During the design of wastewater treatment pumping stations, ensuring the pumps' full output capacity is paramount. This is the only reliable method for transporting wastewater using gravity. Regardless of technological advancements over the past decade, this core objective has remained unchanged.
Although the pumping station functions remain the same, the operating methods are constantly changing, resulting in a wide variety of plant structures that make maintenance more difficult.
In modern industry, to support and maintain existing technologies, WAGO has developed pump control application software that takes even the smallest details into account.
In Germany, pumping stations, along with streets and railway bridges, are among the most basic forms of public infrastructure. Some of these pumping stations, which have been in operation for over 100 years, have been converted into cultural centers or museums.
Advanced technology is evident in pumping stations: pumps driven by steam engines a century ago are now electrically powered and operate primarily through automation. The development of new impellers and sensors significantly improves output, efficiency, and monitoring capabilities.
However, the modernization and automation of pumping stations have undergone a relatively natural development process over the past decade, which is why we can find a wide variety of automated structures in pumping stations.
This is especially common in large-scale wastewater treatment facilities, such as a 70 -pump station operated by an operator that may use pumps or generators from three different manufacturers and be regulated by three or four different control systems.
Modernization brings opportunities
Standardizing pump station hardware and software during modernization can bring unlimited opportunities. Typically, generators and other mechanical components are retained during the modernization process, while sensors, electronic devices, and automation equipment are replaced.
However, this is practically difficult to achieve because most operators modernize pump stations in phases. Instead, system operators tender for modernization in groups of 20 pumps.
Even if operators want to modernize the pumps to the same system and specify the software to be used in their bids, it is impossible to ensure that the software in the equipment is programmed in a similar, standardized way because different engineers or programmers write different software or code.
For operators, the worst thing is that maintenance costs are just as high as modernization costs, because during maintenance or repair, service technicians need to check the programming of each controller individually to find potential problems.
Sophisticated software enables standardized control
To reduce these costs, WAGO has developed specialized application software to control the pumps. In addition to providing basic functions, it also allows for flexible parameter settings. Furthermore, configuring variables within the software eliminates the need for programming, significantly reducing software design costs.
Leveraging the WAGO-I/O-SYSTEM 750 's more than 500 I/O modules and numerous interfaces, this application software can easily connect to different systems. Pump control solutions can then be widely applied, ensuring the system's connection to the entire drinking water and wastewater treatment facility.
Designed for pump stations with 2 to 6 different outputs, the software also meets the precise needs of pump station operation based on WAGO’s extensive experience in wastewater treatment facilities: load management, corrosion protection, and ensuring redundant operation.
Redundant operations
Pumping stations are typically equipped with different types of pumps to ensure normal operation during system interruptions or maintenance. These include base load pumps, peak load pumps, horizontal drainage pumps, and standby pumps.
Auxiliary pumps in pumping stations can be used not only for peak loads or redundant operation, but also for operation at specific time intervals to prevent system interruptions. However, operational failures are inevitable; dust accumulation can cause pumps to stop operating, corrosion can cause connections to break, and equipment components can become clogged.
WAGO application software allows for different function settings for the pumps. When a protection function is set for one of the pumps, the WAGO controller can modify the task after each operating cycle to restore the pump to normal operation.
In addition, to prevent corrosion, the application monitors the pump's operating time and automatically restarts it after a long period of inactivity.
Preventing peak load
When starting the pumps, to avoid putting unnecessary load pressure on the power grid, they should be started one by one, rather than all at the same time, if possible.
WAGO's start-up delay function enables this. The second pump of the same model can only start after the first pump has been running for a preset period of time.
The duration of this period depends on the individual application and efficient load management in the field —and can be easily parameterized in the pump controller. This will help reduce grid load and enable emergency power operation when using generators.
Flexible water level switch
Changing operating parameters can greatly protect pump systems from contamination. For example, grease buildup on the inner walls of the pump shaft is a major headache for operators. Grease from homes or restaurants is discharged into the sewage system and floats on the surface of the pump shaft.
Because the water level inside and outside the pump shaft is the same, grease inevitably accumulates inside. This inner grease can clog the drainage pump and can only be removed mechanically. To prevent or delay this phenomenon, we need to flexibly configure the pump's on/off positions.
The built-in e!COCKPIT programming tool in the PFC 200 and PFC 100 controllers allows for customized settings of this application. The switch position can then be adjusted slightly above or below the water level in the pump. This level difference creates a better grease discharge mechanism.
A panoramic view
The pump station's new, standardized application software enables convenient and intuitive operation. Users can monitor and control the pumps from the control center or directly through a controller with web-based visualization capabilities. Users can freely choose the pump identification method to complete assigned tasks.
The controller, programmed in the IEC 61131-3 standardized language, provides an overall functional framework for controlling up to six different types of pumps, while also allowing for the design of control programs according to user needs.
The system's functions have placed more specific demands than ever before, forcing operators and service companies to adopt entirely new maintenance measures and introduce efficient solutions. Meanwhile, traditional reactive or preventative measures are also constantly evolving to achieve Industry 4.0.
This software solution lays the foundation for future development trends. The acquisition of data such as phase current, flow rate, voltage, temperature, and power factor, along with load and alarm management, enables better preventative maintenance.
In addition, standardized software solutions can reduce the use of different software packages, reduce the number of repeated updates, and reduce the training of service personnel.
