Monitoring and control of pumping stations

Monitoring and control of pumping stations

Based on a range of Grundfos products, gain an understanding of how monitoring can improve your pumping station.

Monitoring is an extremely valuable part of a wide range of industrial applications if you want to know what is going on in the system – especially if the installation is underground as is the case with pumping stations. 

In this task, we’ll introduce you to Grundfos’ monitoring and control products and explain how they can add value to your system and help prevent inconvenient incidents like unscheduled downtime. All products integrate perfectly to make installation, commissioning and self-maintenance of the pumps and pit easy, leaving you with a user-friendly solution with obvious benefits. Let’s take a look at the products and their highlights one by one. 

Grundfos Dedicated Controls is an intelligent monitoring and control system with all the functionalities required to operate and optimise a pumping station. Start and stop levels for the pumps can be transmitted from either float switches, an ultrasonic sensor or a pressure transducer. It controls up to six pumps and comes with the following highlights:

• Automatic energy optimisation through continuous adaptation of pump speed according to demand

• Anti-clogging thanks to automatic flushing sequences and reverse rotation 

• Easy commissioning thanks to built-in setup wizard

• Mixer control to help reduce sludge sediment in the bottom of the pit

• And integration to any SCADA system

All of these features contribute to optimising your pumping station, making it both more energy-efficient and more reliable.

The Grundfos IO 113 sensor module is specially designed for the SL and SE wastewater pumps with a very clear purpose: To protect the motor from damage. This is done by continuously monitoring the moisture in the motor, winding temperature and water content in the immediate oil chamber. 

If the moisture, motor temperature or water content in the immediate oil chamber exceed the accepted level, the sensor issues an alert. This means that service can be carried out before a potential breakdown, resulting in reduced downtime and perhaps equally important peace of mind.

Then there is the MP 204 – Grundfos’ electronic motor protection, which protects your motor 24 hours a day. And it also lets you monitor your energy consumption. It prevents damage to the motor and pump by monitoring a range of parameters, including: 

• Overload and underload

• Motor temperature

• Overvoltage and undervoltage

• Power consumption

• Insulation resistance

• Voltage current

• Phase missing

• Phase sequence

 

For instance, if the MP 204 measures a fall in the power factor, it can be an indication that the pump is jammed or clogged up. Or it could be because the impeller is worn and in need of maintenance to prevent a breakdown or potential flooding.

Then we have the Grundfos CUE frequency converter. It’s designed to secure the most energy-efficient operation by automatically adjusting pump speed according to demand. Let’s quickly take a look at how it works. A pumping station’s performance is typically based on a daily profile with peak flows in the morning and in the evening. A frequency converter allows you to control the discharge flow, ensuring that energy isn’t wasted on constant high speed when the flow is low during the day.

Moreover, the CUE frequency converter is pre-programmed. 

This allows you to reduce commissioning time significantly compared to programming a standard frequency converter manually from scratch.

Next up, we have the IO 351 B module. It exchanges digital and analogue signals between the control unit and the remaining electrical system. 

IO 351 B is used for one or two Grundfos wastewater pumps with a fixed speed. Alternatively, it can be controlled by external variable speed drives, such as a Grundfos CUE frequency converter.

Then there is the CU 362, which essentially is the 'brains' of the Dedicated Controls system. Its features include a built-in wizard function, full graphical display, accessible on-site data, dynamic buttons and much more. 

Additionally, there are a number of adaptive functions built into the CU 362 including:

• Energy optimisation

• Grouping of pumps

• Anti-clogging

• And many more…

 

The CU 362 also supports communication with monitoring equipment or other external units using the Communication Interface Module (CIM) through several protocols.

It also allows advanced data communication, both wired and wireless (GPRS and GSM), to BMS and SCADA systems.

Finally, Grundfos Remote Management is an internet-based system for monitoring and managing pump installations – and a cost-efficient alternative to SCADA systems. It provides you with an overview of your wastewater network, presenting you with access to live monitoring and analysis from the comfort of your office.  

So, if your municipality has many pumping stations, you’ll be able to save a significant amount of time – and staffing costs – as manual visual inspections are made redundant.

To recap, Grundfos’ monitoring and control products provide you with immediate access to your system’s data which can:

• Improve energy-efficiency and reliability 

• Reduce or even completely avoid downtime

• Reduce both commissioning and operational costs 

• And generally offer peace of mind since you’ll know what’s going on in your pumping station 24/7