WET News

| ASSET mAinTEnAnCE Collaboration drives efficiency When Trant Systems Electrical (TSE) was awarded a £1M SCADA upgrade project at wastewater pumping station in Portsmouth, it collaborated with Tata Consultancy Services to help deliver the complex scheme. TSE, A DiviSioN of Southampton-based Trant Group, is a control systems specialist in the design and custom-build of high-quality control panels, motor control centres and automation systems. It has a challenging brief − the refurbishment and upgrade of the site-wide SCADA at Eastney WPS at Portsmouth for BTU, a Southern Water Tier 1 contractor. World-class efficiency inevery inevery wastewaterproduct The Heart of Your Process The ABS EffeX Revolution started with a pump. As the first submersible equipment with an IE3 motor, the ABS submersible sewage pump XFP offered worldclass energy savings already in 2009. Now the ABS EffeX range is complete – making premium efficiency available in all key applications. 2011.06.23 980.3 05:56:19 Low level 1.55 m l/s 0A 352.5 A 0.15 kWh/m3 PUMP 1 1827 l/s 353.8 A 354.1 A PUMP 2 1 ,. 4 ghi 7 PUMP 3 CA 511 3 0 MAIN 07:25:58 STATUS 07:28:10 SETTING TREND m P3 P4 P1 P2 07:30:26 ALARM PUMP 4 pqrs * 2 abc 5 jkl 8 Revolutionary Energy Savings With a full range of premium-efficiency wastewater products, you can save energy throughout collection and treatment. Individual ABS EffeX products save as much as 25-30%, which makes all the difference at today's energy prices. 3 def 6 mno 9 tuv wxyz 0 # ACKN. Esc Pumps, mixers, compressors and control that save energy – plus time and money 8 | WET News | January 2014 Sulzer Pumps www.sulzer.com Need proof? Scan the QR code or visit www.ABSEffeX.com Refurbishment of diesel engine control panels at Eastney WPS Southern Water's wastewater headworks and pumping station at Eastney has been in operation since 1868. The James Watt & Co. beam engine pumps of 1887, housed in the original Victorian engine house, were replaced with diesel engine-powered pumps in 1954 and preserved as museum pieces. In 2011 TSE replaced the 6nr diesel engine control panels as part of the ongoing asset improvements on site. A standard asset provider to Southern Water, TSE chose to utilise the expertise of Tata Consultancy Services (TCS) to assist with the upgrade and enhanced serviceability of this highly complex project. TCS is an IT services, consulting and business solutions organisation that delivers real results to global business. TCS offers a consulting-led, integrated portfolio of IT, BPO, infrastructure, engineering and assurance services. This is delivered through its unique Global Network Delivery Model, recognised as the benchmark of excellence in software development. A part of the Tata group, India's largest industrial conglomerate, TCS has more than 276,000 of the world's best-trained consultants in 44 countries. Tim Bullen, divisional manager of TSE, says: "We are again delighted to be collaborating with TCS on this project and we are totally committed to ensuring a successful outcome for this very challenging brief. We are striving to help our client achieve the required efficiencies within the AMP5 works programme by embracing the proven and effective onsite and offshore model of delivery with the help of TCS." Eastney WPS had a new control system installed in the early 1980s, of which this project automated the site and its automatic plant. The system employed at the time was the Alstom Gem80 platform extensively used in industrial automation. Around 2001, three new SLC PLCs were installed on the LSO MCC, High Lift Storm MCC and Fort Cumberland to further automate the plant and additional processes associated with them. These MCCs were added in conjunction with a larger project name PortseaClean, designed to send storm flows to Budds Farm WTW from Eastney WPS for treatment and to return treated wastewater from Budds Farm to Eastney to be released out to sea. At the Eastney site the PLC hardware is now predominately of two variant types, these being GEM80/131 and GEM80/400s; and Allen Bradley SLC 5/05s. Each of the Gem80s is connected to one other to form a communications network via an existing GEMLAN-T Ethernet network. The existing SCADA visualisation system, Imagem, is connected locally to the site master PLC via RGB cable. The existing SLCs are connected via a more recent (circa 2000) fibre-optic, Ethernet-based system. The site processes were controlled by 17 individual PLCs. Following a detailed study of the existing systems at Eastney, the following upgrades and refurbishments were identified: The upgrade to a modern serviceable system that is easily maintained, ensures reliability and easily allows future expansion, additions and modification in the future. The control philosophy contained within existing GEM80 PLC code was reverseengineered and re-implemented in Rockwell Allen-Bradley Control Logix PLCs. A new integrated Wonderware InTouch SCADA system replaced all existing SCADA/ HMI components to provide a single site-wide SCADA system. The proposal re-engineered like-for-like functionality of the existing GEM80/Imagem control system in modern PLCs and SCADA and was MEDscompliant as far as practicable. Commissioning comprised a rolling programme over a period of 12 months, phased by process area in order to manage risk. ■

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