Control Unit Cleanses Pumps and Prevents Blockages

Control Techniques offers the Intelligent Pump Control (IPC) system as a comprehensive answer to ragging, a problem suffered by water companies where pumps in wastewater systems become blocked. Manual clearing is a costly and unpleasant task, requiring a maintenance team and frequently a crane. Downtime may extend to several days, during which time the back-up systems are under additional pressure.

A total system failure can result in effluent leakage with implications for the environment, human health, clean-up costs and breaches of legislation. Control Techniques offers the Intelligent Pump Control (IPC) system as a comprehensive answer to ragging, delivering measurable improvements in pump reliability, uptime and performance. As well as saving money in operating expenses, IPC system installations have also produced energy savings of up to 15 per cent due to the improved running efficiency of the pumps.

Unlike competitor's systems that measure the motor's nominal current, which can give an error of up to 30-40 per cent for required effective monitoring of impending ragging, IPC measures 'live' active current in real time, on-board the drive. As soon as IPC sees a change in the active current set profile, an automated cleansing cycle is initiated to clear the pump impeller. Over three years Control Techniques has built up a successful base of IPC applications with several of the Major UK water companies as well as installations in Ireland.

Control Techniques' IPC system accurately monitors pump performance, including flow and pump speed where appropriate. The live data is compared to measured values taken during commissioning, plus expected pump profile characteristics. Any out-of-profile performance is instantly detected, giving an early warning indication of ragging. Should the pump's out-of-profile performance extend the profile settings, an automatic drive-based cleansing cycle is initiated to clear the pump impeller.

The system is totally embedded within the drive itself, eliminating the need for external programming (PLC), monitoring or control equipment. Control Techniques has developed two levels of IPC functionality; IPC Lite and IPC Pro, to meet the needs of the broadest range of pump applications. IPC Lite provides ragging detection and cleansing at low cost on pumps rated at less than 132kW. IPC Pro provides full-featured multi-pump control for pumps rated to 1.9MW, with anti-ragging programme, duty control, fault status and back-up, 'dry run' protection and cleansing routines.

It is compatible with telemetry systems and has a watchdog alarm feature. Options include HMI, which provides customers with a clear window on the pumping control operations and also an instant data-logging facility for pump efficiency and energy usage; Ethernet TCP/IP-based solutions for remote monitoring and operation; and drive-based remote telemetry station capability.

As well as detecting and preventing ragging, IPC systems also provide several other intelligent performance optimisation functions, such as surge prevention to protect rising mains power and wear monitoring of pumps. The system also detects low flow in dry run conditions. In the unusual event of a major blockage that cannot be automatically cleared, a system lock-out and sounding of a telemetry alarm prevents successive cleansing routines from occurring in order to protect the pump.

Comments

Post a Comment

Popular posts from this blog

FUSE SIZING CONSIDERATIONS FOR HIGHER EFFICIENCY MOTORS

Image
When selecting the proper fuse for short circuit protection in motor starting applications, it is important to not only ensure that the fuse will not nuisance open during motor start up times, but also that the fuse will coordinate as required with overload relays. When sizing fuses between 125% and 150% of the motor nameplate current, several advantages, including ease of coordination with an overload device, a smaller disconnect, and increased short circuit protection from a lower fuse rating, can be achieved. However, if sizing at this level prevents the motor from starting, it may then be necessary to increase the fuse ampere rating and it then becomes important to know the NEC sizing limitations. As of June 1, 2016, the US Department of Energy has mandated that newly manufactured electric motors will need to meet NEMA Premium® efficiency standards. As motor efficiencies increase, motor locked rotor currents can also be expected to increase. In addition to this, with across-the-lin
Read more

What is Class I Division 2?

Image
A Class I Division 2 is a location: (1) In which volatile flammable gases, flammable liquid-produced vapors, or combustible liquid-produced vapors are handled, processed, or used, but in which the liquids, vapors, or gases will normally be confined within closed containers or closed systems from which they can escape only in case of accidental rupture or breakdown of such containers or systems or in case of abnormal operation of equipment, or (2) In which ignitable concentrations of flammable gases, flammable liquid-produced vapors, or combustible liquid-produced vapors are normally prevented by positive mechanical ventilation, and which might become hazardous through failure or abnormal operation of the ventilating equipment. Class I Division 2 Classification Class I Division 2 refers to the ANSI/ISA 12.12.01 standard. This standard was previously UL1604 until UL recommended the newer ANSI/ISA standard be used and that all hazardous location products be certified under this standa
Read more

7/8 16UN Connectors that Provide 600 Volts and 15 Amps

TURCK announces new A-Size 3 and 4-pin 7/8 16UN powerfast™ connectors that provide up to 600 Volts and 15 Amps of power. These IP67 rated connectors provide a modular wiring system designed to handle high current applications for machine power distribution, while providing resistance to vibration commonly associated with conveyors, motors and material handling applications. The cordsets are available with a tray rated, exposed run PVC flexlife ® cable, with or without STOOW rating, and 14 AWG wires that allow you to replace hard wiring with a robust, quick disconnect system that saves the time and money spent installing a conduit system. The A-Size powerfast line offers male and female, straight connectors, standard and custom lengths, and pigtails or extensions. To make the system complete, fully encapsulated mating receptacles, with 1/2”-14 NPT mounting threads are available.
Read more