Pumping station modernization – Siemens S7-1500 control system and Wonderware InTouch visualization
As part of the pumping station modernization, we implemented a control system based on the Siemens S7-1500 controller and a visualization system using Wonderware InTouch. The scope of work included system deployment, on-site commissioning, staff training, and technical support.
The project focused on a soft-start system for 1.6 MW / 6 kV pumps, which were previously connected directly to the power grid. To reduce inrush current and minimize mechanical wear, a medium-voltage soft starter rated at 1.6 MW was implemented. The system enables controlled starting of four pumps, depending on their availability and current demand.
Goals
- Ensuring soft start of 1.6 MW / 6 kV pumps using a soft starter
- Improved control over technological processes
- Increased operational efficiency
- Ensuring full availability of the facility as an emergency pumping station
Challenges
- Modernization of the control and visualization system
- Upgrading the pump starting system
- Ensuring reliable operation of the standby pumping station
- Reducing electrical and mechanical stress during motor start-up
Solutions
- Wonderware System Platform
- Siemens S7-1500 controllers
- Medium-voltage soft starter for 1.6 MW / 6 kV pumps
- Local operator workstation for system control and start-up operations
Benefits
- Improved pumping station efficiency
- Easier monitoring and control system operation
- Reduced electrical energy consumption costs
- Smooth pump start enabled by soft starter technology
- Reduced mechanical wear of equipment
- Increased availability of the pumping station in emergency operation scenarios
The key objective of the project was to ensure a safe and stable start-up of high-power pumps. Previously, direct connection to the power grid resulted in high inrush currents and increased mechanical stress on the system. The implementation of a medium-voltage soft starter allowed us to mitigate these effects and improve overall operating conditions of the equipment.
Smooth start-up was particularly important in this project, as the pumping station serves as a standby facility. In the event of a sudden failure, it must ensure full availability and rapid start-up capability. Therefore, the pumping station control system was designed with a strong focus on reliability, clear operability, and precise monitoring of equipment status.
The project included the implementation of a control system based on Siemens S7-1500 controllers and a visualization system using the Wonderware System Platform and Wonderware InTouch environment. The modern visualization provides an accurate representation of the entire facility, including pumps, valves, power switchgear, and key installation components.
System start-up and operation are performed from a local operator workstation. This provides operators with convenient access to pump station operating parameters, equipment status, and critical information required for rapid response in emergency situations. The modernization improved energy efficiency, operational safety, and the availability of the pumping station as an emergency facility.
