Here is again set to process control of FlowChief. In addition to operation, modernization and expansion of its own infrastructure tree water has, since 2008, services related to the water supply. Since 2008 water woods allows the monitoring of buildings via a portal solution in a private cloud environment. Allowed to become more than 25 congregations with about 100 buildings. The connection is made with remote control technology of FlowChief.

Here come standard PLC components, which are often installed already in the plants used. About GPRS or DSL communicate this bi-directional and encoded with the portal. The central FlowChief process control system is consistent client capability, making them ideal for running multiple clients on one system. The end customer a complete package comprising native web visualization, alarms and escalation management and detailed reports about its investment purely as a rentable service is provided. The own 24/7 reporting office completes this service. The engineering of all systems is carried out by waldwasser itself. So now designed for all parts of the plant more than 300 process images from his own hand.

Facts FlowChief:

  • Total 6 Control Systems (some hot standby redundancy) with a total of 85000 process variables
  • Engineering by end customer
  • A total of 300 process images
  • waldwasser portal solution:
    Process Control System currently 7500 process variables
    100 Station FlowChief Telemechanics
    Manufacturer: VIPA (200 and 300) and Siemens (S7-300 / S7-1200)
    Panasonic, Phoenix Contact
  • Coupling of 400 GSM datalogger via web portal and "http polling"
  • Multi-tenant structure and parallel access of 25 communities via Web browser
  • Provided services per customer:
    visualization, standby roster, Reporting, Reporting Service
  • Sebam compliant report output for data transmission to the water authorities
  • Remote programming of PLCs via FlowChief VPN portal



Flood protection with FlowChief Software Solutions

Project: Flood protection in Sulmtal 
Customer: Wasserverband Sulm,
Johannes Kübler, 07130-9693,
System Integrator: Modjesch Elektrotechnik,
Dipl. Ing. Jörg Schaber, 07135-2688
Product: Process control system, Remote control system
Sector: Flood protection


A prime example of ambitious flood control is the water board Sulm headquartered in Nord Württemberg Weinsberg. With the foundation in 1973, following a flood of the century and massive damage Weinsberg valley train was "flood-free" to train.

With an investment of EUR 36 million 40 years later were 15 partly ecologically integrated basins completed. So are capacities for around 4.2 million cubic meters of water available for emergencies.

To monitor the 116 km² large catchment products came to 2011 with remote control and process control technology with high dependence on manufacturers to use. "This led to great difficulties in system adjustments," said Mr. Jörg Schaber - responsible for automation technology in Modjesch Electronics. Since 2011 the Association is firmly behind software solutions FlowChief. This is in remote control technology on standard PLC components and supports virtually all relevant control provider. So was resorted in Sulm on components from VIPA. The controllers connect via DSL lines VPN encrypted with the Headquarters. The Remote Control Technology enables not only archive value buffering at disconnections an event-driven transmission of events.

As it has repeatedly caused a shortfall of broadband penetration in the region in case of floods was implemented by timeslot radio a path redundancy. These transfers, in parallel with the more performant "leased line technology" via DSL, data center.

At headquarters the FlowChief process control system takes over the data acquisition, archiving and compression. All employees have access either via a PC or, more recently, via mobile device on the visualization to and are thus always up to date. A free Login level overview, linked on the webpage of the Association also enables the population to tap the current water levels. The integrated standby roster ensures alerting the competent persons in the event of a fault. Here, the association uses Voice Alarm via text to speach.

The Association is responsible for a documentation requirement to all flood events. FlowChief developed it in collaboration with Modjesch Electrical Engineering an automated reporting archived the next times also important numbers of events in chronological order.

Facts FlowChief:

  • Process control 1000 process variables (On Premise)
  • 16 RTUs via DSL (VIPA 300S)
  • Path redundancy through parallel connection of all buildings on timeslot Funktechnik
  • Standby Serves with escalation management and alarms via Text to Speech
  • Login Free level overview link on webpage for everyone
  • Automated Batch Reporting to floods
  • Archive Storage of raw values with continuous online access of 5 years

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