September 2007 Issue

In the past, the nuclear power industry has experienced equipment failures due to improperly set oilers. There was never a precision tool available to help ensure the level was being properly set on a typical oiler . . . until now.
Back in the old days, level control had little or nothing to do with saving energy. In fact, it was often a necessary evil. Today, that is no longer true - the VFD offers the potential for power savings in lift station applications that range from a few hundred gallons per minute to those that have to move thousands of gallons each minute.
Why question the PLC? For many, questioning the application of a PLC to the pump station panel is surprising. After all, the pump station panel was once controlled with a range of relays, timers, and other devices - the exact type of application where the PLC has had such success in industrial automation. pump efficiency
The concept of using a positive displacement pump to transfer dewatered biosolids, commonly called sludge cake, is not new.
Using root cause failure analysis to address equipment design and manufacturing deficiencies that increase pump reliability and reduce equipment failures.
This municipal water system evaluated the cost of upgrading their existing SCADA software and decided it was time to consider replacements. After much research, it became clear that not only was it possible to get all the features they were missing; they could also do most of the configuration in-house.
Economic pressures to minimize production downtime and improve operating efficiency are increasing the emphasis to accomplish on-site problem detection, analysis, and resolution as fast as possible. These requirements place a great deal of pressure on maintenance personnel to have all the right tools readily available in one place.
An automated monitor provides a live, continuous picture of exactly what is happening inside a turbine for protection, prediction, performance monitoring, and integration of the data with process control.
With the old mechanical displacers, level fluctuations ran 4-in to 5-in with a lot of hysteresis and frequent failures, causing operators to control at much higher levels than were optimal. New magnetic technology is changing all that. Here's how.
Currents are induced on the motor shafts when AC motors are employed with VFDs to drive air pumps, chillwater pumps and compressors in HVAC/R systems. Without a grounding device, these currents typically discharge through the motor bearings, causing frosting, pitting, fusion craters, and fluting.
Most VFD systems use some form of closed-loop feedback to avoid surging, excessive noise, and in extreme cases, vibration. A reliable encoder signal is one method that minimizes speed variance and helps eliminate these unwanted effects. Here's how it works.
The pump is a 300-hp integrally geared propylene product pump in a Gulf Coast olefins unit that operates at 25,000-rpm and produces 6000-ft of head.
SCADA can be utilized for remote data acquisition, but because it is primarily a real-time control system, the user must make significant compromises to use it for this purpose. These compromises include cost, data integrity, flexibility, convenience and control of the task. Here are some considerations to think through.
The level transmitter is a small but vital component in a sewage lift or pump station that helps maintain system integrity and avoid unwanted spillage.
Overall vibration trending is excellent for monitoring rotating machinery health, but not generally effective for tracking reciprocating compressors. A new generation of Reciprocating Machinery Protector technology is very sensitive to compressor faults in their early development stages, yet less likely to give false trips. Here's how it works.
A large wastewater processing plant experienced continual problems with its influent raw wastewater pumps for several years.
A large wastewater processing plant experienced continual problems with its influent raw wastewater pumps for several years.
Both pump owners and external suppliers need to continue working together to refine the PIP MTBR standard so that it is better understood and becomes widely accepted.

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