Modernization of the PUW Pumping Station – Siemens Control System and Wonderware System Platform
Supply and commissioning of four 400 kW Danfoss variable frequency drives
We completed a pumping station modernization project for PUW HKW Sp. z o.o., delivering a control system based on Siemens PLCs and the Wonderware System Platform. As a certified system integrator, we possess the expertise, certifications, and resources required to implement Wonderware solutions in demanding industrial and water & wastewater facilities.
The project scope also included the supply, configuration, and commissioning of four 400 kW Danfoss variable frequency drives, as well as the modernization of control and visualization systems for two independent water transmission lines.
Goals
- Ensuring high-quality drinking and industrial water supply
- Improved control over pumping processes
- Enhanced operational efficiency
- Increased reliability of water infrastructure
Challenges
- Modernization of the control and visualization system
- Modernization of the pumping equipment infrastructure
- Integration of existing and newly installed pumping systems
- Ensuring reliable operation of two independent water transmission lines
Solutions
- Wonderware System Platform
- Wonderware InTouch visualization system
- Siemens PLC controllers
- Danfoss variable frequency drives (4 × 400 kW)
- Electrical and I&C (Instrumentation & Control) engineering design
- Communication with a 1.6 MW / 6 kV drive via the Profinet network
Benefits
- Improved efficiency of water production and distribution processes
- More user-friendly monitoring and control system operation
- Reduced electrical energy consumption costs
- Precise control of flow, pressure, and level parameters
- Support for both manual and automatic pumping station operation
- Balanced pump utilization through automatic rotation algorithms
Project scope
The Control-Service project scope included electrical and I&C (Instrumentation & Control) engineering design, as well as the development of a control and visualization system based on the Wonderware System Platform for two water transmission routes:
- Dąbrowa Górnicza pumping route,
- the new Jaworzno pumping route, associated with the construction of the J910 power generation unit.
The first stage of the modernization involved upgrading the control system for four 1.6 MW / 6 kV pumps serving the Dąbrowa Górnicza route. This route supplies water to major industrial facilities, including ArcelorMittal Poland, JSW Koks S.A. – Przyjaźń Coking Plant, and Saint-Gobain.
The second stage involved the implementation of a completely new pumping system consisting of four 355 kW / 690 VAC pumps. The purpose of this installation was to supply water to the newly constructed power generation unit in Jaworzno, operating under supercritical steam parameters.
Visualization of the pumping station medium-voltage switchgear developed in Wonderware InTouch
Control system for the Dąbrowa Górnicza transmission route
Control system for the Dąbrowa Górnicza transmission route
For the Dąbrowa Górnicza route, we delivered, implemented, and commissioned a control and visualization system based on the Wonderware System Platform 2014 R2.
The system manages the operation of four 1.6 MW / 6 kV pumps, field instrumentation including flow meters and butterfly valves, the medium-voltage switchgear, and a 1.6 MW / 6 kV variable frequency drive. Communication with the drive is established via the Profinet network. The system also handles synchronization during transitions between grid power and VFD operation, as well as switching from the VFD back to the power grid.
The pumping station can operate in both manual and automatic modes.
The primary operating parameter of the station is the water level in the Łosień reservoir. Reservoir level data is transmitted via the GSM network from Dąbrowa Górnicza to Jaworzno. Based on this information, the dispatcher controls the pumping station to maintain the required reservoir level. The process can also be carried out automatically without operator intervention.
The system enables a single variable frequency drive to operate four medium-voltage pumps in a cascade configuration. After the first pump is started by the drive, if the reservoir level remains below the required value, the system can start an additional pump. In such a case, the drive is synchronized with the power grid, the first pump is transferred to grid operation, and the drive takes control of the second pump.
The implemented pump rotation algorithm ensures balanced equipment utilization and contributes to the long-term reliability of the entire system.
1.6 MW / 6 kV variable frequency drive, with part of the medium-voltage switchgear visible in the background
Control system for the Jaworzno transmission route
Control system for the Jaworzno transmission route
For the Jaworzno route, we designed, implemented, and commissioned a control and visualization system also based on the Wonderware System Platform 2014 R2. The system manages the operation of four 355 kW / 690 VAC pumps, field instrumentation, flow meters, butterfly valves, and the low-voltage switchgear.
The system supports both manual and automatic operation of the Jaworzno pumping route. The primary control objective is maintaining a pressure level of 8 bar. Each of the four pumps is equipped with its own variable frequency drive, enabling smooth, efficient, and stable operation of the pumping station.
The implemented control system provides precise regulation of flow, pressure, and level parameters. The variable frequency drives selected for water and wastewater applications offer efficiency levels of up to 98%, significantly reducing electrical energy consumption and operating costs.
Variable frequency drive features
In this project, we utilized a range of variable frequency drive features designed to support reliable and energy-efficient pump system operation. Key functions included:
- Master/Follower control mode
- Automatic lead pump rotation
- Balanced pump utilization across the system
- Automatic tuning of four PI controllers
- Flow compensation
- No-flow detection
- Sleep mode operation
- Pump cleaning (de-clogging) function
- Pipeline filling mode
The drives are also equipped with an integrated DC choke, reducing THDi to 40%, and an RFI filter that minimizes electromagnetic interference.
Summary
The modernization of the PUW HKW Sp. z o.o. pumping station resulted in improved efficiency of water production and distribution, enhanced process control, and reduced electrical energy consumption costs. By implementing Siemens PLCs, the Wonderware System Platform, and Danfoss variable frequency drives, we delivered a modern, scalable, and user-friendly pumping station control system.
The implemented solution ensures reliable operation of both pumping routes, precise control of process parameters, and flexible station management in both manual and automatic operating modes.
