|
|
| | In control with ITT Flygt at Ferrybridge Power Station |
|
|
| 
|
|
As the world’s leading manufacturer and supplier of submersible pumping and mixing solutions, it stands to reason that ITT Flygt is also leading the field in practical and easy to use monitoring and control systems for multiple pump and mixer applications.
In addition to supplying the hardware, such as pump controllers, sensors, electrical start equipment and cables, the market-leader also has advanced software systems to enable precise and effective monitoring and control of the wastewater system – and the peace of mind that comes along with it.
Applications for the monitoring and control systems can range from those operating in wastewater treatment plants and pump stations through to products pumping ground water from building sites.
One such system was recently installed at Ferrybridge Power Station, West Yorkshire, which is owned by Scottish & Southern Energy.
|
Outline of requirements
ITT Flygt received an enquiry from Ferrybridge, whose fuel oil system had been damaged by the use of Tall Oil – a renewable fuel it had sourced to help fire its boilers. Used as a substitute for the more commonly used heavy fuel oil, Tall Oil proved extremely abrasive and corrosive, throughout the fuel oil system.
Having a severely damaging effect on the pumps that had originally been installed, the problem was further compounded by the way in which the equipment failed, often without visible signs of reduced mechanical performance or advance notice – making failure diagnosis extremely difficult.
ITT Flygt provided a remote monitoring and control solution, offering advance notice of mechanical deterioration of the pumping equipment, enabling failing equipment to be shut down in a timely manner, avoiding equipment failure and downtime.
|
ITT Flygt proposal
Whilst not being involved in the decision to use Tall Oil, as the sole UK distributor for Allweiler Pumps ITT Flygt remained committed to working with Ferrybridge to devise a technical pumping solution and has worked to replace the original pumps with modern dry installed Allweiler Pumps.
As approximately 60% of Condition Based Monitoring (CBM) can be obtained with the monitoring of the assets vibration levels, ITT Flygt installed a solution consisting of a vibration sensor and MAS unit fitted to each pump along with a single D7000 remote telemetry unit (RTU).
The MAS (Monitoring and Supervision) unit powered the vibration sensor and provides the facility to protect the pump if thresholds are breached, the MAS unit can also act in the same way an aeroplanes black box would, by recording the events leading up to and after an event – enabling the engineer to identify the cause of the problem by post analysis. The MAS units are then connected by a serial loop to a single D7000 remote telemetry unit which maps each pumps current vibration level, logs each point every 5 minutes (adjustable) and monitors pre-defined threshold levels which if exceeded activates a logged alarm and a remote SMS dial-out to an engineer highlighting the alarm. All threshold values, engineers phone numbers, alarm delays/inhibits and live values can be reviewed and adjusted remotely via a dial-up connection to a GSM modem fitted with-on the D7000 RTU.
When time is of the essence it’s essential that issues are flagged up in the shortest possible timeframe. While ITT Flygt was able to remotely access the installed equipment and provide regular condition reports, the M&C solution installed by the firm provided tailored alarms via mobile text messaging directly to nominated customer and Flygt contacts – instantly alerting them to any potential problems.
The accuracy of the alarm signals gave the team at Ferrybridge sufficient time to shut down any faulty equipment and operate from alternative sources – significantly minimising costly downtime. The customer also has the option to use the monitoring and control equipment to automatically shut down any faulty equipment should the need arise.
|
Outcome – the benefits
The solution provided by ITT Flygt dramatically reduced downtime and provided significant return on investment – the cost the customer saved following one prevented failure was greater than the total cost of the solution provided.
By improving planning of site labour resource, Flygt was also able to advise on best practice and effective use of time throughout the plant.
Kevin Woodall, Ferrybridge Power Station: ”ITT Flygt provided a comprehensive service that has resulted in vital and positive operational changes going forward. The specialist knowledge and experience that we were able to call upon was invaluable in ensuring that down time was kept to a minimum and that, going forward, we have the best possible solution in place.”
Following the success of the initial trial, the customer has now purchased additional equipment consisting of vibration sensor and MAS unit for each pump and a single D7000 RTU to log and alarm on all eight boiler fuel feed pumps.
For more information on Monitoring and Control please call Guy Fitzpatrick on 07836285968 or email guy.fitzpatrick@flygt.com. To discuss Allweiler Pumps then please contact Jason Robinson on 07770748138 or email jason.robinson@flygt.com.
|
|
|
|
|
| ![]()
| ![]()
|
|
Products
