Network Pumping Stations & Detention Tanks
Company Wide Standard
by
David K Rushton – United Utilities Engineering
Jeroen van Alstede – Lloyd Morris Electrical
Andrew Welsh - Xylem
Presentation Agenda
•Introduction
•United Utilities Objectives
•Initial Design
•Complete Integrated Design
•Design Equipment Features
•Cost Savings
•Conclusion
Introduction
Project Requirements: To develop a company wide control panel design
which provided:
• Reduced size
• Cost savings
• Simplicity in operation
• Compliance with United Utilities Specifications for Operation and Telemetry requirement for Pumping Station and Detention Tank Control Panels
Why do United Utilities need to do this? …..
Introduction
• No recourse to Engineering• No input from Operations• Design produced without full understanding of requirements• No Design reviews carried out.• Lack of monitoring and control functions
Which created….
The current installations had:
Introduction
• Large kiosk• Large (Form 4) Control Panel / MCC• Intelligent motor starters, which requires PLC and HMI for starter faceplate• Distribution board as an integral part of the Control Panel• Mains / Mobile Generator changeover panel as an integral part of the
Control Panel / MCC. • Separate Telemetry Outstation
Which ultimately delivered….
…. An output of
Introduction
Kiosk for:
•3 No. 24kW VFD’s
•1 No. DOL Pump
•Vac Flush System
Introductionand….
MCC for:
•3 No. 24kW VFD’s
•1 No. DOL Pump
•Vac Flush System
•ICA Section
United Utilities ObjectivesProject Objectives:
• Challenged Asset Standards / Capex Challenge
• Challenged Signature Designs
• Challenged Telemetry requirements
• Reviewed Operational requirements/needs
• Operations/Business buy in
• Consulted with Suppliers on standard equipment on the market to generate an appropriate solution
In Consultation with United Utilities:
• Operations / Maintenance
• Telemetry Section
• Technical and Strategic Managers
Initial OutputThe Initial design output created:
• Smaller Control Panel / MCC• Use of conventional starters (due to the skill gaps of Operations staff, simpler operation)
• Use of ultrasonic control (Framework instrument has 7 No. operationbands)
• Separate distribution board (smaller off the shelf item)• Separate Mains / Diesel Generator change over panel (not all sites requireunit and allows standardisation of Control Panel/MCC)
Initial OutputThe Initial design (Front and Rear access) produced and installed by LME.
Initial Output
Although the Standard ‘back to basics’ design succeeded in:
• Reduced panel size
• Cost savings
• Simplicity in operation
What was needed to fully satisfy the objective was an integrated Control /
telemetry system.
Complete Integrated Design
UU’s Engineering, Operations, Asset management and Telemetry
started a review of available equipment to:
•Review the various options (Capex and Opex).•Understand telemetry interfaces and whether it will work with the options.•Produce a standard control philosophy for the various pumping station types.•Ensure the current TeMACS documents are adhered to by the various suppliers.•Agree the final panel layouts with Operations/Maintenance.•Evaluate the increased Functionality (depending on Supplier).
UU concluded that the best solution was the Flygt controller from Xylem with development from LME.
Complete Integrated Design
Solution: To utilise the APP700 Intelligent Pump Controller which Provides:
•Direct 4-20mA connections from level instruments.
•ATU Gateway module which provides remote telemetry to the UU top end monitoring and control system.
•Application software which has been written to provide a solution that meets
UU’s Telemetry Monitoring and Control Standard (TeMACS).
UU’s User Requirement Specifications for Network Pumping Stations and Detention Tanks.
•Serial link to control Variable Speed drives.
Complete Integrated Design
Telemetry INCL Modem
PLCU/S
Controller
U/SVFDs if Required
M&C
System
Original Design
Complete Integrated Design
APP 700 Incl Telemetry Modem
U/S Level Sensors
PumpSmart(if required)
M&C
System
Serial Link
New Design
Complete Integrated Design
Dual VFD station with:
2 No. PumpSmart Drives
1 No. APP700 / Gateway
Wet Well & Destination level Detection
Dual Fixed speed station:
1 No. APP700 / Gateway
Wet Well level Detection
Design Equipment Features
The solution assumes 2 Pump fixed speed Pumping Station and you add the additional assets on Site:
•Variable Speed Drives
•Scavenger Pump
•1 or 2 Macerators
•Outlet Level Device
•Outlet Riser Drain Valves
•External Flow Meter
•Screen or Mixer
•Additional Input signals available
Design Equipment Features
Fixed Speed Solution
APP700 Pump Controller Unit with Expansion Module
•Gateway Module (Including Modem)
•Ultrasonic Head (4-20mA)
•Current Transformers
•Flow Meter if above 70 l/s (APP derived flow if below 70 l/s)
•No Flow Switches required
•APP controls forward and reversing through panel.
Design Equipment Features
Variable Speed Solution
•APP700 Pump Controller Unit with Expansion Module
•Gateway Module (Including Modem)
•Ultrasonic Head (4-20mA)
•PumpSmart VFDs (Fibre Optic connection + PSU for comms boards)
•Flow Meter if above 70 l/s (PumpSmart derived if below 70 l/s)
•No Flow Switches or CTs
•PumpSmart controls forward and reversing.
•PumpSmart can deliver to consented Forward Flow
Design Equipment FeaturesStandard Features APP700•Local Display (Menus, Level etc)
•Password Protected
•LED display for pump status
•Simple Menu Structure incl start / stop levels
•Pump Alternation
•Remote Control
•Expandable
Standard Features ATU Gateway•PSTN or GSM modules available
•WITS DNPv3, DL/FSK protocols
Design Equipment Features
Advanced Features APP700
•Pump Condition
•Internal Flow Calculation
•Overflow Monitoring
•Low Flow Monitoring
•Energy Monitoring
•Pump Cleaning
•Sump Cleaning
•Service Interval
•Web Server
Design Equipment Features
PumpSmart Features
•All Standard VFD Functions
•Pump Protection (Min Speed, max Torque)
•Pump Efficiency
•Intelligent Features
•Forward Flow
•Pump Cleaning Cycle
•Data communication (Modbus, Profibus, Fibre Optic)
Design Equipment Features
PumpSmart Intelligent Features•Meterless Flow (VFD matched to Pump Curve)•Smart control •Integrated PID •Multi-pump control •Caviation control•Flow economy
Design Equipment Features
PumpSmart - Forward Flow
•Meterless Flow + Multi Pump Control•Set Forward Flow in PumpSmarts•Adjust pump speed to match the system demand over the Pump Cycle Level.•20% of Pump Best Efficiency Point
Design Equipment Features
PumpSmart - Pump Cleaning CycleIntegrated logic that monitors for clogging of the pump. Upon detection:• Pump automatically stops, runs in reverse rotation to remove blockage
• Two reverse run sequences for 30 seconds• Cleaning sequence may be run manually as well or on a timed basis.
Spee
d
Design Equipment Features
PumpSmart System Data
Provides the data to the APP700, gateway for:
Actual Flow
Current (No CTs required)
Speed
Frequency
Torque %
Cost Saving
During the review of the existing designs being produced by Partners / Contractors, the Estimating Team produced a cost comparison between the current design and the development being undertaken.Cost comparisons were carried out extrapolating the cost saving realised at one site based on change from the original design to a conventional design to the Xylem solution design.
Cost Saving to United Utilities in Capex Cost of 39% from the original design to the Xylem solution with added functionality.
Cost Saving
Other Potential Cost Savings• Reduce and simplify the planning permission process, significant
estimated saving. • Reduction in the kiosk size, cost saving on actual kiosk and civil
requirements.• Operational and Maintenance of the equipment.• A standard Solution Scope Book will be produced with site
specific requirements being the only required changes, thus reducing Engineering costs by a significant amount.
Conclusion
The Project Objectives were:
• Reduced size
• Cost savings
• Simplicity in operation
• Compliance with United Utilities Specifications for Operation and remote control and monitoring requirement for Pumping Station and Detention Tank Control Panels