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