Supplying Water Using Networking and Cascading of Drives

2010
Supplying water using networking and cascading of drives

[Sponsored by Siemens]
[supply water for domestic applications by cascading pumps and control the by the means of PLC and networking using profibus cable via USS protocol and monitoring using HMI.]
Prepared by Fady Anton Kareem El harony Adel Elwakeel Abdallah Rashed
Innovators team Helwan University [july-2010]
July 2010
Acknowledgements:
On the behalf of our team, our university and our country, we extend special thanks for Siemens Corporation for its Role in developing the industry in our country and its effort in increasing the industrial abilities of Egyptian graduates by keeping them in touch with the latest updates in industrial technologies. We also thank the staff of Siemens Egypt for their complete supporting in order to get this project done in a way that appropriate with Siemens name and Helwan Universitys name. Thank you
Innovators team 2010
July 2010
Preface:
In todays world the Technological development is the most important factor that determines which nation should lead and which one should follow, as it is the seed of progress. Technological development is the process of research and development of new technologies. Many emerging technologies are expected to become generally applied in the near future. Research and development (also R and D or, more often, R&D) refers to "creative work undertaken on a systematic basis in order to increase the stock of knowledge, including knowledge of man, culture and society, and the use of this stock of knowledge to devise new applications". R&D has a special economic significance apart from its conventional association with scientific and technological development. R&D investment generally reflects a government's or organization's willingness to forgo current operations or profit to improve future performance or returns, and its abilities to conduct research and development. The top eight spenders in terms of percentage of GDP [Gross domestic product] were Israel (4.53%), Sweden (3.73%), Finland (3.45%) Japan (3.39%), South Korea (3.23%), Switzerland (2.9%), Iceland (2.78%) and United States (2.62%) Unfortunately Egyptian research centers ranking it were not in the Top 2000; The Central Laboratory for Agricultural Expert Systems has the world rank of 2184. From these given facts, if we want to make Egypt a leading country, we must have a vision for the technological development and that can be achieved only if every Egyptian takes his own responsibility towards the development of himself and his country. Huge corporations and universities must co-operate to improve the abilities and skills of graduates. The university graduates especially engineers will take their leading roles in various factories, companies and industry developing centers all over the country. If that happen the universities and research centers will take their natural role in providing researches and new technologies to industry not the opposite like what is happening now. As an example of the Important role of such co-operations the governmental initiative represented in ITC Industrial Training Council towards the improvement of engineering students to be familiar with the latest industrial technologies like SIEMENS products and technologies. Finally, we hope that we see all companies make such co-operation with the universities to accelerate the development wheel of our country.
Innovators team
2010
July 2010
Table of Contents
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Introduction
Pumping systems represent nearly 20% of the worlds electrical energy demand. Furthermore, they range between 25-50% of the energy usage in certain industrial plant operations. Since traditional control methods such as: throttling, bypassing, and On/off control (shown in Figure I.1) affect the system performance, operation cost, and upgrading cost.
Figure I.1 Also the reliability of the system will be decrease; due to using of large capacity pump instead of using of multiple pumps in response to the increasing of load demand. So; the purpose of our project is to find an alternative and effective method of controlling pumping system in an automated manner which will increase the efficiency of the system overall, Project added values will be described in details later in that text. The increasing demand of pumping systems with high efficiency requires more reliable and redundant automation systems overcoming the problems coming from using traditional systems listed as follows: Energy loss Risk of damage during startup (Water Hammering) An increase in capacity means reconstruction of the system Lower efficiency of pumping system. Lower system reliability. The modified system is based on using multiple pumps in parallel configuration which also has an enhancement in system performance. Some of drawbacks of using one large pump instead of multiple pumps can be summarized as follows: Affect the system reliability. Do not achieve the continuity of the service. Do not allow the maintenance of different system components.
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Vs.
In the following chapters we will introduce more details serving the comparison between traditional system and our developed system including its components.
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Chapter one Pumping system fundamentals
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Introduction:
To transport water through pipes energy has to be fed to the water. The energy is needed to overcome the dynamic friction losses in the pipe. Also energy is needed to compensate differences in level between the beginning and the end of a pipe (lift energy). Basically a pump is a piece of equipment to feed energy to a water flow. Two types of pumps can be distinguished: Pumps capable of lifting water from one free surface to another: Open pumps or Archimedean screws (fig. 1.1). Pumps capable of feeding energy to water in combination with a closed pipe: For example Centrifugal or impeller pumps (fig. 2.2). Pumps are used for instance to pump water out of the ground, to overcome level differences in treatment processes, to transport drinking or sewerage water over large distances in combination with pipes or to dispose of rain water from polders. Numerous other applications of pumps can be given but they wont be dealt with in this chapter.
Figure (1.1)
Figure (1.2) 8
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Pump types:
The second category obtained above can be classified as illustrated in figure (1.3); it is useful to mention that the most popular type used in industrial applications is the centrifugal pump, as shown in figure (1.4)
Pumps
Positive Displacement
Dynamic
Rotary
Reciprocating
Centrifugal
Axial
Multiple Rotor
Single Rotor
Diaphragm
Piston, Plunger
Figure (1.3)
Figure (1.4)
Pump characteristics:
The hydraulic properties of a pump can be described by some characteristics: Q-H curve Efficiency curve Power curve Net Positive Suction Head (NPSH) curve. Each of the characteristics is explained in the next sections for centrifugal pumps. 9
Supplying water using networking and cascading of drives Q-H curve:
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The Q-H curve is the relation between the volume flow and the pressure at a constant speed of the pump crank. The H in the curve is the difference in energy level between the suction and the pressure side of the pump. Q-H curves will be given by the manufacturer of the pump and can normally be considered as a simple quadratic curve.
An example of a pump curve is given in figure (1.5).
Figure (1.5) Efficiency curve: The hydraulic efficiency of the pump with the motor is given with the efficiency curve. The hydraulic efficiency is the relation between the absorbed hydraulic energy (pressure and velocity) and the provided mechanical energy at the pump crank including the power efficiency of the motor. This relation is illustrated in figure (1.6)
Figure (1.6) Net Positive Suction Head (NPSH) curve: The Net Positive Suction Head curve is the relation between the volume flow Q and the needed margin between the energy level at the suction side of the pump and the vapor pressure of the water to prevent too much cavitation in the pump (fig. 1.7). 10
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At the suction side of a pump negative pressure, i.e. pressures below the atmospheric pressure can occur, especially when the actual weir of the pump is above the level of the reservoir the water is drawn from. This negative pressure is limited to the actual vapor pressure of the fluid at the current temperature. If this allowable negative pressure is subsided, cavitations will take place in the pump. Although a small amount of cavitations within a pump cannot be avoided, this should be limited, as figures (1.8). The NPSH requirements of a pump give these limitations. The effect of cavitation is extra wearing of the pump, which can be unacceptable. The bubbles that are formed at the suction side of the pump will be pressurized at the outlet side. The pressurized bubbles will act as actual grains or small stones and wear the material out. The following figure showing the cavitation process:
Figure (1.7)
Figure (1.8)
To avoid unacceptable cavitations the available NPSH should be larger or equal to the needed NPSH. The available NPSH is defined as: NPSH available = H a + h0 - h v With Ha = suction head at the impeller , ho = Atmospheric pressure , hv = Vapour pressure
With h the pressure at the impeller entrance, v the velocity of the water at the impeller entrance. The various pump curves are provided by the pump manufacturer. 11
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Cavitation has the following bad effects: Intense pressures on metal surfaces exceed material strength resulting in surface fatigue failure. Creates a pitted surface similar to coral or course sandpaper.
Large vapor volumes can cause reduction in head and loss of prime. Surging and unstable flow often results as illustrated in the following figure
System (network) characteristics:

In a pumping system, the objective, in most cases, is either to transfer a liquid from a source to a required destination, e.g. filling a high level reservoir, or to circulate liquid around a system, e.g. as a means of heat transfer in heat exchanger. A pressure is needed to make the liquid flow at the required rate and this must overcome head 'losses' in the system. Losses are of two types: static and friction head. Static head is simply the difference in height of the supply and destination reservoirs, as in Figure 1.9. In this illustration, flow velocity in the pipe is assumed to be very small. Another example of a system with only static head is pumping into a pressurized vessel with short pipe runs. Static head is independent of flow and graphically would be shown as in figure (1.10)
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Figure (1.9)
Figure (1.10)
Friction head (sometimes called dynamic head loss) is the friction loss, on the liquid being moved, in pipes, valves and equipment in the system. Friction tables are universally available for various pipe fittings and valves. These tables show friction loss per 100 feet (or meters) of a specific pipe size at various flow rates. In case of fittings, friction is stated as an equivalent length of pipe of the same size. The friction losses are proportional to the square of the flow rate. A closed loop circulating system without a surface open to atmospheric pressure, would exhibit only friction losses and would have a system friction head loss vs. flow curve as Figure (1.11)
Figure (1.11) Most systems have a combination of static and friction head and the system curves for two cases are shown in Figures 1.12 and 1.13. The ratio of static to friction head over the operating range influences the benefits achievable from variable speed drives which shall be discussed later.
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Figure (1.12)
Figure (1.13)
Static head is a characteristic of the specific installation and reducing this head where this is possible generally helps both the cost of the installation and the cost of pumping the liquid. Friction head losses must be minimized to reduce pumping cost, but after eliminating unnecessary pipe fittings and length, further reduction in friction head will require larger diameter pipe, which adds to installation cost. Combination of the Q-H curve and the network characteristic gives the optimal working point of the combination pump-network, which is represented in figure 1.14. The intersection of the two curves is the working point. At this volume flow the exact minimum pressure is reached in the network attached to this pump. If another volume flow is demanded in this network, for instance a lower volume flow, than the working point will shift on the pump curve. The extra pressure will be the extra pressure in the characteristic point in the network (see figure 1.15). This means that in the network the pressure is higher than the minimum required according to the network characteristic. The manufacturer of the pump will provide the pump curve as a product specification. One must bear in mind that the pump curve only reflects the pump performance in its own and not the performance within the lay-out of the pumping station, for instance in combination with a non-return valve. The network characteristic can theoretically be calculated by combing the pipes in the network to one pipe only. Using network models and a calculation program is a more feasible option.
Figure (1.14)
Figure (1.15) 14
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Flow Control Strategies
Throttling
Bypassing
On/Off control
Variable speed
On/Off control: In this control method, the flow is controlled by switching pumps on or off. It is necessary to have a storage capacity in the system e.g. a wet well, an elevated tank or an accumulator type pressure vessel. The storage can provide a steady flow to the system with an intermittent operating pump. When the pump runs, it does so at the chosen (presumably optimum) duty point and when it is off, there is no energy consumption. If intermittent flow, stop/start operation and the storage facility are acceptable, this is an effective approach to minimize energy consumption. The stop/start operation causes additional loads on the power transmission components and increased heating in the motor. The frequency of the stop/start cycle should be within the motor design criteria and checked with the pump manufacturer. It may also be used to benefit from "off peak" energy tariffs by arranging the run times during the low tariff periods. To minimize energy consumption with stop/start control it is better to pump at as low flow rate as the process permits. This minimizes friction losses in the pipe and an appropriately small pump 15
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can be installed. For example, pumping at half the flow rate for twice as long can reduce energy consumption to a quarter. Flow control valve (Throttling): With this control method, the pump runs continuously and a valve in the pump discharge line is opened or closed to adjust the flow to the required value.
Figure (1.16) To understand how the flow rate is controlled, see Figure 1.16. With the valve fully open, the pump operates at "Flow 1". When the valve is partially closed it introduces an additional friction loss in the system, which is proportional to flow squared. The new system curve cuts the pump curve at "Flow 2", which is the new operating point. The head difference between the two curves is the pressure drop across the valve. It is usual practice with valve control to have the valve 10% shut even at maximum flow. Energy is therefore wasted overcoming the resistance through the valve at all flow conditions. There is some reduction in pump power absorbed at the lower flow rate (see Figure 1.16), but the flow multiplied by the head drop across the valve, is wasted energy. It should also be noted that, while the pump will accommodate changes in its operating point as far as it is able within its performance range, it can be forced to operate high on the curve, where its efficiency is low, and its reliability is affected. Maintenance cost of control valves can be high, particularly on corrosive and solids-containing liquids. Therefore, the lifetime cost could be unnecessarily high. By-pass control: With this control approach, the pump runs continuously at the maximum process demand duty, with a permanent by-pass line attached to the outlet. When a lower flow is required the surplus liquid is bypassed and returned to the supply source. An alternative configuration may have a tank supplying a varying process demand, which is kept full by a fixed duty pump running at the peak flow rate. 16
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Most of the time the tank over-flows and recycles back to the pump suction. This is even less energy efficient than a control valve because there is no reduction in power consumption with reduced process demand. The small by-pass line sometimes installed to prevent a pump running at zero flow is not a means of flow control, but required for the safe operation of the pump. Variable speed:
Effect of varying the speed:
A centrifugal pump is a dynamic device with the head generated from a rotating impeller. There is therefore a relationship between impeller peripheral velocity and generated head. Peripheral velocity is directly related to shaft rotational speed, for a fixed impeller diameter and so varying the rotational speed has a direct effect on the performance of the pump. All the parameters shown in fig 1.6 will change if the speed is varied and it is important to have an appreciation of how these parameters vary in order to safely control a pump at different speeds. The equations relating rotodynamic pump performance parameters of flow, head and power absorbed, to speed are known as the Affinity Laws: QN & H N2 & P N3
Where: Q = Flow rate H = Head P = Power absorbed N = Rotating speed Efficiency is essentially independent of speed The implication of the squared and cubic relationships of head and power absorbed is that relatively small changes in speed give very significant changes in these parameters as shown in an example of a centrifugal pump in fig 1.17.
Figure (1.17) 17
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Points of equal efficiency on the curves for the 3 different speeds are joined to make the isoefficiency lines, showing that efficiency remains constant over small changes of speed providing the pump continues to operate at the same position related to its best efficiency point (BEP). The affinity laws give a good approximation of how pump performance curves change with speed but in order to obtain the actual performance of the pump in a system. The variable speed drive control technique will be discussed in details laterin chapter four.
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Purpose of our project:

Our project purpose is to build a system which is efficient and provide a reliable service for the customer; a water user shall be supplied with water on demand via four pumps. Assuming an output of 100% for each pump, an output of 400% is to be generated by cascading all four pumps. By switching pumps on and off an equal load for all pumps shall be ensured taking into consideration the operating times. The pumping output of a pump which has been released for maintenance shall be automatically taken over by a pump with free capacity. A part from the above described automatic operation, it shall also be possible to operate each pump manually. In order to take into consideration the various pump types, it shall be possible to operate all pumps in positive and negative direction.
By building that system; the benefits of using variable speed drive and parallel techniques [will described in details in chapter four] will be obtained.
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Chapter Two Project components
Covered In Chapter Two: Programmable Logic Controller [PLC S7-1200] Human Machine Interface [Basic KTP600 panel(color, PN) ] Electric Variable Speed Drive[SINAMICS G110 120W] Communication Techniques [USS Protocol]
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Programmable Logic Controller

PLC is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, pumping station, or lighting fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed or non-volatile memory.
Basic Elements of a PLC:

The basic elements of a PLC include: Input modules or points, A Central Processing Unit (CPU), Output modules or points, and A programming device. The types of input modules or points used by a PLC depend upon the types of input devices used. Some input modules or points respond to digital inputs, also called discrete inputs, which are either on or off. Other modules or inputs respond to analog signals. These analog signals represent machine or process conditions as a range of voltage or current values. The primary function of a PLCs input circuitry is to convert the signals provided by these various switches and sensors into logic signals that can be used by the CPU. The CPU evaluates the status of inputs, outputs, and other variables as it executes a stored program. The CPU then sends signals to update the status of outputs. Output modules convert control signals from the CPU into digital or analog values that can be used to control various output devices. The programming device is used to enter or change the PLCs program or to monitor or change stored values. Once entered, the program and associated variables are stored in the CPU. In addition to these basic elements, a PLC system may also incorporate an operator interface device of some sort to simplify monitoring of the machine or process.
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Totally Integrated Automation [TIA]:

The process and analytical instrumentation ranges have been incorporated in the TIA concept to complement the high quality automation system solutions (PLC and HMI) and the power train ranges of switchgear, drives, gearboxes and motors. This is the approach that has taken Siemens to a position of leadership in the automation markets of the world.
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Siemens S7-1200 Family

The new modular SIMATIC S7-1200 controller is at the core of our new offering for simple but highly precise automation tasks. The SIMATIC S7-1200 controller is modular and compact, versatile, a secure investment, and is powerfully fit for a full range of applications. A scalable and flexible design, a communication interface that fulfills the highest standards of industrial communication and a full range of powerful integrated technology functions make this controller an integral part of a complete and comprehensive automation solution. This is exactly where the new SIMATIC S7-1200 series of products with SIMATIC STEP 7 Basic V10.5 comes into its own. It creates a solution in the micro controller segment that provides comprehensive answers to the challenges described above: High flexibility for smart solutions. Simple networking. Intuitive and fast engineering during programming and commissioning. During the development of the micro controller particular attention was paid to seamless integration and perfect interaction between controller, HMI and software In precise terms, this means: Finely scalable hardware allows a solution to be created that precisely fits the automation task. In this way it is possible to keep the level of investment to a minimum and implement subsequent expansions without excessive expense. Powerful, coordinated communication options permit the simple networking of engineering system, controllers and HMI. This keeps the expenditure on decentralization within narrow limits. 23
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A precisely coordinated range of high-performance HMI panels facilitate visualization at minimum expense. The innovative engineering system combines all necessary functions for controllers and visualization, from planning to commissioning and expansion. The previously known boundaries between the individual software products are removed. The uniform look and feel and intelligent editors provide additional support to the user. This provides an ideal basis for all project personnel, from the project engineer to the service personnel.
SIMATIC S7-1200 the modular micro controller SIMATIC S7-1200 is characterized by its versatile and flexible design concept while offering high performance and extremely compact dimensions.
Main characteristics of the micro controllers:

New design concept:
A host of modules and new signal boards considerably increase the degree of scalability and flexibility.
Powerful communication:
The integrated PROFINET interface ensures low-cost communication during programming, HMI connection and CPU-CPU communication. An Ethernet switch is available for networking several devices with one another. Expansion by means of communication modules also allows serial communication.
Integrated technology functions:

High-performance functions for counting, measuring, and closed-loop control and for motion control open up new areas of application for the micro controller.
This offers the user immediate advantages:

Perfect adaptation to the respective automation requirements and flexible modification options at any time. Simple networking between controllers, HMI panels and engineering components. Smart options for demanding solutions in the technology sector.
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Technical Specifications:
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Installation and Wiring
Configuration of the device in STEP 7 Basic

You create the device configuration for your PLC by adding a CPU and additional modules to your project.
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1 Communications module (CM): Up to 3, inserted in slots 101, 102, and 103 2 CPU: Slot 1 3 Ethernet port of CPU 4 Signal board (SB): up to 1, inserted in the CPU 5 Signal module (SM) for digital or analog I/O: up to 8, inserted in slots 2 through 9 (CPU 1214C allows 8, CPU 1212C allows 2, CPU 1211C does not allow any) To create the device configuration, Add a device to your project. In the Portal view, select "Devices & Networks" and click "Add device". In the Project view, under the Project name, double-click "Add new device".
Inserting a CPU
You create your device configuration by inserting a CPU into your project. Selecting the CPU from the "Add a new device" dialog creates the rack and CPU. "Add a new device" dialog
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Supplying water using networking and cascading of drives Device view of the hardware configuration Selecting the CPU in the Device view displays the CPU properties in the inspector window.
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Note The CPU does not have a pre-configured IP address. You must manually assign an IP address for the CPU during the device configuration. If your CPU is connected to a router on the network, you also enter the IP address for a router.
Adding modules to the configuration

Use the hardware catalog to add modules to the CPU. There are three types of modules: Signal modules (SM) provide additional digital or analog I/O points. These modules are connected to the right side of the CPU. Signal boards (SB) provide just a few additional I/O points for the CPU. The SB is installed on the front of the CPU. Communication modules (CM) provide an additional communication port (RS232 or RS485) for the CPU. These modules are connected to the left side of the CPU. To insert a module into the hardware configuration, select the module in the hardware catalog and either double-click or drag the module to the highlighted slot.
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Human Machine Interface

In the industrial design field of human-machine interaction, the user interface is (a place) where interaction between humans and machines occurs. The goal of interaction between a human and a machine at the user interface is effective operation and control of the machine, and feedback data from the machine which aids the operator in making operational decisions. Examples of this broad concept of user interfaces include the interactive aspects of computer operating systems, hand tools, heavy machinery operator controls and process controls. A user interface is the system by which people (users) interact with a machine. The user interface includes hardware (physical) and software (logical) components. User interfaces exist for various systems, and provide a means of:

Input, allowing the users to manipulate a system. Output, allowing the system to indicate the effects of the users' manipulation.
Generally, the goal of human-machine interaction engineering is to produce a user interface which makes it easy, efficient, and enjoyable to operate a machine in the way which produces the desired result. This generally means that the operator needs to provide minimal input to achieve the desired output, and also that the machine minimizes undesired outputs to the human. Ever since the increased use of personal computers and the relative decline in societal awareness of heavy machinery, the term user interface has taken on overtones of the (graphical) user interface, while industrial control panel and machinery control design discussions more commonly refer to human-machine interfaces.
Basic Elements of HMI

Almost all HMI devices consist of common elements that give the operator the complete control on it and that leads to control the whole system as well. The basic elements are the workable screen, the function keys optional, communication port, power pin, central processing unit CPU and internal memory. The workable screen is the most important and sensitive element of the entire panel this is the place where operator can see, observe and control the overall system it can be programmed as needed it can give the programmer endless functions to do based on the panels internal memory. Function keys are the physical keys dont exist on the screen itself but below it; their functions can be assigned as needed Communication port that communicate between the panel and other devices like PLC or any other control elements CPU and internal memory is the place where all instructions and processes can be handled
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Supplying water using networking and cascading of drives This figure shows how multiply HMIs can be connected to multiply PLCS in a complete SCADA network.
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SIMATIC HMI KTP600 Basic color
The new SIMATIC Basic Panels with their attractive SIMATIC HMI industrial design feature a touch display For intuitive operation as standard. Fully graphical displays provide a brilliantly clear presentation of operator screens, opening up new opportunities for Visualization. Apart from touch screen operation on 6" displays, the panels also have fully programmable function Keys with tactile feedback. A device with a 15" touch display is also available for applications Where visualization requires a larger display. A standard feature of the new Basic Panels is communication via PROFINET/Ethernet, although versions designed for connection to PROFIBUS are also available
Area of application:
Panel for HMI tasks of limited complexity yet enhanced requirements in visualization for the use in PROFIBUS or PROFINET networks according to the chosen variant; especially in combination with SIMATIC S7-1200 controllers but also with other controllers.
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Benefits:

HMI- Basic functionality for PROFIBUS or PROFINET environment Low price alternative to panels of series 170 Can be used worldwide with 32 configurable languages (of which 5 are online-switchable)
Functions and features:

The KTP600 Basic color is equipped with a 5.7 inch TFT- display offering 256 colors. A resolution of 320 x 240 pixels enables the representation of less complex operating screens at a convenient size incl. color representation. The panel can be operated by a resistive analog touch screen and additionally by 6 freely configurable function keys which when actuated provide tactile feedback. The KTP600 Basic color is the ideal HMI-component for the small to medium S7-1200 controller systems. It can be configured by using WinCC flexible Compact or alternatively the HMI configuration software of the STEP7 Basic Engineering Software for S7-1200. The KTP600 offers HMI basic functionality (alarms, trend curves, recipes) with 500 tags
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Design:
1. Display / touch screen 2. Recesses for mounting clamps 3. mounting seal 4. Function keys 5. PROFINET interface 6. Connection for functional ground 7. Power supply connector 8. Rating plate 9. Interface name 10. Guide for labeling strips 11. DIP switch
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Technical Specifications:
Display Resolution 5.7 inch TFT Display , 256 colors 320 x 240 pixels Touch screen resistive analog Control elements 6 freely configurable tactile keys User memory 512 KB 1 x RS 485 / RS 422 with PROFIBUS DP-Variant Interfaces 1 x RJ 45 Ethernet with PROFINET-Variant IP 65 (front if mounted) Degree of protection IP 20 rear Installation 196 x 140 mm (W x H) cutout Front panel 214 x 158 mm (W x H) Device depth 44 mm Configuration WinCC flexible Compact software
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Installation and wiring

Use power supply cables with a maximum crosssection of 1.5 mm2. 1. Strip the ends of both power supply cables to a length of 6 mm. 2. Insert the cable sleeve onto the bare cable ends. 3. Fix the cable sleeve onto the cable ends using the crimp pliers.
1. Insert the two power cables into the mains terminal and secure them with a slotted screwdriver. 2. Connect the HMI device to the mains terminal. 3. Switch off the power supply. 4. Insert the two remaining cable ends into the power terminal and secure them with the slotted screwdriver. Ensure correct polarity.
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Configuration of SIMATIC HMI KTP600:

After inserting the device in inserting CPU window in Step 7 basic software we start to configure the parameters in the panel it self Open the Control Panel by pressing the "Control Panel" button of The Loader. Configure your HMI device in the Control Panel. You can make the following settings: Communication settings Settings for operation Password protection Transfer settings Screen saver Acoustic signals
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Changing the network configuration

1. Press the "Profinet" button to open the Profinet Settings" dialog. 2. Choose either automatic address assignment via DHCP, or user-specific address assignment. 3. If assigning a user-specific address, Use the screen keyboard to enter valid IP addresses in the "IP Address, Subnet Mask" text boxes and if applicable in the "Default Gateway" text box. 4. Change to the "Mode" tab. 5. Enter the transmission rate for the PROFINET network in the "Speed" text box. 6. Select "Half duplex" or "Full duplex" as the connection mode. 7. The following functions will be activated if the checkbox "Auto Negotiation" has been set: Connection mode and transmission rate will be detected and set automatically in the PROFINET network. The "Auto-Crossover" function will be activated, which means the HMI device can be connected to a PC or a controller without additional crossover cable. 8. Change to the "Device" tab. 9. Enter a network name for your HMI device. 10. Close the dialog and save your entries with "OK".
Download the program to the panel

To download the program to the device you have to do the following steps 1. Put the HMI into the transfer mode from the starting screen 2. Plug the Ethernet cable into your PLC 39
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3. Assign the IP address of the device in the network view in your step7 basic software the same as the assigned ip address that had been assigned before in network configuration in the HMI as above 4. Choose the HMI from network view in step7 basic software and press download
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Electric Variable Speed Drive

A viable-speed drive is an electronic controller that adjusts the speed of an electric motor by modulating the power being delivered. Variable-frequency drives provide continuous control, matching motor speed to the specific demands of the work being performed. Variable-frequency drives are an excellent choice for adjustable-speed drive users because they allow operators to fine-tune processes while reducing costs for energy and equipment maintenance.
BENEFITS of using VSD

Single-speed drives start motors abruptly, subjecting the motor to high torque and current surges up to 10 times the full-load current. In contrast, variable-frequency drives offer a "soft start" capability, gradually ramping up a motor to operating speed. This lessens mechanical and electrical stress on the motor system and can reduce maintenance and repair costs and extend motor life. Variable-frequency drives allow more precise control of processes such as water distribution, aeration and chemical feed. Pressure in water distribution systems can be maintained to closer tolerances. Wastewater treatment plants can consistently maintain desired dissolved oxygen concentrations over a wide range of flow and biological loading conditions by using automated controls to link dissolved oxygen sensors to variable-frequency drives on the aeration blowers.
Elements of variable speed drive

Any variable speed drive consists of basic elements like input pins, output pins, communication pins and user interface. This figure obtain the power conversion in any variable speed drive The sequence of power conversion is as follow: 1. Power input to device 2. Voltage and current are converted into DC 3. Power pass into the dc link and then converted to adjustable AC power 4. The operator can control this process by changing parameters of the drive via the operator interface
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SINAMICS G110
SINAMICS G110 is a frequency inverter with basic functions for a variety of industrial variable-speed drive applications. The particularly compact SINAMICS G110 inverter operates with voltage frequency control on single-phase supplies (200 V to 240 V). It is the ideal low-cost frequency inverter solution for the lower power range of the SINAMICS family.
Typical usage
SINAMICS G110 is especially suited for use with pumps and fans, or as a drive in various industrial sectors, such as the food, textile and packaging industries. As well as for conveyor systems, factory gate and garage door drives, and as a universal drive for moving billboards and fitness equipment.
Characteristics and Features

Main Characteristics 1. Easy installation 2. Easy commission 3. Quick commissioning 4. Reset function (allowing the reset of all values to the preset factory defaults) 5. Rugged EMC design 6. Can be operated on IT line supplies (unfiltered variants) 7. 1 digital output Isolated optocoupler 8. 5 digital inputs (non-isolated) 9. 1 Analog input, AIN: 0 10 V (Analog variant only). Can be used as 4th digital input 10. High pulse frequencies for low-noise motor operation 11. Status information and alarm messages using the Basic Operator Panel 12. Optional Basic Operator Panel with the capability to clone parameter sets 13. USS communications interface Performance Characteristics 14. Fast repeatable response time to control signals 15. Fast Current Limitation (FCL) for trip-free operation 16. Built-in DC injection brake 42
Supplying water using networking and cascading of drives 17. Compound braking 18. Fixed Frequencies 19. Motor potentiometer function 20. Acceleration/deceleration times with programmable smoothing 21. Multi-point V/f characteristic 22. 150% overload for 60 seconds 23. 2-wire/3-wire control 24. Automatic restart after a mains failure 25. Flying start
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Inverter block diagram

This figure show the various inputs and outputs of the device There are many inputs and output variants in this device Like analog variant, USS variant, digital variant or bop variant
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Design
1. Input terminals Single phase 220-240 volt L1, L2and the protective earth terminal PE
2. Output terminals Motor terminals U, V, W and protective earthPE
3. The dipswitch The dip switch consist of three little switches Switch1 is used to choose the operating freq. of your electric network Switch2 and 3 are used to terminate the bus in the last device on the bus
4. Controlling terminals Controlling pins are 10 pins located at the bottom of the device and have various functions and their functions can be assigned from the bop
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Supplying water using networking and cascading of drives 5. The basic operating panel BOP
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Technical specifications
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Quick commissioning
Quick commissioning is an easy way to optimally configure the SINAMICS G110 inverter to a specific motor. The motor data, taken from the motor rating label, is entered into the inverter and then the inverter calculates the dependent control and protection parameters. An alternative to quick commissioning is parameter cloning that can be used if a large number of inverters are to be commissioned to the same specific motor
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USS variant parameters

After quick commissioning you need to change these parameters in order to connect the drive via USS protocol
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Diagnoses and troubleshooting

Sinamics g110 provide a very fast and easy way to know the error or the fault and their reasons and that aids the engineers too much in trouble shooting this is done by means of faults alarms errors and read only parameters that is provided in the device.
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Communication Techniques [USS Protocol]

according to the master slave principle for communications via a serial bus. This also includes, as subquantity, the point-to-point connection.
Essential features

It supports a multi-point-capable coupling, e.g. EIA RS 485 hardware Master-slave access technique Single master system Max. 32 nodes (max. 31 slaves) Simple, reliable telegram frames Easy to implement Operation with either variable or fixed telegram lengths.
One master and a maximum of 31 slaves can be connected to the bus. The individual slaves are selected by the master via an address character in the telegram. A slave itself can never transmit without first being requested to do so, and direct message transfer between the individual slaves is not possible. Communications is realized in the half-duplex mode. The master function cannot be transferred to another node (single-master system
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Data transfer procedure

The master implements cyclic telegram transfer. The master consecutively addresses all slave nodes using a task telegram. The addressed nodes return a response telegram. In accordance with the master-slave procedure, the slave must send the response telegram to the master after having received a specific task telegram, before the master addresses the next slave.
Data transfer format for the net data

For net data, which consist of more than one byte, for data transfer via the bus, the most significant part is first transferred. This definition is identical with that for the transfer of net data via PROFIBUS. The following are valid: Transfer of word formats: The high byte is always transferred before the low byte This is valid for all 16-bit data types: e. g. V2, unsigned 16, integer 16, etc. (refer to /1/) Transfer of double-word formats: A high word is always transferred before a low word. When transferring high and low words, the following data transfer regulations apply for word formats. This is valid for all 32-bit data types: e. g. unsigned 32; integer 32, floating point, etc. (refer to /1/) Transfer of byte formats: In this case, there is no particular sequence. Data is transferred in the same sequence that it is stored in the converter "internal memory". This is valid for data, type: Byte string (= octet string, according to /1/) Transfer of texts: Texts are comprised of individual characters. Each character has a byte format. There is no particular sequence for transferring the individual characters. The characters are transferred in the sequence in which they are stored in the converter "internal memory". The data type for text characters is the visible string, refer to /1/. The data transfer syntax is explained in the following example using the parameter description. According to PROFIBUS profile /1/, a parameter description belongs to each converter parameter. The parameter description itself consists of several elements, e. g. the ID, normalization etc... Depending on the converter degree of expansion, the parameter description is either completely or only partially present. Structure, scope and significance of the parameter description are explained in detail in /1/.
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Configuring the protocol on the bus system

The following is valid for communications between the master and a slave: The task- and response telegrams have the same length, I. e. the same length regarding the PKW and PZD areas. This length must be set before the bus system is first commissioned, and may not be changed during operation. A fixed telegram length means that the net data block has a fixed size. The size of the PKW area (in words) is set via parameter "PKW_ANZ", if PKW_ANZ is set to 3, the PKW area in the net data block always takes-up 3 words. The size of the PZD area (words) is appropriately set via parameter PZD_ANZ. For example, if PZD_ANZ = 2, then the PZD area takes-up 2 words in the net data block. If the master issues a task which should have a response as result, which would extend beyond the selected size of the PKW area, this task must be responded to with the response ID "task cannot be executed". Example: For PKW_ANZ = 3, the task "request PWE (double word)" cannot be executed. In this case, PKW_ANZ must be set to 4. Before setting the size of the net data block, it must be defined, which tasks are to be issued by the master. Based on this, the PKW area size must be defined. This means, that if double-word processing is used, then before first commissioning, the PKW area must be set to 4 words, even if mostly single-word processing is used.
Data transfer sequence and message structure

The start character STX (=02 hex) is, by itself, not sufficient for the slaves to clearly identify the start of a telegram, as the bit combination 02/hex can also occur in the net characters. Thus, before STX, a characterless start delay of at least 2 character run times is specified for the master. The start interval or delay is part of the task telegram. Only an STX with preceding start interval identifies a valid telegram start. The speed of transferring data is specified by what we call baud rate. This table gives Minimum start interval for various baud rates Data transfer is always realized in the schematic illustrated below (halfduplex operation).
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Using USS protocol to connect S-7 1200 PLC with Sinamics G110
The USS Protocol library makes controlling Siemens drives which support USS protocol. The instructions include functions that are specifically designed for using the USS protocol to communicate with the drive. The CM 1241 RS485 module communicates with the drives on RS485 ports. You can control the physical drive and the read/write drive parameters with the USS library.
Requirements for using the USS protocol

The library provides 1 FB and 3 FCs to support the USS protocol. Each CM 1241 RS485 communications module supports a maximum of 16 drives. A single Instance Data Block contains temporary storage and buffers for all drives on the USS network connected to each PtP communication module you install. The USS functions for these drives share the information in this data block.
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All drives (up to 16) connected to a single CM 1241 RS485 are part of the same USS network. All drives connected to a different CM 1241 RS485 are part of a different USS network. Because the S7-1200 supports up to three CM 1241 RS485 devices, you can have up to three USS networks, with up to 16 drives on each network, for a total of 48 USS drives supported. Each USS network is managed using a unique data block (three data blocks are required for three USS networks using three CM 1241 RS485 devices). All instructions associated with a single USS network must share this data block. This includes all USS_DRV, USS_PORT, USS_RPM, and USS_WPM instructions used to control all drives on a single USS network. The USS_DRV instruction is a Function Block (FB). When you place the USS_DRV instruction into the editor, you will be prompted by the "Call options" dialog for which DB to assign for this FB. If this is the first USS_DRV instruction in this program for this USS network, then you can accept the default DB assignment (or change the name if you wish), and the new DB will be created for you. If however this is not the first USS_DRV instruction for this channel, then you must use the drop-down list in the "Call options" dialog to select the appropriate DB that was previously assigned for this USS network. Instructions USS_PORT, USS_RPM, and USS_WPM are all Functions (FC's). No DB is assigned when you place these FC's in the editor. Instead, you must assign the appropriate DB to the "USS_DB" input of these instructions. The USS_PORT function handles actual communication between the CPU and the drives via the PtP communication module. Each call to this function handles one communication with one drive. Your program must call this function fast enough to prevent a communication timeout by the drives. You may call this function in the Main or any interrupt OB. The USS_DRV function block provides your program access to a specified drive on the USS network. Its inputs and outputs are the status and controls for the drive. If there are 16 drives on the network, your program must have at least 16 USS_DRV calls, one for each drive. These blocks should be called at the rate that is required to control the functions of the drive. You may only call the USS_DRV function block from the main OB. The USS_RPM and USS_WPM functions read and write the remote drive operating parameters. These parameters control the internal operation of the drive. Only one read or writes request can be active per drive, at any given time. You may only call the USS_RPM and USS_WPM functions from a Main OB.
Calculating the time required for communicating with the drive

Communications with the drive are asynchronous to the S7-1200 scan. The S7-1200 typically completes several scans before one drive communications transaction is completed. The USS_PORT interval is the time required for one drive transaction. The table below shows the minimum USS_PORT interval for each baud rate. Calling the USS_PORT function more frequently than the USS_PORT interval will not increase the number of transactions. The drive timeout interval is the amount of time that might be taken for a transaction, if communications errors caused 3 tries to complete the transaction. By default, the USS protocol library automatically does up to 2 retries on each transaction 55
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This table gives the minimum call interval in milliseconds and drive interval timeout per drive for each baud rate Baud rate indicates the speed of data transfer via USS protocol
Wiring detail for connecting s7-1200 plc and G110 drive via profibus cable
1. 2. 3. 4. shuck the profibus cable by Siemens scaler and remove the white layer and the shield connect the red wire to terminal no 8 in G110 drive connect the green wire to terminal no 9 in G110 drive connect the cable to the connector and connect it to the communication module in S71200
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Addressing of bus stations and terminating a RS485 bus with USS protocol
An RS485 bus transmitting data using the USS protocol via a 2-wire connection between a master (e.g. CPU 1214C) and up to 31 slaves (e.g. SINAMICS G110). It is necessary here to identify each slave via a unique address between 1 and 31. The USS protocol allows only one master which does not require an assigned address. In order to avoid reflections at the bus start or end, which may cause a falsified data signal, the bus, must be closed off with terminating resistors as illustrated in Figure below. As illustrated in Figure 2-5, in this example it is done on the control side via the PROFIBUS connector and at SINAMICS G110 of pump 4 by switching on both assigned DIP switches below the BOP.
This figures show how to terminate the bus in both the drive and the connector,
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Chapter Three Actual system
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Required components:
Four asynchronous motors are each connected via the communication module CM1241 (RS485) with the frequency converter SINAMICS G110 and are to be controlled by a S7-1200 controller (CPU1214C). Communication between control and frequency converter will be performed by USS protocol. Operation and visualization takes place via a KTP600 touch panel which is connected via an Ethernet connection to the S7-1200 controller. STEP7 Basic v10.5 is used as configuration tool for the control program and the HMI.
Item PLC S7-1200 HMI KTP600 Basic color PN SINAMICS G110 Pump Communication Module STEP 7 Basic V10.5 Communication wires Pressure transmitter
Number 1 1 4 4 1 1 -1
Specifications CPU 1214C DC/DC/DC 24v DC ,Touch screen 3 phase , drive system ,0.12KW with BOP Three phase, 380v, 0.12 KW. RS485 communication module CM1241 Programming software for PLC and Touch screen PROFIBUS cables, Ethernet Cables Output 0-10v indicate 0-10bar 59
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Connection diagram
Controlling bus stations via RS 485 bus USS protocol:

The USS protocol was developed in order to exchange process data between a central controller and bus stations on a RS485 bus. Each bus station is identified here via a unique bus address. Even if PROFIBUS uses the same physical RS485 technology; PROFIBUS and USS protocol differ considerably. Communication of the S7-1200 controller is performed via the communication module with the bus station by integrating the STEP7 Basic library included in delivery.
Communication with bus stations:

For a command to be sent from control to the bus station, a function is necessary that controls communication between CPU and the bus stations. This is achieved using the "USS_PORT" block. During each call of the block, the communication with a bus station is processed. Communication with the bus stations is asynchronous. This means that the S7-1200 controller runs several cycles before the data exchange with a bus station is completed. This is why the block is usually called from a delay alarm OB in a defined 60
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interval. However, it can also be called up cyclically, which does not increase the number of transactions. The "port" block parameter specifies the communication module via which the bus is connected. The "USS_DB" parameter defines the "USS_DRV_DB" instance data block in which the send and receive data is called up or stored (Figure 3-2). The instance data block is a buffer which all USS_Operations can access.
Transferring and reading data to bus stations:

The "USS_DRV" block exchanges data with the bus station by creating request messages and evaluating answer messages. The instance data block is used as storage. For each bus station an own "USS_DRV" block has to be used. Up to 16 called "USS_DRV" blocks share an instance data block. Up to 16 bus stations can be managed with a "USS_DRV" block. Using the parameters on the left side of the "USS_DRV" block the switch on signal (RUN), for example, or the desired speed is sent to the assigned bus station. The status signals of the bus station are provided by block "USS_DRV" on the right block side. The current speed of the bus station is indicated by the parameter "Speed" (Figure 3-2).
Figure (3.2)
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Technological Features:
As mapped out in Figure 3.3, the control program takes into consideration that activated and cascaded pumps must have an identical flow rate. This prevents the throttle check valves from reducing the water flow rate.
Figure 3.3
The delivery head H of each pump depends on the conveying current Q. Figure 3.4 shows how the delivery head is increased for a quadrupled conveying current when cascading 4 pumps.
Figure 3.4
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Controlling the pumped amount:

The control algorithm shall be explained using the following graphic The algorithm controls pump P1 when demand <100% If the demand increases to >100% and remains below 200%, the load is distributed between pump P1 and P2. For a load of 200% both pumps are used at 100% load each. If the demand increases to >200% and remains below 300%, the load is distributed between pump P1, P2 and P3. For a load of 300% all 3 pumps are used at 100% load each. If the demand increases to >300% and remains below 400%, the load is distributed between pump P1, P2, P3 and P4. For a load of 400% all 4 pumps are used at 100% load each. The used algorithm assumes that all used pumps have the same characteristics
Balancing of operating hours:

Recording the pump operating hours The control program records the operating hours of each pump. As soon as a pump is running (even if only slowly) it is considered as switched on. The speed of the pumps does not enter the calculation of the operating hours. Only the effective runtimes are calculated. Switch-on priorities of the frequency converters
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Each pump is assigned a priority, which controls which pump will be switched on next when required. The pump with the lowest operating time receives the highest priority. This means that this pump is the next to be switched on if required. The control algorithm shall be explained using the following graphic Figure 3.5. The algorithm controls pump P4 if the demand is <100%, since with 5 hours it has the lowest amount of operating hours. If the demand increases to >100% and remains below 200%, the load is distributed between pump P4 and P3. Pump P3 is selected as with 10 hours it has the lowest number of operating hours. For a load of 200% both pumps are used at 100% load each. If the demand increases to >200% and remains below 300%, the load is distributed between pump P4, P3 and P2. Pump P2 is selected as with 15 hours it has the lowest number of operating hours. For a load of 300% all 3 pumps are used at 100% load each. If the demand increases to >300% and remains below 400%, the load is distributed between pump P4, P3, P2 and P1. For a load of 400% all 4 pumps are used at 100% load each.
Figure 3.5
Maintenance:
The plant also offers the possibility of excluding individual pumps from the process, e.g. during failure or if a pump needs to be serviced (as shown in Figure 3.6). As long as the requested water consumption is lower or equal 300%, and an active pump is taken out of the group for servicing, its task is taken over by a pump which is inactive at that time. The control algorithm shall be explained using the following graphic. 64
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The algorithm controls pump P1 when demand <100% If the demand increases to >100% and remains below 200%, the load is distributed between pump P1 and P2. For a load of 200% both pumps are used at 100% load each. If the demand increases to >200% and remains below 300%, the load is distributed between pump P1, P2 and P4. Since pump P3 is not available due to maintenance works, the task is taken on by pump P4. For a load of 300% all 3 pumps are used at 100% load each. After terminating the maintenance works and enabling the maintained pump, it is reintegrated into the process according to the above rules.
Figure 3.6
Configuration:
Installing and wiring the hardware: 1. Mount the fuse the PM 1207 power supply unit the S7-1200 CPU 1214C the CM1241 and the frequency converters on a top hat rail. 2. Mount the motors onto a suitable fixture. 3. Connect the controller to the 24 V DC supply voltage of the PM 1207 4. Connect the frequency converters with the motors. 5. Connect the PROFIBUS cable with the S7-1200 CM1241 and the frequency converters 65
Supplying water using networking and cascading of drives Connect S7-1200 with PG/PC:
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Supplying water using networking and cascading of drives Load project in the S7-1200 CPU1214C
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Supplying water using networking and cascading of drives Load project into the SIMATIC Panel KTP600
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Supplying water using networking and cascading of drives Connect SIMATIC Panel KTP600 and S7-1200 CPU 1214C
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Close off RS 485 bus with terminating resistors
Parameterization of frequency converters: Parameterizing the frequency converter of pump P1 (address 1)
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Parameterizing the frequency converter of pump P2 (address 2):
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Supplying water using networking and cascading of drives Parameterizing the frequency converter of pump P3 (address 3):
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Supplying water using networking and cascading of drives Parameterizing the frequency converter of pump P4 (address 4):
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Describing the program algorithm:

Our system is a closed loop control system that can be simplified as follows: The feedback quantity which taken from the output of the system is the pressure which indicate the load demand. As the load demand is increased the pressure inside the pipe is drops to a value proportional to the load demand, the difference between the set point for the pressure and the actual value is the error The error signal is fed to a controlling algorithm to translate it into variation of the pumps speed so as to return the pressure value to its desired value. The following figure (3.7) illustrates a block diagram of the system.
Figure (3.7)
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Program flowchart:
Start
Point B
Read system state [Manual, Auto, Simulation] Read system set point from [Touch screen, pressure sensor] Get the new set point
Check the available pumps, Operating times of each pump and pump priority
Check the Qnew operating region
0 100
100 200
200 300
300 400
Operate one pump in priority table [Min operating times] with equal sharing
Operate two pumps in priority table [Min operating times] with equal sharing
Operate three pumps in priority table [Min operating times] with equal sharing A
Operate four pumps in priority table [Min operating times] with equal sharing
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Supplying water using networking and cascading of drives A To point B Operate pumps according to priorities
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Chapter Four Added values [variable speed drive and parallel pumping and their benefits]
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Parallel pumping
Generally speaking, AC drives are the most energy-efficient method for the control of pumps. In this application, every water pump is controlled by one drive. The power range of the drives can be between 0.12 kW and 5,600 kW (depending on the application). An example with three drives controlling three parallel water pumps is shown in figure 4.1. The adoption of communications between the drives (using fiber-optical cables) eliminates the need for an external PLC), thus permitting energy savings, shortening repair times, and preventing blocking of the rotation of the water pump and jam (blocking of the flow).
Figure 4.1 Variable-frequency water-pump configuration: Optical fiber connections are used between the drives.
The operation of a multi-pump system at efficient speed therefore offers potential for significant savings.
Energy-saving principles:
Pump control using general-purpose drives is mainly implemented through the control of flow rate. As in many other variable-speed drive applications, this enables notable energy savings. Figure 4.2 depicts the head of a pump in function of its flow rate. The curve 2a traces the headflow characteristic at pump-rotation speed n1. 2b shows the same at a reduced rotation speed n2. 2c shows the characteristic of the pipe resistance and 2d the characteristic with an increased pipe resistance (achieved with a valve constricting the flow). With the pump running at the rotation speed n1, and the pipe resistance set to its lowest value 2c, the working point of the pump is at A (intersection of 2a and 2c). The output flow rate Q1 is maximal and the power P1 applied to the shaft is proportional to the area Q1H1. 79
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If the flow rate must be reduced from Q1 to Q2, the traditional method is to change a valve setting, increasing the resistance of the pipe from 2c to 2d. The working point hence changes to B. This increases the pump lift from H 1 to H2. The power P2 now applied to the shaft is proportional to the area Q2H2. If instead of a valve, a drive-control mode is used, the pipe resistance remains at 2c but pump rotation speed is decreased from n1 to n2. The new head-flow curve is thus 2b and the working point moves to C. The pump head is decreased substantially to H3. The power P3 applied to the shaft is directly proportional to the area Q2H3. This represents a reduction (compared to P2) proportional to the area Q2 (H2-H3). The energy savings achieved will be similarly impressive.
Figure (4.2) Power applied to the shaft is reduced significantly when drives rather than valves are used to control speed.
Pump control using general-purpose drives is mainly implemented through the control of flow rate. As in many other variable-speed drive applications, this enables notable energy savings.
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As illustrated by figure 4.4, the relationship between the efficiency, power, rotation speed, flow rate and lift of a system can easily be determined. In moving from working point A to B (upper diagram), the flow-rate is reduced by about 40 percent, on the other hand, power is reduced by about 60 percent (lower diagram). The operation of a multi-pump system at efficient speed therefore offers potential for significant savings.
The initial investment cost makes up a small portion of the total lifetime cost compared to the cost of electricity consumed in day-to-day operations:
Life-cycle costs:
If a product competes in the market only by relying on its sale price, its operating costs can be high. If lifecycle costs (LCC) are considered on the other hand, the customer can reap tremendous economic benefits. For a water pump, motor and drive, these costs can be divided into three parts: initial cost, electricity costs and maintenance costs. Figure 4.3 shows that the initial investment cost makes up a small portion of the total lifetime cost compared to the cost of electricity consumed in day-today operations. Cost savings focusing on this area can therefore return the greatest benefits.
Figure 4.3 Energy costs constitute the largest part of a pumps lifetime costs.
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Figure 4.4 Flow-power and flow-lift diagrams for a pump at different rotation speeds
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Benefits of using VSD

Using VSD [Variable speed drives] and equal sharing algorithm with parallel operation of pumps results in many benefits such as: Improving system performance. Increasing pump efficiency and energy saving. Improving system performance: By controlling and monitoring of process variables and balancing operating times. Operating with the described algorithm will allow the system upgrading without reconstructing the system. Water service will be continuous and more reliable. For pumps efficiency and energy consumed: The idea of improving pump efficiency can be realized from the following figure (4.5)
Figure (4.5) When a VFD [Variable Frequency Drive] slows a pump, its head/flow and brake horsepower (BHP) curves drop down and its efficiency curve shifts to the left. This efficiency response provides an essential cost advantage; by keeping the operating efficiency as high as possible 83
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across variations in the system's flow demand, the energy and maintenance costs of the pump can be significantly reduced.
Recommendable (green), allowable (yellow), and avoidable (red) operating region. Q-H characteristics curve can be easily divided into different regions on the basis of pump and drive system efficiency. In addition, the limiting effect of various other factors is considered in the analysis. The main reason to operating pumps in parallel is to allow wider range of flow than it would be possible with single pump. New parallel pumps may be installed because, at normal state, the required flow is much less than the maximum needed, or the pumping system has expanded and the cheapest and easiest option to get to the wanted flow level is to add more additional pumps. Therefore the most efficient way to operate the parallel pumps in traditional way in this kind of situations may not be so simple. Controlling the pump speed is the most efficient way to control the flow, because when the pumps speed is reduced, the power consumption is also reduced and that will improve the efficiency. VSDs allow pump speed adjustments over a continuous range, avoiding the need to jump from speed to speed as with multiple-speed pumps.
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Supplying Water Using Networking and Cascading of Drives

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Supplying Water Using Networking and Cascading of Drives

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2010

Supplying water using networking and cascading of drives

Prepared by Fady Anton Kareem El harony Adel Elwakeel Abdallah Rashed

Innovators team Helwan University [july-2010]

Supplying water using networking and cascading of drives

Innovators team 2010

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Chapter one Pumping system fundamentals

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives Q-H curve:

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

System (network) characteristics:

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Flow Control Strategies

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Purpose of our project:

Supplying water using networking and cascading of drives

Chapter Two Project components

Supplying water using networking and cascading of drives

Programmable Logic Controller

Basic Elements of a PLC:

Supplying water using networking and cascading of drives

Totally Integrated Automation [TIA]:

Supplying water using networking and cascading of drives

Siemens S7-1200 Family

Supplying water using networking and cascading of drives

Main characteristics of the micro controllers:

Integrated technology functions:

This offers the user immediate advantages:

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Installation and Wiring

Configuration of the device in STEP 7 Basic

Supplying water using networking and cascading of drives

Adding modules to the configuration

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Human Machine Interface

Basic Elements of HMI

SIMATIC HMI KTP600 Basic color

Supplying water using networking and cascading of drives

Functions and features:

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Supplying water using networking and cascading of drives

Installation and wiring

Supplying water using networking and cascading of drives

Configuration of SIMATIC HMI KTP600:

Supplying water using networking and cascading of drives

Changing the network configuration