{"id":3740,"date":"2016-06-13T18:00:45","date_gmt":"2016-06-13T18:00:45","guid":{"rendered":"https:\/\/ecc-automation.com\/?page_id=3740"},"modified":"2016-12-15T16:58:21","modified_gmt":"2016-12-15T16:58:21","slug":"duplex-pump-control-panel","status":"publish","type":"page","link":"https:\/\/ecc-automation.com\/work\/duplex-pump-station-control\/duplex-pump-control-panel\/","title":{"rendered":"Duplex Pump Control: In Depth"},"content":{"rendered":"

Duplex Pump Control for a Work Campus Wastewater Station<\/h2>\n

Managing important systems like wastewater for a commercial building is SOP, but managing it for an entire campus of buildings that houses thousands of employees is another matter .\u00a0A large government facility contracted\u00a0ECC to build and install a duplex pump control panel that would replace their old system. When the ECC team went in for the discovery phase what we we saw was not pretty. Old control panel components were falling apart and the wiring was rapidly breaking down. The existing wastewater system was still running off of mechanical floats and lacked redundant power feeds. It\u00a0was an antiquated duplex pump control system, demanding constant upkeep and higher labor costs to keep it operating. It also\u00a0posed a greater environmental hazard for the campus.<\/p>\n

Duplex Pump Control Built to UL508A<\/a><\/strong> Standards<\/h3>\n

Electronic Control Corp. is a UL508A certified<\/strong>\u00a0control panel shop. So we apply the highest design and installation standards, to ensure the duplex pump control panels we install function at peak performance. In addition, UL508A certification means that we follow stringent UL safety and reliability requirements, adhered to\u00a0throughout the entire electronic control process.<\/p>\n

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Electronic Control Duplex Switches<\/a> Electronic Control Duplex - Front View<\/a> Electronic Control Duplex Panel<\/a> Electronic Control Duplex Rear View<\/a><\/div><\/div>
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Programmable Logic Controller or Relay Logic?<\/h4>\n

We provided\u00a0our customer with two design options when engineering this system. The first was a programmable logic controller – PLC:<\/strong>\u00a0a single powerful computerized module that reads inputs and controls outputs of nearly any type. The PLC programming software was written in-house by ECC programmers, custom tailored for each panel. The second option was to use a series of mechanical relays to perform the order of operations; known as relay logic<\/strong>. The customer decided relay logic was their preferred option, based on the requirement that in-house technicians diagnose and troubleshoot issues. \u00a0Therefore we used several small, yet robust IDEC relays<\/a> to get the job done.<\/p>\n

Ultrasonic Sensors<\/h4>\n

Wastewater from across the campus is collected in a tank at a central location, then relies on the mechanical float process to kick off discharge\u00a0out into the public sewer system. ECC installed an ultrasonic sensor with a 4-20 signal<\/strong> above the tank. The sensor sends an ultrasonic pulse down to meet the surface of the wastewater. It then bounces back to the sensor and provides an accurate depth of the wastewater,\u00a0providing an extra level of reliability on top of the duplex pump station mechanical floats<\/strong>.<\/p>\n

Red Lion NEMA 4X Rated Meter<\/h4>\n

The sensor installed by ECC communicates with a Red Lion<\/a> meter, programmed to vary when the duplex pumps come on, and how long they run. The Red Lion meter also communicates with the Building Management System<\/strong> to let technicians know immediately if any issues arise. The meter enclosure is rated at\u00a0NEMA 4X<\/a>. This means that the meter is\u00a0completely water proof, can be used in direct sunlight and is a more cost-effective electronic control solution.<\/p>\n

Additional Electronic Control Components<\/h4>\n

Additional sensors,\u00a0installed\u00a0on the duplex pump control panel, detect wastewater flow through the sewage pipes. Abnormal measurement returned indicates that a pipe is clogged or leaking. ATC timers<\/strong>\u00a0calibrate how fast the alarm kicks in, should something go wrong. Current sensors<\/strong> monitor the amperage load on each pump<\/strong> to detect pump problems. This serves as a good early warning system to protect against a failing or aging pump.<\/p>\n

Duplex Pump Power Redundancy and Load-Balancing<\/h3>\n

The wastewater pumps were designated by the client as “mission critical.” So ECC added\u00a0redundant power feeds into the duplex pump control panel<\/strong>. Now, if power drops in one feed, the ATC voltage monitors detect it and Eaton Cutler-Hammer<\/a> contactors would switch power feeds.<\/p>\n

The duplex pumps, designed to operate in a load-balancing manner,\u00a0are\u00a0switched on and off by Eaton Cutler-Hammer contactors as well. When one pump is not enough,\u00a0then the second kicks in. When the duplex pump system runs, each pump is switched between being the lead and lag pump<\/strong>, controlled by another ATC component.<\/p>\n

Finalizing the Project<\/h3>\n

When all of the components were installed and configured properly, the entire system was then calibrated on-site and confirmed to be fully operational\u00a0prior to the ECC team leaving the premises.
\nThis new duplex pump control replaced an antiquated and hazardous wastewater pump system, critical to servicing a multi-building campus with thousands of workers. With modern electronic control technology, it now runs with far more fail-safe efficiency, greatly reducing the amount of time and resource allocation to troubleshoot, fix and maintain the system. It also ensures that risks of hazardous-related failures\u00a0are greatly limited.<\/p>\n

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In need of a customized electronic control system?
\nCall us today at 443-201-9409<\/strong><\/span><\/p>\n

\n<\/div>

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See Our Other Projects<\/h3>
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Extreme Precision Flow Control<\/p>\n<\/div><\/div><\/div>Extreme Precision Flow Control Designed by ECC<\/a><\/div><\/div><\/div><\/div>\n

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Fuel Control System<\/p>\n<\/div><\/div><\/div><\/a><\/div><\/div><\/div><\/div>\n

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Water System Pressure Control<\/p>\n<\/div><\/div><\/div><\/a><\/div><\/div><\/div><\/div>\n

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Plastic Extrusion Machine Control<\/p>\n<\/div><\/div><\/div>extrusion control panel for plastic manufacturing<\/a><\/div><\/div><\/div><\/div>\n

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Waste Ejector Compressor Control<\/p>\n<\/div><\/div><\/div>Electronic Controls Waste Ejector Control<\/a><\/div><\/div><\/div><\/div>\n

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