Amsterdam, Netherlands – October 2024 – Amsterdam’s largest water treatment plant has reduced energy consumption by 18% and improved regulatory compliance after upgrading to the ABB PP886H 3BSE069297R1 HMI panel. The upgrade, completed in Q3 2024, addressed the plant’s struggle to optimize energy-heavy processes (e.g., pump operation, chemical dosing) and meet strict Dutch water quality reporting requirements with its outdated control system.
The Challenge: Outdated HMI Held Back Sustainability & Compliance
Before adopting the PP886H, the Amsterdam plant— which treats 500,000 cubic meters of water daily for 1.2 million residents—relied on a 12-year-old HMI to monitor its filtration and disinfection processes. The system’s flaws created two critical barriers:
- Inefficient Energy Use: The old HMI couldn’t track real-time energy consumption for pumps or adjust their speed based on water demand. Pumps ran at full capacity 24/7, even during low-demand hours (e.g., 2–6 AM), wasting 1.2 GWh of electricity annually—equivalent to powering 300 homes.
- Manual Quality Reporting: The system didn’t integrate with water quality sensors, so technicians spent 20+ hours weekly manually compiling data (e.g., chlorine levels, turbidity) into Dutch environmental agency reports. Errors in these reports led to a €90,000 fine in 2023 for missing a turbidity compliance threshold.
- Slow Alarm Response: The old panel’s alarm system was disorganized—critical alerts (e.g., “chlorine level too low”) were mixed with minor ones (e.g., “filter pressure slightly high”), leading to delayed responses. In 2024, a delayed chlorine alert caused a 4-hour shutdown to re-disinfect water, affecting 50,000 residents.
“We had two goals: cut our carbon footprint and eliminate compliance errors,” said Pieter Bakker, the plant’s operations director. “Our old HMI made both impossible—we needed a system that could connect our sensors, optimize energy, and simplify reporting.”
After evaluating three industrial HMIs, the plant selected the ABB PP886H 3BSE069297R1 for its energy monitoring features, sensor integration, and compliance tools:
- Real-Time Energy Dashboards: The PP886H connects to energy meters on pumps and blowers, displaying real-time consumption data in custom dashboards. Operators can set up automated rules (e.g., “reduce pump speed to 50% during 2–6 AM”) to cut energy use. “We’ve optimized pump speed for demand, and our electricity bills have dropped by 18%,” Bakker said.
- Automated Quality Reporting: The panel integrates with 24 water quality sensors (e.g., turbidity meters, chlorine analyzers), automatically compiling data into Dutch environmental agency-compliant reports. Reports are generated in 5 minutes instead of 20 hours, with zero manual errors. “We submitted our first automated report in July, and the agency praised its accuracy,” Bakker added.
- Prioritized Alerts: The PP886H lets operators categorize alerts by severity (critical, warning, informational) and send push notifications to their phones for critical issues. “Last month, a chlorine sensor detected low levels—we got an alert within 10 seconds and fixed it before it affected water quality,” Bakker explained.
- Durable Design for Wet Environments: The panel’s IP65-rated front resists water splashes and humidity—essential in the plant’s damp filtration rooms. It also operates in -10°C to +55°C, so it works reliably in the plant’s outdoor pump stations.
Results: Energy Savings, Compliance Success
Three months post-upgrade, the Amsterdam plant has achieved transformative results:
- Energy use cut by 18%: Optimized pump operation saved 216 MWh of electricity in three months—on track to save 864 MWh annually. This reduces the plant’s carbon footprint by 432 tons of CO₂ yearly.
- Compliance fines reduced to €0: Automated reporting eliminated errors, and the plant’s 2024 Q3 water quality report passed with no violations.
- Alarm response time down 80%: Prioritized alerts and remote access cut average response time from 45 minutes to 9 minutes, preventing any water quality incidents.
“The PP886H isn’t just an HMI—it’s our sustainability and compliance tool,” Bakker said. “We’re saving energy, avoiding fines, and delivering better water to Amsterdam residents. It’s the best investment we’ve made in years.”
Elise Visser, ABB’s HMI product manager for water infrastructure, noted the PP886H’s relevance to global water challenges. “Water plants need HMIs that turn data into action—optimizing energy, ensuring compliance, and protecting public health,” she said. “The PP886H 3BSE069297R1 does that, helping plants meet sustainability goals while keeping water safe.”
The plant plans to install 4 more PP886H panels in its secondary filtration unit by Q2 2025, with the goal of cutting energy use by an additional 10%.
