Munich, Germany – August 2026 – Munich’s main wastewater treatment plant (WWTP) has achieved a 35% reduction in maintenance costs and a 99.9% operational reliability rate after deploying the ABB CP676 3ABD00038801 Human-Machine Interface. The upgrade, completed in Q3 2026, replaced the plant’s aging HMI systems that were installed in 2010, which were prone to failures and unable to provide real-time monitoring of critical treatment processes.
The Challenge: Aging HMIs Threaten Wastewater Treatment Reliability
Munich’s main WWTP processes 800,000 cubic meters of wastewater daily, serving 1.5 million residents and 120,000 businesses. The plant’s treatment processes include primary sedimentation, biological treatment, and disinfection, all of which require precise monitoring and control to meet strict environmental regulations. The legacy HMIs presented significant risks to operational reliability:
- Frequent System Failures: The old HMIs had a mean time between failures (MTBF) of 6 months, leading to 2-3 unplanned shutdowns per year. Each shutdown required 4-6 hours to restore operations, resulting in untreated wastewater discharge risks and €250,000 in annual emergency response costs.
- Lack of Real-Time Monitoring: The legacy systems did not provide real-time data on key treatment parameters such as pH levels, dissolved oxygen, and sludge concentration. Operators had to manually sample and test water quality every 2 hours, leading to delayed response to process deviations and an increased risk of non-compliance with environmental regulations.
- Complex Maintenance Requirements: The outdated software and hardware of the legacy HMIs required specialized maintenance technicians, leading to annual maintenance costs of €320,000. Spare parts were also difficult to source, increasing maintenance lead times by 2-3 weeks.
- Poor User Interface for Critical Alerts: The legacy HMIs had a basic alert system that did not prioritize critical alarms, leading to 3-4 instances per year where operators missed important process deviations. This resulted in €180,000 in annual fines for non-compliance with water quality standards.
“Reliable monitoring and control are essential for wastewater treatment plants to meet environmental regulations and protect public health,” said Claudia Schmidt, Plant Manager at Munich WWTP. “Our legacy HMIs were a significant risk to our operational reliability, with frequent failures and delayed process monitoring. We needed a robust, easy-to-maintain HMI solution that could provide real-time visibility into our treatment processes and withstand the harsh conditions of our plant. The ABB CP676 3ABD00038801 was the ideal solution after a thorough evaluation.”
ABB CP676 3ABD00038801: Robust HMI for Water and Wastewater Applications
The ABB CP676 3ABD00038801 HMI was selected for its industrial-grade reliability, real-time monitoring capabilities, easy maintenance, and advanced alert system. Key features addressing Munich WWTP’s challenges include:
- High Reliability: Designed with redundant components and an MTBF of 10 years, the CP676 3ABD00038801 ensures continuous operation even in harsh industrial environments. The IP65 protection class and corrosion-resistant materials prevent damage from moisture, dust, and chemicals commonly found in wastewater treatment plants.
- Real-Time Process Monitoring: The HMI integrates with the plant’s sensors and control systems, providing real-time data on 20+ key treatment parameters. Operators can access real-time dashboards and historical trend data, enabling immediate response to process deviations and reducing manual sampling by 80%.
- Easy Maintenance: The CP676 3ABD00038801 features a modular design that allows for easy replacement of components, reducing maintenance time by 60%. The HMI also includes remote maintenance capabilities, enabling technicians to diagnose and resolve issues without on-site visits.
- Advanced Alert System: The HMI’s customizable alert system prioritizes critical alarms based on severity, ensuring operators never miss important process deviations. The system also includes automated notification via email and SMS, enabling 24/7 monitoring even when operators are not on-site.
- Regulatory Compliance Tools: The CP676 3ABD00038801 includes built-in reporting tools that generate compliance reports required by environmental agencies. This reduces the time and effort required to prepare regulatory documentation by 70%.
Results: Improved Reliability, Reduced Costs, and Enhanced Compliance
Six months after deploying the ABB CP676 3ABD00038801 HMI, Munich’s main WWTP achieved significant operational improvements:
| Metric |
Before ABB CP676 3ABD00038801 |
After ABB CP676 3ABD00038801 |
Improvement |
| Operational Reliability Rate |
98.2% |
99.9% |
1.7% Increase |
| Annual Maintenance Costs |
€320,000 |
€208,000 |
35% Reduction |
| Unplanned Shutdowns (annual) |
2-3 |
0 |
100% Elimination |
| Regulatory Compliance Fines (annual) |
€180,000 |
€0 |
100% Elimination |
| Manual Sampling Time (per day) |
4 Hours |
0.8 Hours |
80% Reduction |
“The ABB CP676 3ABD00038801 HMI has significantly improved the reliability and efficiency of our wastewater treatment operations,” said Schmidt. “The real-time monitoring capabilities and advanced alert system have eliminated unplanned shutdowns and regulatory fines, while the reduced maintenance costs have delivered substantial savings. We plan to deploy the CP676 3ABD00038801 across all our regional wastewater treatment plants by 2029.”
Elena Wagner, ABB’s Global Product Manager for Water and Wastewater Solutions, commented: “Water and wastewater treatment plants require HMIs that can operate reliably in harsh environments and provide real-time visibility into critical processes. The CP676 3ABD00038801 is engineered to meet these unique requirements, helping plant operators enhance operational reliability, reduce costs, and ensure compliance with environmental regulations.”
