We undertook the implementation of the pumping station modernization project. We are an intregator company, i.e. we have the appropriate certificates and resources to implement Wonderware solutions.
The scope of activities of the Control-Service company included the electrical design and I&C, the implementation of a control and visualization system based on the Wonderware System Platform for two directions of water transmission: pumping direction – Dąbrowa Górnicza and a new pumping direction – Jaworzno (newly built power unit J910).
The first stage of the pumping station modernization was the implementation of changes to the control system for four 1.6 MW 6 kV pumps for the direction of Dąbrowa Górnicza, which supplies water to plants such as ArcelorMittal Poland, JSW Koks SA Oddział Koksownia Przyjaźń and Saint-Gobain. The second stage was the implementation of a completely new system of four 355 kW, 690 VAC pumps, the task of which is to supply the newly built largest power unit in Poland with supercritical parameters (i.e. those above which water is only in the gaseous state, which increases the efficiency of 37% -41% to 46% and reduces carbon dioxide emissions).
In the next stage, Control-Service delivered, executed and launched a control and visualization system based on the 2014R2 Wonderware System Platform for the direction of Dąbrowa Górnicza.
This system manages the operation of four 1.6 MW 6 kV pumps, field fittings (flow meters, dampers, etc.), MV switchgear (switching on / off appropriate devices) and a 1.6 MW, 6 kV converter (communication via Profinet network, synchronization with the network during switching from mains to drive and from drive to mains). The system allows the pumping station to work in both manual and automatic mode.
The main operating parameter of the pumping station is the level of the Łosień reservoir. The level of the reservoir is sent via the GSM network from Dąbrowa Górnicza to Jaworzno. On its basis, the dispatcher controls the operation of the pumping station in such a way as to maintain the appropriate level of the tank. The process can also take place automatically without the participation of the dispatcher. The system allows the operation of one converter with four MV pumps in the so-called cascade of pumps.
Example: We turn on the pump No. 1 from the converter, after the start-up – if the level of the tank is not sufficient, the second pump can be turned on. When the dispatcher or the system gives a command to turn on the pump No. 2, the converter is synchronized with the mains and the system switches the first pump to mains operation, and the converter switches to operation with the second. The rotation algorithm implemented in the control system ensures even wear of the pumps.
For the direction of Jaworzno, the Control-Service company delivered, made and launched a control and visualization system based on the 2014R2 Wonderware System Platform. This system manages the operation of four 355 kW 690 VAC pumps, field fittings (flow meters, dampers, etc.), LV switchgear. It allows you to work in the direction of Jaworzno in both manual and automatic mode. The main operating parameter for the Jaworzno direction is to maintain the pressure at 8 bar. Each of the four pumps has its own frequency converter, which allows for effective, smooth and trouble-free control of the pumping station.
The applied controller ensures precise regulation of flow, pressure and level control, and the frequency converters used, dedicated to work in water and wastewater management, are characterized by a very high efficiency of 98%, which allows you to save up to 25% of investment costs in the first year of system operation.
One of the most important functions of the converter is work in the so-called Master/Follower mode, change of the guide pump (after a specified time, we change the pump to even wear of all pumps in the system), auto-tuning of 4 PI regulators, flow compensation, no flow detection, sleep mode, decontamination function, pipeline filling mode . The converter has a built-in DC choke that reduces THDi to 40% and an RFI filter that reduces electromagnetic interference.