DWLS Stormwater Transfer

Pump Station at GPM

Generator Property Management (GPM) operates a dirty water catchment reservoir located in a remote location. The stormwater from around 40 acres is channelled into the Dirty Water Lift Station underground reservoir. Once the reservoir is full the pump station automatically transfers the collected water to an 8 ML dam with an oil separator. The pump station is equipped with an 80 kW submersible pump. Due to remote location the pump uses a diesel generator for its power supply. The original setup had a number of challenges. ControlX was engaged to address these challenges.

Challenges

Off-the-grid Location

The pump station remote location lacks 415V power supply and requires a diesel generator.

Overloads on Pump Startups

The diesel generator and the alternator were experiencing overloads during the Direct-On-Line (DOL) starts.

Routine Pump Inspections

Lack of telemetry and the remote location requires technicians to visit the site for constant manual checks and confirmation of pump operation.

Solution

Solar + Generator

A completely autonomous control system was designed to solve the challenge associated with off-the-grid location. A diesel generator was used to start up automatically and power up the pump when the well water reaches the high level. To power the control system while the generator is off, a solar system is implemented. The solar connected to a 12V battery to store the solar energy. It allows the reuse of the stored energy for the system “health” monitoring system during the night and cloudy days.

Modern Power Controls

To reduce stress on the generator’s system during pump startup a 90kW Variable Speed Drive (VSD) was added. The VSD smoothes the startup current and accelerates the pump gradually. The VSD start signal received from a controller via local or remote request. Importantly, the VSD starts automatically once the high level signal is triggered. In addition, the VSD provides important pump motor protections.

Remote Monitoring

A web based control panel was developed to control and monitor the pump station. The panel allows checking the pump state and past or active alarms. The control panel displays important parameters such as fuel level and battery level. Also, the site local control system has a sleep function to reduce power consumption, however the remote control panel is capable of starting the pump remotely without a need to get to the pump station. Once the pump run is requested the system will automatically start the pump at the next wake cycle.

Result

Reduced Maintenance and Operational Costs

By automating the system and enabling remote monitoring, manual site visits are minimised, cutting down on travel expenses and labour costs.

The integration of the solar system and sleep mode minimises diesel fuel usage, reducing fuel consumption and generator wear.

Smoother pump startups decrease the likelihood of equipment damage, lowering maintenance and replacement costs.

System Monitoring using Green Energy

Real-time monitoring of pump status, fuel levels, and alarms allows for quicker response to issues, preventing potential system failures or overflows.

Solar power reduces the dependency on diesel fuel, making the system more environmentally friendly and cost-efficient over time.

This also provides a clean energy solution in an off-grid scenario, reducing the overall carbon footprint of the operation.

Increased System Uptime and Reliability

The installation of the VSD reduces the startup current, minimising generator overloads and extending the generator’s lifespan.

The VSD’s ability to gradually accelerate the pump reduces mechanical stress, leading to longer equipment life and fewer breakdowns.

The solar-powered control system ensures that critical system monitoring is available even when the generator is off, improving overall reliability.

Report abuse