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Pump control system to solve the sewage pumping station blockage problem
Prior to installing Retroflo's Sewage Control System, a European sewage pumping station operated at a higher cost despite the latest pump and frequency converter (VSD). Frequent pump blockages often result in downtime. We found that there is a new way to eliminate the clogging, and can greatly reduce operating costs. Skinningrove Sewage Pump Station is located on the scenic northeast coast of England. The blockage of the pump drew the attention of Northumberland Water Company. By introducing Retroflo's pump control system, pumping stations not only reduce clogging but also greatly reduce the pump's energy costs. The pump control system controls the pump station as a whole rather than separating the various components inside the pump station. By continuously monitoring the pump's characteristic parameters dynamically, the system can optimize pumping station performance using all pumping parameters obtained from the Skinningrove pumping station. The system is the first system in the market that combines multiple functions such as early warning of blockage, safety, smart wash cycle, periodic efficiency monitoring and asset data storage. As waste debris accumulates on the blades of the pump, the sewage pump will clog. This will reduce the efficiency of the pump and eventually lead to failure, resulting in time wasted and costly downtime. Pump Control System In the first 12 months after the Skinningrove pump station was installed, a total of more than 1000 routine block pre-tests were successfully performed. All feedback data is used to optimize pump performance, eliminating the need for operator / service personnel to manually remove the blockage. During the initial phase, the pump was also regularly checked and the blade's cleanliness was greatly improved. The improvement of the condition After the pump station is installed with the inverter, the pump control system is installed, mainly to ease the blockage problem. By starting the pump reverse run procedure to detect a partial blockage and return the pump to its optimum operating condition, the energy consumption of the pump during normal operation can be reduced by 12%. This measure saves Skinningrove pumping stations £ 0.45 every 12.2 seconds. This energy savings - plus savings from no downtime - can make the system installation costs quickly recoverable within five years. Retroflo's Smart Rinse Cycle feature also dramatically improves wet well conditions, making the wet well cleaner and therefore alleviating solid deposition and corrosion problems. As a result, the risk of blockage of the pump is reduced and the conventional cleaning procedure is reduced. Improvements at the Skinningrove pumping station include the replacement of the RPC_2000 controller in the existing infrastructure. The patented jamming early warning function allows dynamic monitoring of pump operating parameters. If the system detects abnormal operating parameters of the pump, it indicates that the pump may be clogged and remedial action can be taken at this time. However, after up to three unsuccessful reversals, the defective pump will shut down and stop inefficient operation in order to save operating costs. After the problem pump is shut down, the backup pump will continue to work. The accumulation of waste on the impeller of the pump leads to an interruption of the pumping of the sewage which results in a low pumping efficiency which eventually leads to a shutdown. If the working pump fails, the previously stopped pump restarts and runs to ensure that the pumping station can continue Pumping operation, although inefficient, but to ensure the continuity of pumping. At the same time, the regional remote sensing system will receive an alert informing the operator of the need to take some action. Smart wash cycles can be chosen by volume or time to ensure that the solids deposited are sufficiently diluted to allow the solids to pass. At the same time in order to prevent the deposition of large solids in the well, but also regularly improve self-cleaning rate. This can be done when the electricity bill is low. When the flow meter fails, the factory also optimizes the existing control system. The flowmeter is installed on the processing equipment and the generated flow signal is transmitted to the PLC of the pumping station through the communication network. In the past, when the flow signal sent to the pump station PLC was lost, the pump stopped and prevented the device from operating at an unknown flow rate. At this point the operator needs immediate action to prevent flooding. In the current improved mode, the pump can continue to operate when the meter fails. The working pump reacts to the start-up and shut-down water level set-points of the regular working pump to operate at a selected fixed speed without damaging the equipment. With new operating modes and early warning signals, the factory saved a lot of maintenance costs. Operating principle The pumping station operates in a work / standby mode. When any pump starts running, it runs at full speed for 30 seconds to reach the desired speed for the entire system. The pump was then controlled at a specific speed to maintain a pre-set water level in the wet well-currently 1.6 meters. This method of control perfectly matches the pump's theoretical flow rate with the incoming flow rate to achieve maximum pump efficiency. As the water flow rate increases, the water level in the wet well will also rise. Therefore, the pump speed increases, the delivery flow rate will increase. Retroflo's plug-in preflight system completely eliminates clogging and ensures efficient pump operation. As shown in the figure, this pump is very clean. In the same way, when the water flow rate is reduced, the water level in the wet well will also drop. The speed of the pump slows down and the delivery rate decreases. Working pump speed will be the minimum delivery rate control 60l / s. When the flow rate drops to this setting, the water level in the wet well eventually drops to the level that caused the pump to shut down. The working pump will then run at full speed for 10 seconds to prevent solids from settling and fragmenting into a ball. Then the working pump starts to rotate. Under normal conditions - the working pump is in operation and the wet well level monitored is below the high water level - if the clogging pre-inspection equipment detects that the pump is operating under abnormal operating parameters, remedial measures should be taken: ◆ work Pump down. The system will not pressurize before shutting down to prevent the congestion problem from getting worse. In this case, blocking preflight monitoring does not work. ◆ working pump reverse (60% speed) for 30 seconds, try to eliminate the blockage. After that, the working pump is operating at full speed for 30 seconds. After the normal operation is restored, the jam preflight function is restarted. ◆ If the blockage is still significant, the reversal cycle will take up to 3 attempts and the problem pump will be detected and shut down by the system. The alarm signal is transmitted to the regional remote sensing system. ◆ standby pump to replace the work pump to continue running. If the control system detects that the pump is operating at abnormal operating parameters, a maximum of three reversals are performed and the pump continues to operate. Valid alarms will be transmitted to the regional telemetry system. This shows that although the flow of water will not be interrupted, but the efficiency will decline. This needs to take certain measures to solve this problem. ◆ Whenever a pump is stopped by the system and the running pump fails for any other reason, the stopped pump will be restarted and run by the system without regard to efficiency and cost to prevent damage Continuity of water flow. By controlling the working pump speed, the maximum flow rate is limited to 82l / s. When the flow rate is greater than this value, the wet well level will increase to the "High Water Level" set point. At this time high water level alarm signal will be transmitted to the regional remote sensing system. The jam preflight function fails, while the continuous alarm monitoring function takes effect. The system maintains a flow rate of 82 l / s at high water level. This is to ensure that people pay more attention to the speed of the process during heavy rains, rather than fearing that in the event of a partial blockage, efficiency will decline and operating costs will increase. It is unwise to repeatedly invert under heavy rain conditions, as this increases the risk of flooding. Advantages of the Preflight System Small jams in the pump body may lead to more debris passing, which aggravates the initial blockage problem. The pre-retrofit will only be carried out if the pump can not be continuously transported or the pump protection fails. This can result in downtime, requiring removal of the blockage by removing the pump. Removing smaller debris prevents the formation of large deposits. Within a year, the control system conducted more than 1000 block preflight checks and pump reversals. Not all potential blockages require downtime maintenance, but each reversal will automatically pump back into efficient operation. Eliminate the early blockage, but also to avoid the related security issues. At high water levels, the pump delivery rate is maintained at 82 l / s. Each pump is running at its best, 96% of the speed to maintain the 82l / s delivery speed, and change is small. Over time, sedimentation will increase, the pump will continue to accumulate debris. Normally (not including high water level conditions), the blockage pre-inspection system detects a partial blockage and performs a reversal cycle; however, if the water flow is continuous, the reversal cycle operation need not be performed because it increases the overflow Danger. As a result, debris continues to degrade the performance of the pump, and the control system raises the pump speed for poor performance to achieve the desired flow rate of 82 l / s. The pump is running at full speed (not 96%). In theory, the reduction of pump power from 100% pump speed to 96% pump speed can be calculated. The calculation shows that a 4% reduction in speed and an actually 12% reduction in energy consumption. Without a clogged preflight system that detects a local blockage, the partially blocked pump will eventually run at maximum speed. This condition can only be detected in the event of major blockage and downtime. Blocking preflight ensures that the pump can operate efficiently at all times while reducing the risk of downtime. (Pump control system to solve the problem of sewage pumping station blockage)