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Lift Station Monitoring& Control – Theprocess begins here

2015 ISA Water / Wastewater and Automatic Controls SymposiumAugust 4-6, 2015 – Orlando, Florida, USA

Speakers:Alan Vance – E+H – Industry Mgr W/WWTerry Sages – Rockwell – W/WW Florida Team Lead

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA 2

Presenter

• Alan Vance –– Endress+Hauser

– Industry Manager W/WW

Has worked since 1984 in process controlinstrumentation:

7 years with Fischer & Porter

22 years with Instrument rep company in FL

2.5 years as Industry Mrkt Mgr with E+H

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA 3

Presenter

• Terry SagesRockwell Automation

Florida Water Wastewater Team Leader

• Rockwell Automation – 27 years

• Last 12 years as Florida W/WW Team Leader

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA 4

Presentation Outline

• Brief overview of lift stations

• Hydrostatic pressure sensors forcontinuous level measurement

• Ultrasonic level transmitters for continuouslevel measurement

• Discussion of pump control software

• Review and Questions

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

Collection System – Series of Lift Stations

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2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA 6

Lift Station – Dry Well / Wet Well or Wet Wellwith submersible pumps

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

Hydrostatic Pressure Transmitters

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• Housing:max. 22mm

• Material:stainless steel

• Typicalapplication:freshwater

• Housing:max. 1.65”

• Material:stainless steel

• Typicalapplication:wastewater

• Optional birdcage assembly onthe bottom foradded weight andprotection

• Housing:max. 29mm

• Material:stainless steelcovered with ashrink hose outof Polyolefin (noMetal contactwith processmedium

• Typicalapplication:saltwater

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

Why Hydrostatic Pressure?

• Simple two-wire devices (10.5-35 Vdc)

• Most are fixed range ie. 0-5 psi, 0-10psi,but some manufactures use HART andunits are field adjustable.

• Area classification – Class 1 Div 1

• Low Maintenance – Periodic cleaning

• Simple installation – dropped in lift stationof stilling well

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2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

Ultrasonic Level Transmitter – (Non-Contacting)

• Separate instrumentation ofsensor and transmitter

• Measuring rangeup to 230ft

• Multichannel, optionalup to 6 relays

• Output 4…20mA HART®,optional PROFIBUS®

• Functions for W/WWindustry

• Flow measurement, screenand pump control

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2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

Ultrasonic Level Transmitter (Non -contacting)

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• Unit monitors theamplitude of the signal atthe transducer face

• When amplitude changes– transducer face hasbuild up

• Unit automatically adjustspower to the transducerface, continuouslyensuring transducer faceis free of build up.

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

Why Ultrasonic?

• Non contacting to the process

• 4-wire transmitter typically can have up to6 relays for pump control (alternating)

• Easy installation

• No maintenance – no wetted parts

• Optional outputs such as Profibus, HART,Modbus

• Sensor has IP68/ NEMA 6P rating

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2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA 12

What is an Automated Pump ControlSystem?

• A standard pre-engineeredpackage using standardproducts.

• A PreprogrammedApplication – No User PLCprogramming required!– The complete PLC Ladder

File is available for download

• HMI Screens arepreprogrammed– A complete Panelview (OIT)

Component File is availablefor download

• A full set of schematics,panel layout drawing, and abill of material is provided.In CAD format, & PDF.

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA 13

Why Choose open control platform forPump Control?

• Tough, Industrially HardenedComponents = ProvenReliability

• You can add your owncustom features any time –standard ladder logicprogramming

• If needed, Parts are Availableat your local distributor –pretty much everywhere youare.

• This application is supportedby A-B tech support, and canbe serviced by A-B fieldservice, or by any qualifiedSystem Integrator.

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA 14

Desired Pump Control System Features

• Setup Wizard forcommissioning of a new Station

• Save/Copy configuration usingEEPROM memory cards

• Advanced Pump ControlFunction for up to 4 pumps

• VFD or Starter motor control

• Flexible RTU function withEthernet, DF1, Modbus &DNP3 protocol for SCADA &local connectivity

• Power monitoring when usedwith VFD control

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

Pump Control Functionality

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Supports the 3 Most Common Pump Station Applications• Lift Station Pumping with Level Control – Water Reclamation• Fresh Water distribution – Pump to Elevated Tank• Fresh Water pressure zone – Pump to pressure setpoint

• Supports analog level sensors and float level sensors• Supports Lead/Lag, and Alternate pump control• Intrinsic Barriers and a backup relay shown in case of control

system failure• Advanced closed loop pressure control• All Interlocks are selectable – overtemp, seal water, &

overpressure + others.• Run timers - resettable and non resettable for each pump• Supports Alarm Dialers, and SCADA communication• Time/Date stamped Alarm Log

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

Maintenance Features

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• Save/Restore VFD parameters for drive replacement• EEPROM backup of all software – No laptop required for

maintenance, and no programming required.• Display of running motor current and voltage for each pump

when VFD is used.• Time/Date Stamp when Generator is running• VFD provides power monitoring faults that are Time/Date

stamped for Overvoltage, Undervoltage, and VFD Fault foreach motor.

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

Maintenance Features

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• All alarms are Time/Date stamped• Both System Alarms, and VFD Alarms are on the same list• Alarms can be configured individually to activate an optional

alarm dialer / pager.

2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

Drawings are provided in PDF and DWGformat for schematic and panel layout

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2015 ISA WWAC SymposiumAug 4-6, 2015 – Orlando, Florida, USA

Summary

• Continuous Level monitoring and control is replacingon/off type float control. Floats can be used as alarms

• Hydrostatic Pressure and/or Ultrasonic non contactingare both excellent choices each with some pros/cons.

• Pump control software is available (pre-written)

Thank you for your time!

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Standards

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Questions?

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