intelligent drive solutions for the water industry

Intelligent Drive Solutions for the Water IndustryUp to 1.9MW

110V / 200V / 400V / 575V / 690V

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Control Techniques high efficiency pump control drive systems - save energy and reduce costs

Water companies are under unprecedented pressure from rising costs associated with maintaining services in line with tighter legislation and increasing energy bills. A further challenge is adapting to more frequent extreme weather events such as severe drought or flooding. Developing strategies to reduce operating costs, optimise the performance of assets and meet the public’s ecological expectations is critical. Control Techniques provide new solutions to enhance connectivity, reduce energy consumption, minimise downtime and to react intelligently to real problems as they occur.

Optimised drive solutions for the water industry

Control Techniques present an innovative approach to managing your clean and waste water assets. We combine high reliability and compact size, together with industry specific features such as real-time Intelligent Pump Control (IPC - anti-ragging program), I/O for instrumentation and TCP/IP based telemetry solutions; all onboard the drive.

Reducing energy costs and improving processes

Installing variable speed drives to control pump flows to match operational demand, can significantly contribute to a reduction in energy consumption and improve process control.

Technical expertise to meet supply harmonics and EMC regulations

In many cases, meeting the regulatory requirements for harmonics and EMC can be demanding, especially in residential locations or for sites far from the electrical sub-station. Control Techniques can provide a range of cost effective solutions to meet requirements for both EMC interference and supply harmonics.


Compact drives with built-in operational redundancy

Control Techniques drives are extremely compact, allowing them to be used for retrofit applications using existing control panels; making them easy to handle for installation and maintenance. Drives above 132kW adopt a modular approach, connecting several units in parallel. This has the added benefit of allowing redundancy to be incorporated.

Direct support and availability, 24 hours a day

24 hour technical support is provided with every Control Techniques drive. Our support engineers have unrivalled experience to solve problems in a wide range of applications. For emergencies we are also able to despatch a wide range of drives from stock 24 hours a day.


Filtration, monitoring& control

Bore hole

Desalination plant

Domestic use

Waste

Waste

Industrial use

Screens

Fine screens Secondary treatment Final settlement

Sludge reception & thickeningSludge de-watering& methane power plant

To land oragricultural fertiliser

Inlet

Pumping station

Storm overflow Outlet

Monitoring control& tertiary treatment

Primary treatment sedimentation

Waste

Water tower

Lake

River

Coagulation

Clean and waste water pumping using drives

Water pumping stations

➜ Variable speed drives for energy efficient pumping ➜ TCP/IP based telemetry for network control and monitoring

Control Techniques’ variable speed drives may be used to control pumps, fans and other motors throughout the water cycle to improve energy efficiency and process control. The diagram illustrates some of areas where Control Techniques offers unique advantages.


Filtration, monitoring& control

Bore hole

Desalination plant

Domestic use

Waste

Waste

Industrial use

Screens

Fine screens Secondary treatment Final settlement

Sludge reception & thickeningSludge de-watering& methane power plant

To land oragricultural fertiliser

Inlet

Pumping station

Storm overflow Outlet

Monitoring control& tertiary treatment

Primary treatment sedimentation

Waste

Water tower

Lake

River

Coagulation

Centralised control

➜ Intelligent water resource monitoring and management ➜ High speed telemetry for drive system monitoring and control

Water treatment

➜ Variable speed drives providing energy efficient operation ➜ Variable flow enabling process optimisation ➜ Precise chemical dosing using variable speed drives

Waste water pumping station

➜ Variable speed drives with Intelligent Pump Control (IPC) anti ragging solution for eliminating pump blockages and energy efficient pumping ➜ TCP/IP based telemetry for network control and monitoring

➡ Untreated fresh water

➡ Treated water

➡ Dirty/waste water

➡ Methane

➡ Semi-treated water


Totally embedded within the drive, Control Techniques have 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 for very little cost on pumps rated at less than a 132kW

➜ IPC Pro

Fully featured multi-pump control with anti-ragging program, duty control, under-load protection and cleansing routines. Compatible with the majority of telemetry systems, a watchdog feature generates an alarm if a problem is detected

IPC Lite

IPC Pro

Single pump ✔ ✔

Configurable cleansing routine ✔ ✔

Integration with telemetry through I/O ✔ ✔

Torque monitoring ✔ ✔

Manual pump control ✔ ✔

Dry running detection * ✔

Multi-pump - Duty Assist control – ✔

Flow monitoring to enhance pump ragging detection – ✔

Configurable pump control logic – ✔

HMI for configuration ** ✔

Ethernet TCP/IP based telemetry ** ✔

Enhanced pump diagnostics

(e.g. pump and bearing wear monitoring)– ✔

* Available as standard on Unidrive SP drive ** Available as option on Unidrive SP drive

Control Techniques’ Intelligent Pump Control (IPC) system delivers measurable improvements in pumping reliability, up-time and performance. In real installations it significantly reduces the costs associated with operating these assets while improving throughput and availability.

Solutions to real problems

Ragging is a long standing pumping problem suffered by water companies, where pumps can be partially or fully blocked in waste water systems. 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’ IPC system accurately monitors pump performance by ‘live’ continuous measurement of torque producing current, plus 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 'out of profile' performance extend the profile settings, an automatic drive based cleansing cycle is initiated to clear the pump impeller.

Control Techniques’ Intelligent Pump Control (IPC) anti-ragging solution


IPC case study Kelly’s Bay, Skerries, Ireland

IPC case study Levenhall SPS, Scotland

Challenge

To dramatically improve the process control of an Irish pumping station with the aim of reducing expensive and time consuming maintenance work. Traditionally the system would run for two weeks and then 3 or 4 call-outs would be required in a week to clear blockages.

Control Techniques solution

➜ Replace existing drive with Commander SK and onboard IPC Lite

Results

➜ System reliability hugely improved with real time detection of problems, customised cleansing cycles, surge prevention and lock-out/alarm facilities resulting in call outs reduced to just one in 6 months

➜ Maintenance costs further reduced with remote performance monitoring by telemetry

➜ Improved energy efficiency reacting instantly to different flow rates, providing rapid payback

➜ Enhanced product life. Previously, main and standby pumps switched fortnightly to spread the load, but now only one pump used around the clock

Challenge

Levenhall SPS was identified as a site which is prone to pump blockages, especially during wet weather, with four foul pumps rated at 43kW each. Often blockages and partial blockages would occur 2 to 3 times each week. Refurbishments and alternative pumps had failed to curb the issue and potential replacement pumps were expensive compared to Control Techniques’ IPC solution.


➜ Unidrive SP with onboard IPC introduced to all four pumps

Results

➜ Control Techniques' IPC solution has eradicated pump blockages and reduced operational intervention by 90%

➜ Energy costs for the pumps have reduced by up to 15%, due to clean pumps drawing lower nominal current

➜ Wear to pump impellers is far less in new system, thus enhancing system component life

➜ Quick return on investment


Control Techniques scalable water pumping solutions

Water treatment case study Mount Titlis, Switzerland

Challenge

To create a highly efficient, environmentally sound and compact water treatment solution for a tourist and leisure site that produces 20,000 litres of sewage a day, located 3,000m high on a mountain peak that is only accessible by cable car.


➜ 6 x Commander SK drives using onboard PID control

➜ 1 x 37kW unit to maintain defined pressure level and flow for ultra filtration

➜ 5 x (1.1 to 4kW) units for high performance biological filtration units

Results

➜ Fully automated plant with outstanding reliability, requiring minor attention and maintenance, with minimal service costs

➜ Real time error detection, with automatic action to prevent blockages and maintain flow rates

➜ Environmentally friendly system, with cleaned water re-used for flushing toilets or to run into glacier

➜ Accurate drive controlled flow rates save energy and extend the life system components

System N

System 2

System 1

Commander SK

AC Motor

Pump

PressureTransducer

In order to supply constant pressure control and realize maximum energy savings, drives have become a standard in water industry pumping. Rather than constantly running the motor at full speed and restricting flow through valving, a drive control system can monitor the pipe pressure and run the motor only as needed at the right speed and power.

Additionally, an intelligent Control Techniques drive can provide useful diagnostic and detection information that will reduce down time and save costs in all water pumping applications from agricultural irrigation to residential and commercial building supply. Advanced flow rate monitoring and error detection software can prevent pump blockages long before they occur.

Control Techniques energy efficient drives offer the following features

➜ Constant pressure control - needed to ensure the pump supplies the demand without over-pressuring the pipe

➜ Maximum energy savings - running the system only when demand requires it (sleep/wake function)

➜ System flexibility - able to be controlled locally via a keypad or remotely through telemetry

➜ Diagnostics for dry well, no flow detection, over pressure, transducer loss etc, to prevent downtime

➜ Fixed speed and constant pressure operation - important for maintenance purposes in the event of a transducer loss


Water treatment case study Mount Titlis, Switzerland

Duty Assist is an effective method of controlling multiple pumps in parallel, to maintain the required process demand.

Pumps and fans are often used in parallel banks to:

➜ Avoid motor overload

➜ Provide security of supply (system redundancy)

➜ Reduce running cost due to system load cycles

➜ Provide wide range of control and flexibility

A typical system consists of a ‘duty’ drive and several assist starters of any type (e.g. D.O.L, star-delta, auto-transformer, soft starter or inverter). The duty drive can control one dedicated motor (fixed duty) or, with additional external switchgear, control other motors within parallel configuration (flexible duty).

The duty is controlled by a PID loop which will maintain the process level required. If the demand exceeds the duty capacity, then the assist starters will be enabled one by one to assist with the delivery until demand is met.

3 Phase Supply

AssistStarter

Control Techniques optional onboard Duty Assist Solutions software

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Control Techniques high performance drives

Unidrive SP

0.37kW – 1.9MW

200V / 400V / 575V / 690V

Unidrive SP is Control Techniques’ flagship AC solutions drive, covering the complete power range and offering maximum onboard intelligence and communication flexibility.

For more information please refer to the Unidrive SP brochure

Commander SK0.25kW – 132kW

100V / 200V / 400V / 575V / 690V

Commander SK is Control Techniques’ simple, low cost drive solution covering a wide part of the power range. Commander SK provides a simple user interface with only 10 settings required for the majority of applications.

For more information please refer to the Commander SK brochure

Control Techniques are also involved in innovative water related power systems, such as the first hydrodynamic screw generator in the UK:

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PC software and Smartcard tools for rapid commissioning

Innovation case study River Dart Country Park, Devon

Challenge

To convert energy generated by a hydrodynamic screw, modelled on the ancient Archimedes design, and provide power for the River Dart Country Park; with no adverse affect on the river’s protected and diverse wildlife.


➜ 1 x 55kW Unidrive SP in braking mode to control speed of system, to maintain maximum efficiency

➜ 1 x 55kW Unidrive SP in regenerative mode to produce electricity

Results

➜ The renewable energy generated is sufficient to power the entire site for more than eight months of the year, even generating excess to export back to the electricity grid when the river is in full flow

➜ The turbine produces an estimated £35,000 worth of electricity a year

➜ Environmentally-friendly solution which generates power even when the river is very low, without harming any of the river life

➜ The River Dart Country Park has won the prestigious Business Commitment to the Environment Award because of its commitment to reducing its environmental impact, with this solution being a key contributor

Smartcard

A memory device supplied with every Unidrive SP. It can be used to back-up parameter sets and PLC programs and copy them from one drive to another.

LogicStick

Onboard PLC and parameter storage/cloning device for Commander SK. Can be used to store IPC Lite software

Achilles UVDB registered

Control Techniques are a fully registered supplier on the Achilles Utilities Vendor Database (UVDB) for the following product/service categories:

1.08.18 Programmable Logic Controllers (PLC’s)

1.24.13 Switchgear - Variable Speed/Soft Driven

1.24.14 Switchgear - Direct Current (DC)

Control Techniques software suite makes it easier to access the drive’s full feature set. It allows you to optimise the drive tuning, back-up the configuration and set-up a communications network. The software tools can connect using Ethernet, Serial, USB or Control Techniques’ drive-to-drive network, CTNet.

CTSoft

A drive configuration software tool for commissioning, optimising and monitoring Control Techniques drives

CTScope

A full featured software oscilloscope for viewing and analysing changing values within the drive. The time base can be set to give high speed capture for tuning or for longer

CTOPCServer

A free of charge OPC compliant server which allows PCs to communicate with Control Techniques drives, using Ethernet, CTNet, RS485 and USB. OPC is a standard interface on SCADA packages and is widely supported within Microsoft products.

© Control Techniques 2011. The information contained in this brochure is for guidance only and does not

form part of any contract.The accuracy cannot be guaranteed as Control Techniques have an ongoing process

of development and reserve the right to change the specification of their products without notice.

* Operated by sister company

DRIVINg ThE WoRLD...

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intelligent drive solutions for the water industry

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