Management system solves pump run-time issues

Problem
The City of Winter Park, Fla., was experiencing excessive pump run times and unacceptable pressures because of multiple lift stations pumping into a single force main.

Solution
The city implemented Symphony – Harmonious Pump and Flow Management from Data Flow Systems, which coordinates the systemwide operation of lift stations to reduce force main pressures and equalize flow. It corrects the random operation of stations and synchronizes pumping on a minute-by-minute basis.

Result
The city significantly reduced energy costs and resolved its daily peak flow and pressure spikes. Research continues to improve the pumping algorithm and enhance the gains. Initially, average run-time reductions were 24 percent and the energy cost reduction was 39 percent. Recent run times are reduced 34 percent and energy costs 42 percent. 321/259-5009; www.dataflowsys.com.

Radio telemetry keeps sanitary district usage data in order

Problem
The Parkland Sanitary District No. 1 in South Range, Wis., extended low-pressure sanitary sewers to nearly 350 rural customers, many of whom had failing onsite wastewater treatment systems. Officials required a volume-based method for billing customers, rather than a flat fee.

Solution
Each customer has a pump monitored in real time for status, and the volumes pumped are measured and recorded. A SCADA system from Energenecs uses a meshing radio telemetry network to upload customer data automatically to a master SCADA computer for automated invoice generation and status monitoring.

Result
The volume-based automated billing system saves the district nearly $25,000 annually in invoice generation, and the telemetry provides substantial additional savings in early detection of system troubles. 262/377-6360; www.energenecs.com.

Cellular network provides reliable communication

Problem
The Northwest Bergen County Utilities Authority in Waldwick, N.J., used leased lines to connect the remote terminal units in its distributed pumping stations to the master SCADA system at its treatment plant. The leased lines were unreliable.

Solution
The authority worked with Phoenix Contact and its distributor, GCF of Northvale, N.J., to design a new system that communicates over the cellular network. The new remote terminal units rely on GSM/GPRS Ethernet modems, which establish secure VPN communications through the cellular network and Internet. Each modem also functions as a firewall, protecting the industrial control system from cyber threats.

Result
While the authority added a Phoenix Contact FL mGuard router as a back-up communications path, the cellular network has proven reliable. The new RTUs work with the existing Wonderware SCADA interface, providing continuity, so that the operators could focus on running their process efficiently, rather than learning new hardware or software. 800/322-3225; www.phoenixcontact.com.

Non-PLC system allows for user installation

Problem
The Lakes Region Sanitary District (LRSD) in Lake County, Ill., needed to replace a failing SCADA system. The integrator was no longer in business, leaving no source for replacement equipment. As units failed, the district lost the ability to monitor its stations, leading to high overtime expenses. The district needed a cost-effective replacement installed and operational as quickly as possible.

Solution
After a public bidding process, the district selected the Scadata-Pac packaged SCADA system from Precision Systems, a non-PLC system. The system’s simplicity allowed the district to install it in-house and save money.

Result
LRSD personnel installed the system on time and under budget. It monitors 20 lift stations with more than 200 inputs, delivering detailed alarm messages to operators’ cellphones and performing complete trending and historical analysis of all connected processes, features not available with the old system. 708/891-4300; www.precison-systems.com.