Network Pumping Stations & Detention Tanks Company Wide Standard - PowerPoint PPT Presentation

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 The current installations had: • 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….

Introduction …. An output of • 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….

Introduction •3 No. 24kW VFD’s •Vac Flush System •1 No. DOL Pump Kiosk for:

Introduction and…. MCC for: •3 No. 24kW VFD’s •1 No. DOL Pump •Vac Flush System •ICA Section

United Utilities Objectives Project 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 Output The 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. operation bands) • Separate distribution board (smaller off the shelf item) • Separate Mains / Diesel Generator change over panel (not all sites require unit and allows standardisation of Control Panel/MCC)

Initial Output The 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 U/S PLC Controller Telemetry INCL Modem M&C System Original Design U/S VFDs if Required

Complete Integrated Design APP 700 Incl Telemetry Modem M&C System Serial Link U/S Level Sensors New Design PumpSmart (if required)

Complete Integrated Design Dual VFD station with: Dual Fixed speed station: 2 No. PumpSmart Drives 1 No. APP700 / Gateway 1 No. APP700 / Gateway Wet Well level Detection Wet Well & Destination 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 Features Standard 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 Cycle Integrated 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. Speed

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