Lift Station Monitoring & Control The process begins here Standards Certification Education & Training Publishing Conferences & Exhibits Speakers: Alan Vance E+H Industry Mgr W/WW Terry Sages Rockwell W/WW Florida Team Lead 2015 ISA Water / Wastewater and Automatic Controls Symposium August 4-6, 2015 Orlando, Florida, USA
Presenter Alan Vance Endress+Hauser Industry Manager W/WW Has worked since 1984 in process control instrumentation: 7 years with Fischer & Porter 22 years with Instrument rep company in FL 2.5 years as Industry Mrkt Mgr with E+H 2
Presenter Terry Sages Rockwell Automation Florida Water Wastewater Team Leader Rockwell Automation 27 years Last 12 years as Florida W/WW Team Leader 3
Presentation Outline Brief overview of lift stations Hydrostatic pressure sensors for continuous level measurement Ultrasonic level transmitters for continuous level measurement Discussion of pump control software Review and Questions 4
Collection System Series of Lift Stations 5
Lift Station Dry Well / Wet Well or Wet Well with submersible pumps 6
Hydrostatic Pressure Transmitters Housing: max. 22mm Material: stainless steel Typical application: freshwater Housing: max. 1.65 Material: stainless steel Typical application: wastewater Optional bird cage assembly on the bottom for added weight and protection Housing: max. 29mm Material: stainless steel covered with a shrink hose out of Polyolefin (no Metal contact with process medium Typical application: saltwater 7
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 and units are field adjustable. Area classification Class 1 Div 1 Low Maintenance Periodic cleaning Simple installation dropped in lift station of stilling well 8
Ultrasonic Level Transmitter (Non- Contacting) Separate instrumentation of sensor and transmitter Measuring range up to 230ft Multichannel, optional up to 6 relays Output 4 20mA HART, optional PROFIBUS Functions for W/WW industry Flow measurement, screen and pump control 9
Ultrasonic Level Transmitter (Non - contacting) Unit monitors the amplitude of the signal at the transducer face When amplitude changes transducer face has build up Unit automatically adjusts power to the transducer face, continuously ensuring transducer face is free of build up. 10
Why Ultrasonic? Non contacting to the process 4-wire transmitter typically can have up to 6 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 11
What is an Automated Pump Control System? A standard pre-engineered package using standard products. A Preprogrammed Application No User PLC programming required! The complete PLC Ladder File is available for download HMI Screens are preprogrammed A complete Panelview (OIT) Component File is available for download A full set of schematics, panel layout drawing, and a bill of material is provided. In CAD format, & PDF. 12
Why Choose open control platform for Pump Control? Tough, Industrially Hardened Components = Proven Reliability You can add your own custom features any time standard ladder logic programming If needed, Parts are Available at your local distributor pretty much everywhere you are. This application is supported by A-B tech support, and can be serviced by A-B field service, or by any qualified System Integrator. 13
Desired Pump Control System Features Setup Wizard for commissioning of a new Station Save/Copy configuration using EEPROM memory cards Advanced Pump Control Function for up to 4 pumps VFD or Starter motor control Flexible RTU function with Ethernet, DF1, Modbus & DNP3 protocol for SCADA & local connectivity Power monitoring when used with VFD control 14
Pump Control Functionality 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 15
Maintenance Features 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 for each motor. 16
Maintenance Features 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. 17
Drawings are provided in PDF and DWG format for schematic and panel layout 18
Summary Continuous Level monitoring and control is replacing on/off type float control. Floats can be used as alarms Hydrostatic Pressure and/or Ultrasonic non contacting are both excellent choices each with some pros/cons. Pump control software is available (pre-written) Thank you for your time! 19
Questions? Standards Certification Education & Training Publishing Conferences & Exhibits 20