CONTROL

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CONTROL MONITORINGPUMPSTATIONS
Techsys Corporation
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CONTROL MONITORING

• CONTROL
• Getting the pump to do what is required
• MONITORING
• Overview of operation

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PUMPS SO SIMPLE ?

• Pumps are probably the most simple piece of
  machinery in the workplace but the most probable
  to break down.
• This is 99 due to
• APPLICATION
• CONTROL
• Good Application and Control will allow a pump to
  operate for the full design life Generally
  15,000 hr depending upon the specific job

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What Control Parameter ?

• PRESSURE
• Provides the ability to sense the load
• Easy to sense
• Provides a full picture of the system load via
  the system curve
• Suits over 90 of applications

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Pump Curve
Static Head
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Typical Control Parameters
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BASICS

• VARIABLE SPEED PUMPING is only advantageous when
  there is a
• VARIATION in the FLOW
• demand of a system
• If the system is fixed flow with no variations
  the VFD pumping is not beneficial

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VFD Vs PRESSURE SYSTEM

• VFD System can vary the flow efficiently over
  most of the pump curve

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VFD Vs PRESSURE SYSTEM
Starting costs become significant at high cycle
rates
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DIFFERENT TYPES OF VFD CONTROL SYSTEMS

• Three types of VFD pump control
• On pump control Motor VFD
• Lead VFD backup soft start
• True VFD VFD rotates to all pumps.

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ON MOTOR VFD

• Neat Engineering solution
• Purpose built Inverter for pumps
• Very compact

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ON MOTOR VFD

• Suffer from Vibration and
• overheating
• Replacement components can
• be difficult to source
• Multi mump co-ordination
• difficult

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ONE VFD PER PUMP

• Operational VFD on each pump
• When extra pumps are required the system calls in
  additional VFD/Pump combinations
• The system can have all of the VFDs functioning
  at a speed
• All pumps vary the speed together

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ONE VFD PER PUMP

• Most expensive option
• Pumps operate furthest from B.E.P. as the load is
  shared on all pumps
• Tight control difficult
• Does not justify extra expense for risk
  management

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LEAD VFD - LAG SOFT STARTER

• Multiple pump
• First pump started is the VFD pump
• Lag pumps operate on fixed speed
• Set point 20

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LEAD VFD - LAG SOFT STARTER

• System pressure can
• Spike at changeover
• Requires rapid reaction
• time at changeover
• Needs damped reaction
• at operating set point
• Basic instability at
• SET Point

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ROTATING VFD SYSTEM

• VFD starts on First pump
• As the load increases the First pump is switched
  to fixed speed
• The second pump starts on VFD etc.

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ROTATING VFD SYSTEM

• Smoothest operation
• Best set point holding characteristics
• Lowest starting current
• Softest on pumps and reticulation

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WHY MULTI PUMP SYSTEM ?

• CAN HOLD BEST
• EFFICIENCY POINT
• OVER A GREATER RANGE
• MORE ECONOMICAL FOR THE FULL RANGE OF FLOW RATES
• COST OF COMPONENTS (VFD AND SWITCHGEAR) LOWER FOR
  SMALLER POWERS
• SEAL COOLING CONSIDERATIONS FOR MINIMUM FLOW RATES

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MULTI PUMP
Efficient Range 60-100 of design flow
rate If the flow span is greater than this then
the system is operating outside best efficiency
50
40
60
70
Pump curve
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MULTI PUMP
Pump Head
50
40
50
40
60
60
70
70
Efficient Range 30-100 of design flow rate
with multiple pumps
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RISK ANALYSIS OF SYSTEMS
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CURRENT DRAW FOR VARIOUS SYSTEMS
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SUMMARY

• VFD Systems are ideal for pumping with
• systems that have variable flow rates
• Variable speed systems generally operate best
  with Pressure control
• Multiple pumps typically are most efficient and
  are the least expensive
• Use a Brand Name control system

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PUMP CONTROL
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STAND ALONE PUMPSTATION

• Nearly all pumpstations operate on a site
  specific capacity.
• Some operators need to see what is going on

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BASICS

• FAULT MONITORING
• OPERATING
• POWER AVAILABLE
• RUN HOURS

• To keep the service operating

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CONTROL PROGRAM
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LOCAL CONTROL
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COMMUNICATIONS PROTOCOLS

• All communications between devices require that
  the devices agree on the format of the data. The
  set of rules defining a format is called a
  protocol. At the very least, a communications
  protocol must define the following
• rate of transmission (in baud or bps)
• whether transmission is to be synchronous or
  asynchronous
• whether data is to be transmitted in half-duplex
  or full-duplex mode

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STANDARDS AUTHORITIES
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TCP IP

• Transport Control Protocol - provides connection
  oriented transport services host-to-host
  (end-to-end) across the internet.
• Internet Protocol - used for routing

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MARLIN SHUTDOWNROUTINE
NO FLOW IS CALCULATED FROM THE INPUT SHUTOFF
HEAD OF THE PUMP
FULL SPEED
THE PUMP STATION WILL ONLY SHUT DOWN IF

• THE PUMP IS AT MINIMUM FREQUENCY

SETPOINT

MINIMUM FREQUENCY

• THERE IS ONLY ONE PUMP RUNNING

PRESSURE

• THE DELAY TIMER HAS TIMED
• OUT

LOW FLOW WILL NOT SHUT DOWN
FLOW
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MINIMUM FREQUENCY
Minimum frequency calculation
AFFINITY LAWS
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FRICTION LOSS COMPENSATION

• Increases set point with flow
• Linear relationship between flow and pressure
• Calculated between min frequency and full speed