Yarra Glen Plumbing Proposal - Jayanga Rajapakse

ENG30001 ENGINEERING DESIGN ACADEMY
ENG30001 Engineering Design Academy
Design Report
[03/02/2017]
Jayanga Rajapakse 1
Contents
1 3
2 3
2.1 Background 4Error! Bookmark not defined.
2.2 Concept and Solution Overview 4Error! Bookmark not defined.
3 4
3.1 Mechanical Engineering Design Summary 4Error! Bookmark not defined.
3.1.1 Piping Design 4Error! Bookmark not defined.
3.1.2 Pump Design 4Error! Bookmark not defined.
3.1.3 Etc. 4Error! Bookmark not defined.
3.2 Civil Structural Engineering Design Summary 4Error! Bookmark not defined.
3.2.1 Piping Design 4Error! Bookmark not defined.
3.2.2 Bulk Earthworks Design 4Error! Bookmark not defined.
3.3 Electrical & Control Systems Engineering Design Summary 4Error! Bookmark
not defined.
3.3.1 Power Reticulation 4Error! Bookmark not defined.
3.3.2 Control System 4Error! Bookmark not defined.
4 39
4.1 Mechanical Engineering Deliverables 5Error! Bookmark not defined.
4.1.1 Calculations5Error! Bookmark not defined.
4.1.2 Drawings 5Error! Bookmark not defined.
4.2 Civil Structural Engineering Deliverables 5Error! Bookmark not defined.
4.3 Electrical & Control Systems Engineering Deliverables 5Error! Bookmark not
defined.
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1 Design Summary
The Yarra Glen Pipeline is a project intended to deliver water from the Goulburn reservoir to
the town of Yarra Glen. It is expected that 50GL of water will flow from the reservoir every
year and this flow rate will be constant for the life of the system. Other requirements
include a high-lift pump station (HLPS), which shall pressurise the water so that it can flow
to higher elevations. The pipeline shall be 70km long and shall follow a particular path. The
HLPS shall be powered by electricity from two substations at 33kV. In the event of an
emergency, the equivalent of two days of annual water flow will be stored in a steel tank or
steel tanks.
2 Overview of Proposed Design
The scope of this report is to ensure the piping design is capable to fulfil the demand of
delivering water from the Goulburn River Pump Station to the storage tank located at the
Yarra Glen with a flow rate of 1585 L/s.
2.1 Background
First phase: Design life, Environmental requirements, constructability and maintainability,

cost analysis.
Second phase: The characteristics of the fluid, flow rate and allowable head loss, design
codes and procedures, type of piping material and valves, mechanical equipment, distance
between the pump station to the water storage, pipe diameter, pipe wall thickness, stress
analysis and structural analysis. Finally, with the piping and instrumentation diagram.
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4 Engineering Narrative
4.1 Mechanical Engineering Design Summary
The design criteria of the pipeline characterize into two separate phases before progress
into the piping system design. As for the pipeline to transport 1585L/s, it could be
considered a high pressure service.
The first phase of the design is taking consideration on the geometrical coordination as the
pipeline is design to follow the route of the existing Sugarloaf Pipeline. The second phase of
the project is the output features from the Goulburn River Inlet and Killingworth pump
station such as flow rate, pressure and temperature has to take concern during the
transportation to the next high lift pump station. The sizing of pipe, Valve list, type of the
pump and piping material will determine the entire operation of the piping system and
efficiency in cost and work.
4.1.1 Piping Design
Types of Materials used in piping
Metallic
Galvanized Steel
Galvanized Steel has the oldest history in plumbing industry history as majority of the
industry in the world used it as the piping material. It was the traditional material to
construct the piping system. Galvanized is a technology which give internal and external
protection to the metal pipe by total engagement in molten zinc. The use of galvanized steel
as a piping material is decreasing due to the internal and external corrosion. The problem is
due on the low flow rate of liquid and remain statics for a period of time cause the internal
corrosion. Galvanized Steel is a weighty material and it is generally joined by threading and
screwing which it only capable to sustain low pressure.
Copper
Copper is a more flexible material compare to galvanized steel in overall diameter and
installation. It has less weight, degree of corrosion and assemble such as compression
fittings, couplings, or brazing. Copper is a good material to handle hot water due to its
thinner wall section. A concern for designing piping system using copper is that the water
flows rate must not exceed 3 meters per second. If the water flow rate has surpassed the
limitation, high risk for the internal bore of the piping system will be eroded.
Cast Iron
Cast Iron is a suitable material for building a pipe to withstand high water pressure. It is a
quite historical type of material used in pipe manufacturing industry for the purpose in
transmission of water with high pressure. Most cast iron pipes are manufacture by using
either pit casing or spin casting. Unfortunately, cast iron has a poor record in piping industry
due to its low mechanical strength. It will break down fast as the external and internal of the
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cast iron pipe corroded in an aggressive behavior. Moreover, cast iron is a heavy material.
With not sufficient support to the pipe, structural failure and leakage will occur reasonably
fast.
Steel
Steel are the reasonably expensive as they have high tensile strength, compressive strength,
wide range of diameters and wall thickness, installation methods, manufacture and
corrosion protection system. Steel pipe generally made with carbon steel which give them
the characteristics to overcome high water pressure and variety of diameter sizing in pipe.
Steel pipe can be made using extrusion, welded and casting process. Among these
manufacturing process, Extrusion molding is the most expensive in return for its reliability.
Welding process is much less costly but unreliable for high pressure situations compare to
extrusion process. On the other hand, casting mold is not very common among pipe
manufacturing industry as the primary benefit of this method is the overall steel pipe
strength as these pipes will starting bending under abnormal pressure instead of sudden
crack under high pressure situation.
Non-metallic
Chlorinated polyvinylchloride (CPVC)
CPVC is a thermoplastics produced by polymerization of vinyl chloride with chlorination. It
was manufactured by extrusion methods with a limited range of 0.635 cm to 30.5 cm refer
to standard dimension ratio. The mainly usage of non-metallic material is due to its
resistance to corrosion and high tolerance to acids. In addition, CPVC has extremely light
weight for handling and transportation. It offers an operating pressure of 600kPa at a
temperature of 95 Celsius.
Plasticized polyvinylchloride (PVC)

PVC has the same characteristics and usage to Galvanized Steel as a solvent cement jointing
system. Unlike Galvanized Steel, PVC is non-corrosive and extremely light. As a non-metallic
material, PVC has a lower operating temperature compare to CPVC as it cannot excess the
temperature of 65 Celsius or else it will turn soft and deform.
Polyethylene (PE)
PE has three groups which are high-density, medium density and low density PE. High-
density PE usually can withstand high temperature than PVC which it is apply in drainage in
human lives. It normally installs by electrofusion or butt fusion welding or compression type
joints for smaller diameter pipes and fittings. As a more flexible material than high-density
PE, medium density PE has thinner wall which supported it in resisting high internal
pressure. Is has the same joining method with high density PE. Low density PE can only
operate in low pressure condition but thanks to its high degree of flexibility. It is a suitable
material for the irrigation industry.
Selection of Materials used in piping

Steel
As the scope of the project is to make sure to supply 50GL water per year. A high strength
and durable material that could service in long period for the pipeline is necessary. As the
flow rate of water supply is 1585 L/s, a large diameter pipeline sizing is required. Moreover,
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more factors need to be consider such as material strength, ease of installation, high-flow
capacity, leak resistance, service life, reliability and versatility.
Strength Steel pipe has high resistance against internal and external pressure as the
minimum yield strength of most steel is 290MPa.
Ease of installation The modulus of elasticity of steel is 207Gpa. Grade C steel pipe has
high moduli, therefore the pipe ring is thinner. This is the factor that steel pipeline has high
longitudinal strength and smooth outer surface that steel pipe lends itself to connection by
micro tunneling.
High-flow capacity Low frictional in steel pipe.
Leak Resistance As steel pipeline could be connected by welding joints method which this
installation method provides leak-proof.
Service life Steel pipeline usually could serve for 70 to 100 years under normal
circumference.
Durability Steel, itself has high service life which mean it is a durable material. With the
use of coating and cathodic protection. The service life and durability of steel pipe to
corrosive outer environment and internal abrasion will increase.
Australia Standards for Piping Materials
Metallic material and Non-metallic material
This standard requirement applies specific to pressure pipe:

1. BS 806
2. ANSI/ASME B3.1
3. ANSI/ASME B31.3
4. ANSI/ASME B31.5
This standard is necessary for risk and hazard assessment:
A. The internal and external pressure effect as might cause incident as excess internal
pressure will cause projectile or explosion. As overloaded external pressure will cause
collapse and buckling of the pipe structural.
B. Release of contents are harmful to human beings such as hot, cold, corrosive, toxic gas
or liquid.
C. Release of contents which cause directly or indirectly damage.
D. Metallic piping has been classified into three classes: Class 1, Class 2 and Class 3 which
it is refer to type of material, design, welding, testing. Another subdivision in Class 2 as
2A and 2P.
E. Non-metallic piping is not being classified.
F. Qualification of the material in pipe component has to comply the following
standards(Figure1.1):
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Figure 1.1 Australian Standard
Australian Standard on Steel pipe
AS 1074 Steel tubes and tubulars for hollow sections

AS 1163 Grade C Structural steel hollow sections
Mechanical Properties:
1. Minimum Yield Strength 250 MPa
2. Minimum tensile Strength 320 MPa
3. Minimum Elongation 22%
4. Tolerance +50mm/0mm
5. Length (DN 20-150) 6.5m
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Design
Reverse Engineering
Diagram 1.1: Ideal state
To fulfill the scope of the project, I began my task with another group mates to find
out how many pumps we are using and how much power we are provided. With a suitable
pump is selected and confirmation on the number of pumps. I have make an assumption in
an ideal state which shown on the above diagram 1.1 which provided by another group
member, Sabastian on the pump and software calculation. With the provided information
on the motor, I have use the flow rate to figure out the sizing of the pipe and valves sizing as
the below figure 1.2 shown.
Depth of understanding
The depth of understanding of the water behavior and pipe should be consider as
basic. With the future changing in calculation using software make me more confuse in
how to calculate the sizing of the pipe and the most technical thing is the drawing.
Recommended improvements
For the pump, we could use one strong pump. Future more, with the large landscape. We
could use multiple tank to store the water instead of one massive tank. Finally, it is the
requirement of the step up transformer tank to prevent the oil leakage spread around the
station
4.1.2 Pump Design
The pump that has been selected to pressurise the water is a Ruhrpumpen Horizontal Split
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Case Centrifugal Pump ZW 18x14x32. This particular type of pump was chosen for its ability
to handle very high flows and to provide very high amounts of head, as this application
requires. The pump is oriented horizontally as that is the direction in which the water must
predominantly travel. For safety reasons, we have a stand-by pump.
Ruhrpumpen Horizontal Split Case ZW 18x14x32 Pump Source:

http://www.ruhrpumpen.com/productos/ZW
It will be expected that we need 330m of head to pump the water to the maximum
elevation and for an equivalent water column, this translates to requiring 32.4 bars of
pressure and that falls well below the maximum pressure of the pump (98 bars). However,
no pump could be found that would be able to simultaneously generate the sufficient and
handle the flow rate. Therefore, two pumps were required.
The selected pump is capable of producing the sufficient head required but only half the
flow rate. The appropriate arrangements for two identical pumps, in this case, is placing the
pumps in parallel. Placing two identical pumps in parallel will double the total flow rate of
the system, because 0.8 m^3/s is passing through each pump. With the second similar
pump, 0.8 m^3/s also passes through that pump, hence 1.6 m^3/s is flowing in total.
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The above plan will also include a stand-by pump and that pump will be activated in an
emergency. A large garage door will be in the HLPS, in order to bring any new pump inside
so it can be installed.
Unfortunately, Ruhrpumpen had yet to provide the physical dimensions of the pump, at the
time of writing this report, and there can be none listed in the report. But, the impeller
diameter (81cm) is taken to be the diameter of the flow out of each pump.
Each pump is 83.6% efficient and in total, it requires 6.1MW of power to elevate the water
by 300m. But Ruhrpumpen recommends motors producing at least 3.17MW per pump
(possibly to compensate for any frictional power loss in the shaft) and so the appropriate
motor size for each pump is 3.2MW, requiring a total of 6.4MW of electrical power for the
pump system.
4.1.3 Valve Design
Valves are mechanical devices that controls the flow and pressure within a system or
process. They are essential components of a piping system that conveys liquids, gases,
vapours, slurries etc.
Different types of valves are available, each of these types has a number of models, each
with different features and functional capabilities. Some valves are self-operated while
others manually or with an actuator or pneumatic or hydraulic is operated.
Some functions of the valves includes.
Start and stop of flow

Increasing or decreasing of a flow
Guiding the direction of flow
Adjusting a flow or process pressure
Valve List and Specification

Types of Valve Specification/Standard
Diameters 25mm~1000mm.
Pinch valve Temperature -50 C~160C.
Operating Pressure 0 to 100bar.
Body Types-Enclosed or Open.
Enclosed body- cast iron, fabricated
carbon steel, stainless steel,
aluminium and plastic. The
minimum valve diameter is 25mm.
Open body- designed for isolates
vibration and endures minor
misalignments of pipeline. As it
designed for non-corrosive and light
weight. Open body usually only
apply in lower pressure and
temperature operation. Its body
diameter is designed from a range

of 80mm by using carbon steel or
stainless steel.
Check Valve The usage of check valve is to

ensure the fluid flow in only one
direction. Therefore, check valves
has variety of design built for
handling different situation.
Every unique physical feature of the
check valve has its own function in
different operation process.
By referring to the below check
valves, we will clarify the
specification of each design and
material affectless.
Lift Check valve Life Check Valve usually has a size

range of 40~300mm.
By determine the figure number of
the Valve will give us both the type of
operation it does and the material for
evaluating the valve operating
pressure and temperature.
On/Off Valve This type of valve usually acts as a safety
Cast
task. Iron- stop
It could 10~21the
barfluid
220 C.
flow quickly
Cast Steel- 17~35 bar 425C.
without any leakage. It helps to isolate part
oftheBronze-
system.19~35 bar 250C.
This on/off valve is reference on
international standard.
ISO 5208- Pressure Testing for Valves.
ANSI B16.5- Pipe Flanges and Flanged
Fittings.
BS 1560- Steel Pipe Flanges with sizing of
12.7mm~ 609.6mm.
BS 1655- Specification for Automatic
Control and Process Control Industry.
Gate Valve Gate Valve has many design with the same
purpose to control the flow rate, pressure
and temperature for installing in different
position.
Gate valve is made by using steel or iron.
Every smaller size valve consists one yoke
but for larger size is necessary to have two
yokes.
Gate valves was designed due to the

standard API Standard 600 and BS 1414.
The gate valve will have to be tested under
API Standard 598.
The Trim and seating surface must be done
according to API 600 Standard.
The linking method will reference to which
methods as different method regarding
different standard.
Face-to-face refer to ANSI B16.10.
Flanged ends to ANSI B16.5.
Butt-welding ends to ANSI B16.25.
Angle Valve Materials- 304 S. S.

Design requirement with ANSI B 16.34
Standard.
A testing process is required by referring to
API 598 Standard.
Wall thickness dimension follow API 600
Standard.
For the installation to the pipeline has to
follow the Standard of ANSI B16.10. As the
flow direction need to specify whether
horizontal or vertical.
The needle valve sizing is categorizing as
class 150, 300, 600, 900 and 1500. Class 600,
900 and 1500 which are different classes
compare to 150 and 300 because they have
a standard thrust bearings refer to NPS 6 or
larger.
Needle Valve Server up to 689.4757 bar

Materials: Body- A108 CRS, Bonnet- A108
CRS, Stem- ASTM A479316SS, Handle- A108
CRS, Bonnet Hood- Polyethylene
Body design used international

Butterfly Valve flanges- AS2129, BS10, ANSI, DIN and
JIS Standards in sizes 50mm~300mm.
For the gear operators where have 10
Control Valve Actuators Valve Method of Control and

Function: Rotary motion and Linear
motion.
Work as isolation device or
throttling device
Actuator types are mechanical,
electro-mechanical, linear motor,
piezoelectric, hydraulic and
pneumatic.
ISA S20.50
ISA S75.01
ISA S75.05
ISA S75.11
ISA SP75.17
ISA RP75.23
The pressure relief valve (PRV) is a type

Pressure Relief Valve of valve used to control or limit
the pressure in a system or which can build
up for a process upset, instrument or

equipment failure, or fire. The pressure is
relieved by allowing the pressurised fluid to
flow from an auxiliary passage out of the
system.
API Standard/Recommended
Practice 520 Sizing, Selection and
Installation of Pressure Relieving
Devices
API Standard 521 Guide to
Pressure Relieving and
Depressuring Systems
API Standard 526 Flanged Steel
Pressure Relief Valves
API Standard 527 Seat Tightness
of Pressure Relief Valves
API Standard 2000 Venting
Atmospheric and Low Pressure
Storage Tanks
API Recommended Practice 576
Inspection of Pressure Relief
Devices
Choke Valve Choke Valves are severe service valves

which are designed specifically for wellhead
applications, both in a surface and
subsurface context. Choke Valves are
subjected to typical wellhead extreme
conditions which can cause erosion,
corrosion and other damage.
Working pressures up to 15,000 PSI for
Standard Service and up to 10,000 PSI for
H2S applications.
The accepted limit for the standard seal
material is 230F (110C).
ISA S20.50
ISA S75.01
ISA S75.05
ISA S75.11
ISA SP75.17
ISA RP75.23
Control Valve A control valve is used to control fluid flow by
varying the size of the flow passage as directed

by a signal from a controller. This enables the
direct control of flow rate and the
consequential control of process quantities
such as pressure, temperature, and liquid level.
ISA Guide Control Valves, Practical
Guides for Measurement and Control
ISA S20.50 Specification Forms for
Process Measurement and Control
Instruments, Primary Elements and
Control Valves
ISA S75.01 Flow Equations for Sizing
Control Valves
ISA S75.05 Control Valve Terminology
ISA S75.11 Inherent Flow Characteristic
and Rangeability of Control Valves
ISA SP75.17 Control Valve Aerodynamic
Noise Prediction ISA RP75.23
Considerations for Evaluating Control
Valve Cavitation.
Valve Standard
Types of Valve Standard
Check Valve BS 1868 - Specification for steel
check valves. (flanged and butt-
welding ends)
BS 1878 Specification for steel
globe and globe stop and check
valves.
BS 5152 Specification for cast iron
valves for general purpose.
BS 5153 Specification for cast iron
check valves for general purposes.
BS 5160 - Specification for steel
valves and lift type check valves.
BS 5352 - Specification for steel
wedge gate and globe and check
valves 50mm and smaller.
On/Off Valve BS 6759.1 - Capacity of safety
valves.
ANSI/ASME B31.1 Reaction loads
on the piping system due to the
operation of safety valves.
AS 1271 Safety valves, other
valves, liquid level gauges and other
fittings for boilers and unfired
pressure vessels.
BS 6759 Safety Valves
STD 600 Steel gate valves,

Gate Valve flanged and butt-welding end.
STD 602 Compact steel gate
valves.
STD 603 Class 150, cast,
corrosive, resistant, flanged-end
gate valves.
STD 606 Compact carbon steel
gate valves.
ASTM 1414 Specification for
steel wedge gate valves (flanged
and butt-welding ends) for the
petroleum, petrochemical and
allied industries.
BS 5150 Specification for cast
iron gate valves.
Control Valve Actuators ISA S20.50 Specification Forms for

Control Valves.
ISA S75.01 Flow Equation for
Sizing Control Valves.
ISA S75.05 Control Valve
Terminology.
ISA S75.11 Inherent Flow
Characteristic and Range ability of
Control Valves.
ISA RP75.23 Consideration for
Evaluating Control Valve Cavitation.
FCI 70-2 Control Valve Seat
Leakage.
MSS-SP-61 Pressure Testing of
Steel Valves.
ISA Guide Control Valves, Practical

Relief Valve Guides for Measurement and
Control.
ISA S20.50 Specification Forms for
Control Valves.
ISA S75.01 Flow Equation for
Sizing Control Valves.
ISA S75.05 Control Valve
Terminology.
ISA S75.11 Inherent Flow
Characteristic and Range ability of
Control Valves.
ISA SP75.17 Control Valve
Aerodynamic Noise Prediction.
ISA RP75.23 Consideration for
Evaluating Control Valve Cavitation.
FCI 70-2 Control Valve Seat
Leakage.
MSS-SP-61 Pressure Testing of
Steel Valves.
Foot Valve AS 1722.1 Pipe threads of

Whitworth form part 1: sealing pipe
threads.
ISO 7 Pipe threads where pressure
tight joints are made on the
threads.
Control Valve Actuators and Positioners

Types of Actuators
1. Electro-Pneumatic Valve Positioners

2. Electrical Actuators
Pneumatic operation and options
1. Piston Actuators
2. Diaphragm Actuators
3. Direct Acting Actuators
4. Positioners
a) More accurate control and position is required.

b) Speed up the valve operation.
c) Act as amplifier.
d) Overcome the friction that causes unnecessary error.
e) Safety secure as no explosive incident will occur
f) Typically need 4-20mA electrical input to operate.
Electrical Actuators operation and options

Valve Motor Drive as it basically drives the valve open or close with voltage require with the
following range of 230V, 100V and 24V in AC circuit or DC circuit of 24V as well. As this
device is control with motor, fail factor is lower than pneumatic actuators which it is
supported by battery power rather than piston and air pressure. The only disadvantage is
the maximum pressure differential is lower than the pneumatic actuators by referring to the
below table 1.1,
Reason on Selecting these valve

All valves are being selected to install in the piping system due on one idea as a safety to
ensure anything go wrong. The pump station pipeline could be isolate for securing the
safety of the pipeline. As for the check valve is just the flow direction is constantly one way.
Only the control valve is use to isolate the tank with the pipeline when the water level has
reached the maximum.
4.2 Civil Structural Engineering Design Summary
During the project, our Civil Engineer left the unit. Our group has been left without a Civil
Engineer to design the pipeline, relevant earthworks and the supports and foundations for
the steel storage tank. Hence, the following recommend actions, goals and tasks shall be set
for Civil Engineers, joining the project in the future.
The steel storage tank will be a closed cylinder. For two days of annual water flow, must
store at least 274ML of water. To minimise the amount of material required to make the
tank, calculus was used to find the lowest possible surface area of the cylinder. Minimal
surface area occurs when the height-diameter ratio is 1. The inside of the tank (to store the
water) is to be 71m tall and 71m wide. The maximum wall pressure is at the bottom of the
tank and is 800kPa. Using a 0.5 metre thick wall, hoop stress at this point is 56.8 MPa. Given
the the radius is 35.5m and its thickness is 0.5m, the water tank can be considered thin-
walled. Thick-walled cylinders have a wall thickness more than 10% of the tank radius, so
the formula for thin-walled hoop stress was used. The tensile strength for AIS1040 carbon
steel is 620MPa. Since hoop stress is a tensile stress, the tank can withstand the pressure of
71m of water.
Particular consideration must be paid to placing a large section of the tank underground but
such that the maximum head required for water to reach the top of the tank is less than the
maximum head required.
As stated by Tanzela (Visiting Civil Engineer), this is a very large tank. It would be less of a
problem with several smaller tanks, however surface area was the main consideration in the
tank design, but it can be seen how exclusively on surface area ignored more important
environmental concerns about constructing such a large tank. Concerns about its size,
concerns about the amount of earthworks required to place such a large tank.
However, in light of the above concerns, it is recommended that several smaller storage
tanks be designed to support the required capacity.
4.3 Electrical & Control Systems Engineering Design Summary
Mainly the supplied voltage of 33kV is dropped down to 6.6kV at the High voltage
substation with the performance of the high voltage transformer and this dropped down
6.6kV voltage is directly driven to the High voltage switchboard of 6.6kV, which later used to
drive the pumps at the pump station via the variable speed drive units.
In the other hand, the initially dropped down voltage of 6.6kV is further dropped down to
400v at the Low Voltage substation with the aid of a Low Voltage transformer, which is in
contact with the Low Voltage 400Vwitchboard to power up the Safety systems, lighting
systems and the control systems of the entire plant
The control system is to control the whole station. PLCs are located at all substations and
the PLCs are connected to each other via the farLink wireless network to transmit to a
control centre. The control centre has a sequential program in operation and its linked to a
SCADA system to make it enable to be operated remotely.
4.3.1 Power Reticulation
1. General Arrangement
First, the placement of a single main power house containing all the substations and control
rooms was proposed as per convenience of networking, and maintenance. Also, it was rated
as a cost effective proposal.
Reflective Assessment
Assumptions
The source voltage of 33kV is present closer to the power station.
The Motor control centre (Pump station) is adjoined.
Issues raised.
Risk of placing the control units with transformer units.
Heat conduction and ventilation Issues.
Solutions suggested.
Constructing a blast wall surrounding the High Voltage and Low voltage transformer
units.
It was identified that the most of the heat generation would be from the
transformers and was directed to fix wind powered exhaust fans to eliminate the
heat directly out of the substations without heat being penetrating to the main
power station. In this manner there would be no heat hazard for the other control
systems operated inside the control rooms.
Therefore, considering all the concerns the following arrangement was submitted to the civil
Engineers along with the;
Dimensional data of each equipment.
Ventilation requirement of the each equipment.
Safety requirement by equipment.
2. Single Line Diagram (SLD)
Mainly the supplied voltage of 33kV is dropped down to 6.6kV at the High voltage
substation with the performance of the high voltage transformer and this dropped down
6.6kV voltage is directly driven to the High voltage switchboard of 6.6kV, which later used to
drive the pumps at the pump station via the variable speed drive units.
In addition, a standby pump is proposed to install as a secondary plan for emergency

breakdowns and maintenances requirements.
In the other hand, the initially dropped down voltage of 6.6kV is further dropped down to
400v at the Low Voltage substation with the aid of a Low Voltage transformer, which is in
contact with the Low Voltage 400Vwitchboard to power up the Safety systems, lighting
systems and the control systems of the entire plant.
Alongside, an uninterrupted power system installed with an automatic transfer switch to

supply uninterrupted power in an evet of a power failure. The batteries of the UPS is
charged by the supply current from the low Voltage switchboard.
Design of the Substations.

The ground level electrical system is architect with dual substations to power up the Motor
control centre and the other to the control system and the other safety appliances.
The substations are assumed to be located with 3 phase current load of 33KV at its
convenience
Low voltage substation planted alongside with the High voltage station at a safer distance
apart and parallel to each other. This is particularly to be placed at a reasonable distance for
the convenience in cabling layout and maintenance purposes.
Safety of Substations
Its recommended that the Civil engineers to consider constructing blast Walls (red walls)
surrounding the transformers, as they are placed indoor adjoining to many other control
systems.
Further, the switchboards are placed along with the transformers at each substation, and
they require access regularly. Therefore it is advised that the transformers are separated at
a safe distance. In addition, maintenance requirements are also to be considered.
Access to water.
Oil removal drain systems.
3. High Voltage Substation

6.6kV Transformer
Figure 2 High Voltage Transformer
Assumption the Rated Pump Voltage 6.6kV.

The High Voltage transformer is to be procured by the ETEL Company. This transformer has
a rated power of 6.3Kv and a Rated voltage of 33kV with an Output voltage of 6.6kV. It is a
three phase transformer with three windings in it. It is using a tertiary coil as per solution of
dropping off high voltages directly to a quite a low voltage. First, the voltage of 3kV is
dropped to 12.6kV at the secondary winding and then to 6.6kV at the tertiary.
The pumps has a total 6.2MWA with a single pump at 3.1MWA. The transformer chosen
has the ability of producing 6.3MVA which emphasises its suitability for the application. It is
much accountable to handle low currents through cable at high voltages. Still, chosen to
operate at a lesser voltage of 6.6KV, as propriety was set to minimize the long term.
6.6kV Switchboard.
Figure 3 High Voltage Switchboard
The High Voltage switchboard is also to be procured by the ETEL Company. The stepped
down voltage of 6.6kV is driven to the 6.6kV rated switchboard. The switchboard is secured
with ELCB, and each power outlet runs through a MCB. It operated at 50/60 Hz frequency
which satisfies the condition of the pumps. Power is drawn from three individual outputs for
the pumps, and the external main output is connected to the Low voltage transformer.
Port Connection
O1 VSD 1 to Pump 1
O2 VSD 2 to Pump 2
O4 VSD 3 to Pump 3 (Standby
pump)
EO5 Low Voltage Transformer.
Table 1 HV switchboard output ports list
4. Low Voltage Substation

LV Transformer 33kV/6.6kV
Figure 4 Low Voltage Transformer
As stated, the Low Voltage Substation is supplied with a 6.6kV as an Input voltage from the
output of the High voltage transformer. This 6.6kV/400V low voltage transformer step down
the input voltage of 6.6kV to 400V.
Further, calculatedly required power to operate the CCTV system, Fire alarm, Control
system, Charge of the ups batteries at a full drain is less than 10KVA. Even then, selected a
more powerful transformer with a rated power of 30KVA leaving bit of space for future
improvements such as, installation of cooling system in the event of overheating.
Port Connection
O1 Interior and exterior Lights
O2 Control system (PLC) The 6.6kV Switchboard
O3 Fire alarm (VESDA)
O4 CCTV system
O5 UPS
Figure 5 Low Voltage Switchboard.

The Low Voltage transformer is also to be procured by the ETEL Company. The stepped down
voltage of 400V is directed to the 400V rated switchboard. The switchboard is secured with ELCB,
and each power outlet runs through a MCB. It operated at 50/60 Hz frequency which satisfies the
condition of the regular operated equipments. . Power is drawn from five individual outputs to
operate the safety and control system as listed below
.
Table 2 Table 1 LV switchboard output ports list
5. Cables Layout
This project is proposed to be completed with V-90 type cables. Absolutely, the cable
gauges would be different depending upon the current each section proposed to be carried.
Accordingly, the cable scheduling is attached listing respective characteristics of cables at
each section.
Promptly, given that there is no roof celling inside the building covering/sealing the roof,
civil engineers are informed to place hanged wire trays to navigate all the interior cables. It
was considered in the measure of easy maintenance and better ventilation of the cables for
maximum conductivity.
The two stations are attached together, so that no many cable are laid outside requiring for
an underground layout. Still, the earth wires are laid underground in conduits buried
24inces below the ground level.
The respective cable is been carefully determined upon the handling voltage and the power.
The different gauge of cables is proposed as per current that each path of cables conduct.
6. Lighting Arrangement
Lighting arrangement is designed to be operated in two different modes, as Regular system

and the maintenance system. Where circle lights are the lights that are proposed to be
switched on at regular operations of the plant. They could be manually operated by
switches located at the entrances.
Then, in an event of a maintenance the square lights could be turned on separately from the
square switches located at the side corners of the building structure. The power supply is
navigation followed alongside the above mentioned cable layout. All the light fitting are
listed below.
Uninterrupted Power Supply
Figure 6 UPS
The Hitachi Uninterrupted power supply unit is projected to an outright purchase due to its
availability. The proposed model is a 3 phase and has an input voltage of 240/400VAC and
an output deliverable voltage of 110/120VAC. Its selected to have 10KVA giving the
privilege of powering up the entire Low Voltage switchboard in an event of a power failure
respective calculated power drain at present.
Further, it operated as a stabiliser on battery mode. Hence, provide adequate protection in

a power failure. Moreover, it has its factory fitted battery maintenance notification feature
in the mode of a Buzzer Alarm, which is more elaborated on the data sheet.
4.3.2 Control System
1. Control System Architecture

The control system is a more of a sequential process, and upon complete itll run through
the loop again.
Step 1
First, the tanks level gauge sensor is active at all times. Control system keeps a regular check
on the tank level. Where the water level of the tank is 90% the control system will shut
down the pump centre.
When the water level drops below 20% the control system closes the tanks output water
delivery valve. In the event where the water level is less than 90% but more than 20% the
water delivery will not be interrupted.
Step 2
Where the water level is less than 90% the control system will be checking for the status of
the gate valves at Yarra Glen.
Step 3
If Opened, The pump station will be stated via the VSD systems. Given its closed, the system
will alarm for assistance.
Step 4
Whenever, the pump station is in operation the Flow rate sensor is active and the control
system keeps monitoring the flow rate and regulates the flow rate at a nominated value at
both the pumps.
2. PLC Design
There are three PLC used to have control over the pumps by connecting the pumps VSDs
and control system to regulate the flow rate.
The PLC receives the speed of the motors at which they operates via the Flow rate sensors
as an analogue signal at port AI0, which is converted to a digital signal and transferred to the
control system. There the PLC converts it back to an analogue signal and send it through the
AO1. Similarly, the valves and the level gauge communicates to the control system via
secondary and tertiary PLCs at each sub locations.
Figure 7 PLC design.
3. SCADA SYSTEM
The SCADA (Supervisory control and data acquisition) is used to process control the
gathering of data in real time from remote locations in order to control the equipment
and conditions of the pump station.
The SCADA system sent all the information gather of all the systems to the control
system (Computers) via PLCs with the aid of the SCADA software. The SCADA system
analyses and display the updated status of the entire system, and could be operated
from elsewhere.
This enables every aspect of the station to be operated from elsewhere, which makes it
exclusively an automatically operated station.
4. farLink wireless Systems
Figure 8 farLink plan
Farlink is a long Haul and high reliable UHF point-to-point solution. The Farlink E, which is a
full outdoor system operates at 400MHz transmitting Ethernet data. This system is used to
combine the three sub locations namely, the Yara Glen gates and Storage tank to the main
control centre located at the Power station.
In this manner it enables to send and receive data from the gate valves status from Yara
Glen and the Water level information from the storage tank wirelessly, making it a one
whole network. Farlnik is capable of operating in a radius of 100km, and both the sub
stations of the proposed project is located in a radius less than 70km, which makes it
possible.
Advantages
Cost-effective;
Customizable traffic;
Digital intercom channel;
Automatic backup of channel groups based on BER, signal strength, and hardware
failure;
Additional channels with digital and analogue interfaces
Future Improvements
In the future the system has the capability of adding up new sub location, which provides
the ability of adding new subs stations. Further, it has another operating system farLink P
that transmits both TDM and Ethernet Data, which could be upgradeable upon necessity.
5. Variable speed drive (VSD)

Reflective study.
First, it was the idea was to use the automatic operated control valves along with pressure
sensors. This method had couple of issue as the mechanicals introduced the secondary
pump to the system. A single pump could have been easily operated with the aid of a
control valve and a pressure sensor via a solo PLC. Still, when two pumps are in operation it
was important that the control valves data to each other so that the output
flowrate/pressure in the pipe remain at a constant rate. Eventually, the study illustrated
that, this could not be achieved with the use of control valve, rather using VSD systems at
each pump enables to counter balance the flowrate at each pump by simultaneously
regulating the motor speed.
Cost Analysis
The drivers also enable saving in installation cost; switchgear is eliminated, motor cables are
reduced from 6 to 3 wires, power facto correction capacitors are not required, size and cost
of cabling and fuses could be minimized as the starting current is kept at nominal a value.
Figure 9 Variable speed drives.
VSD selected is suitable for the HAVC applications where the speed control of motors from
the main supply to variable frequency and voltage enabling motors to be used with
maximum efficiency resulting in significant energy savings. The control keypad is to be
located two meters away.
The selected motor of VSD this designed to be used in HVAC environments, it enables fans
and motors to deliver water at such variable flow applications. Where the flow rate is
reduced the motor energy is significantly cut as the to control the relationship between flow
rate and the power flow that operate in a cube law, hence reducing flow by 20% reduces
power by 50%. It operates at 440VacThe PLC -VSD I/O configeration is shown below
6. Tank Level Gauge
Figure 10 Tank level gauge.
The tanks level gauge chosen LC-100 provides continuous level measurement in water. It
was important to find a device with spontaneous update, as the level gauge is prioritised in
the designed control system. It is capable of measuring the 4-20 mA analogue signal from
the sensor and communicating externally via Modbus. It has a six character digital
display combined with a 40 segment bar graph, reads in depth, volume or mass; has
alarms, status lights, and push button panel for programming the configuration interface
via a PLC.
The proposed tank is 70meters in depth and the objective was to find a level gauge that
operates in such depths. This LC-100 level gauge sensor has the ability of measuring the
water level at a maximum depth of 0-200meters, so it ideally suits for the purpose.
The level gauge sensor is submerged and installed leaving the controller fixed at the
control unit. The sensor is navigated to the bottom of the tank, aligned against the wall
of the tank. It is mounted to the wall at a distance using wall brackets considering the
optimal operation of the sensor.
Figure 11 Installation of the level gauge sensor.
7. FIRE DETECTION AND ALARM SYSTEM

Cultural property management is delegated the responsibility of protecting and preserving
an institution's structures, logistics and occupants. Attentiveness is key to minimize adverse
effects due to climate, pollution, theft, vandalism, insects, mold and fire. Due to the speed
and totality of the destructive force of fire, it happens to be one of the more serious threats.
An uncontrolled fire can obliterate an entire room and its contents within a few minutes and
completely burn out a building in a couple hours.
A fire detection system is designed to sense smoke, excessive heat or fire to ensure an alert
is provided for a particular area of the building. The type of fire alarm system required
depends on the age of the building and the layout of the structure. Hence the Australian
Development Act of 1993 specifies that commercial and residential rental properties must
have smoke alarms installed in their structures. The smoke alarms must adhere to the
Australian Standard AS 3786 which outlines the minimum criteria required to appropriately
detect and alert in the event of a fire.
FIRE DETECTION AND ALARM SYSTEM OF THE BUILDING
Considering all the factors, we came up with a system for our building. Multiple fire
detecting and alarm system will be installed including a fire hose reel along with fire
extinguishers. The whole system is connected with the control panel under VESDA fire alarm
system. Moreover, a 6 monthly routine service will also be conducted.
All the standards were followed and safety of the building and staff members was carefully
undertaken.
The following equipment is required for the system:-

VESDA Very Early Smoke Detection Apparatus
Air aspirating smoke detection is selected. This device consists of two main components: a
control unit that houses the detection chamber, an aspiration fan and operation circuitry;
and a network of sampling tubes or pipes. Along the pipes are a series of openings which
permit air to enter the tubes and be transported to the detector. Under normal conditions,
the detector constantly draws an air sample into the detection chamber, via the pipe
network. The sample is analysed for the existence of smoke, and then returned back into
the environment. If smoke is present in the sample, an alarm signal is transmitted to the
main fire alarm control panel. Air aspirating detectors are extremely sensitive and are
typically the fastest responding automatic detection method. Many vast technology
organizations, such as telephone companies, have standardized on aspiration systems. In
cultural properties they are used for areas with high value settings such as collections,
storage vaults, and safe rooms. These are also frequently used in aesthetically sensitive
applications since these mechanisms are often easier to conceal, when compared to other
detection methods.
FIRE SPRINKLERS
For most fires, water represents the ideal extinguishing agent. Fire sprinklers utilize water
by direct application onto flames and heat, which causes cooling of the combustion process
and prevents ignition of adjacent combustibles. They are most effective during the fire's
initial flame growth stage, while the fire is relatively easy to control. A properly selected
sprinkler will detect the fire's heat, initiate alarm, and begin suppression within moments
after flames appear. In most instances sprinklers will control fire advancement within a few
minutes of their activation, which will in turn result in significantly less damage than
otherwise would happen without sprinklers.
FIRE ALARMS
A fire alarm system has a number of devices working together to detect and warn people
through visual and audio appliances when smoke, fire, carbon monoxide or
other emergencies are present. These alarms may be activated automatically from smoke
detectors, and heat detectors or may also be activated via manual fire alarm
activation devices such as manual call points or pull stations. The alarm system used for the
building are two wall mounted siren alarms with alternating frequencies.
FIRE EXTINGUISHERS
A fire extinguisher is an active fire protection device used to extinguish or control small fires,
often in emergency situations. Typically, a fire extinguisher consists of a hand-held
cylindrical pressure vessel containing an agent which can be discharged to extinguish a fire.
Fire extinguishers manufactured with non-cylindrical pressure vessels also exist, but are less
common. A total of four fire extinguishers will be used.
FIRE HOSE REEL

A fire hose (or firehose) is a high-pressure hose that carries water or other fire
retardant (such as foam) to a fire to extinguish it. An indoor hose reel is use which is
attached permanently to the plumbing system.
The usual working pressure of a firehose can vary between 8 and 20 bar (800 and 2,000 kPa;
116 and 290 psi) while its bursting pressure can be up to 83 bar (8,300 kPa; 1,204 psi)
After use, the fire hose is should be hung to dry, because standing water that remains in a
hose for a long time can deteriorate the material and render it unreliable or unusable.
Conclusion
Figure 12 Standardising procedure.
All the instruments proposed for the project are from suppliers standardised at AS/NZs
4801:2001, regardless of it is newly manufactured or an outright purchase. First, we studied
the OHS policies and standards. Then designed and planned the proposal of the project with
respect to the quality standards and to satisfy OHS rules and conditions. Afterwards, the
evaluation of the implementations are to be standardised for confirmation.
Finally, all the deliverable are drafted approved. As a group we are highly satisfied with the
proposed designs at each every stage, and looking forward to address oncoming issue upon
construction.
5 Appendices
5.1 Mechanical Engineering Deliverables
5.1.1 Calculations
Bernoullis equation:
Credit to: http://www.globalsecurity.org/military/library/policy/army/fm/5-482/Appa.htm

Now, because of a constant flow rate and constant pipe diameter throughout the length of
the pipeline and because of no additional pressure head, the equation reduces to:
1 + = 2 +
= (2 1 ) +
The height differential was 200-300m, so I used the maximum possible height 300m as that
would be the most demand possible.
2
= ( )( )
2
The above is the Darcy-Weisbach equation and it is used to calculate the pressure drop in a
pipe. The head loss would also include loss from the valves but the effects of the valves have
yet to be made clear to me. I would imagine valves would have negligible effect on head loss
because of 70km of piping was under one-tenth of the elevation head and because of the
slow water velocity.
Determining Pipe Internal Diameter:
I was informed by Dwayne that for pipelines, the best speeds for water were between 1-1.5
m/s. Using the head loss equation, I will choose the speed that causes the least head loss.
V=1.5m/s
Volumetric Flow Rate= 50GL/year=50,000,000 cubic metres/year=1.585 cubic
metres/second
2
=
4
Solving for D, the answer at 1.5m/s: D=1.16m
f=friction factor=0.0118 (This was obtained through textbooks)

L=pipe length=70km
D=pipe diameter=1.16m
V=flow velocity=1m/s
g=9.81 m/ 2
70 103 1.52
= 0.0118 ( )( )
1.16 2 9.81
= 81.66
Solving for D, the answer at 1m/s: D=1.42m
f=friction factor=0.0118
L=pipe length=70km
D=pipe diameter=1.42m
V=flow velocity=1m/s
g=9.81 m/ 2
70 103 12
= 0.0118 ( )( )
1.16 2 9.81
= 29.65
= 300 + 29.65 = 329.65
= /
= 1.585 1000 9.81 329.65/0.836
= 6.13
The pump is 83.6% efficient, hence the amount of power needed will significantly rise. But,
according to the datasheet from Ruhrpumpen, 3,169kW is required per pump. Power
required is now 6.4MW.
Pipe Pressure Calculation
Diagram 1.2 Software Calculation for pipes
5.1.2 Drawings
Design Methodology
2. Reverse Engineering
Diagram 1.1: Ideal state
gure 1.3 Piping System Design
Figure 1.4 Process Flow Diagram
Datasheets
1. Valves
Table 3.1: Specific Maximum differential bar for each model
2. Pipes
Figure 1.2 Flow Rate Calculation
Figure 1.5 Pressure analysis
Figure 1.6 Assumption make as the whole piping sizing in the system remain the same
Recommended improvements
Diagram 1.7 New calculation as the pump station is same level with the tank.
For the pump, we could use one strong pump. Future more, with the large landscape. We
could use multiple tank to store the water instead of one massive tank. Finally, it is the
requirement of the step up transformer tank to prevent the oil leakage spread around the
station.
Further improvements
3. Pumps
4.
Source for carbon steel strength: http://www.azom.com/article.aspx?ArticleID=6525
7.1.1 Etc.
Though it was not specified in any particular standard, a rule of thumb for water tank design
was that the height-diameter ratio is between 0.8 and 1.3. The appropriate standard is the
API650. Below is the datasheet of the pump from Ruhrpumpen.
7.2 Civil Structural Engineering Deliverables
7.2.1 Calculations
For the development of the storage tank, a minimal surface is necessary to reduce the
amount of steel used. Assuming a closed cylinder, it was found the best ratio to minimise
surface area was 1.
Evidence:
= 0.25 2
= 0.5 ( + 2)
V=275000 cubic metres

=
0.25

=
0.25 2
To find the optimal surface area, differentiate the surface area equation and make the
derivative equal 0.

= 0.52 + ( )
0.25 2
4
= 2

4
0 = 2

4
= 2

3 4
=

Volume is 2 days of the annual river flow. Roughly 275,000 cubic metres. V=275000
34 275000
=

= 70.48
Check height
275000
=
0.25 (70.48)2
= 70.48
So the optimal ratio is 1. The tank will be 71m in diameter and 71 metres tall.
Hoop stress:
In order to determine what hoop stress equation to use, the ratio between wall thickness
and tank radius must be found:
35.5
= = 71
0.5
The ratio is greater than 10. So use the equation below:

=

800,000 35.5
=
0.5
=56,800,000Pa
Or 56.8MPa.
7.2.2 Drawings
7.3 Electrical & Control Systems Engineering Deliverables
7.3.1 Fault Current Calculations
7.3.2 Drawings
1. Design of The power station.
Figure 13 General arrangement of the power station.
8. Single Line Diagram (SLD)
Figure 14 Single line diagram
9. Design of the Substations.
Figure 15 HV and LV Substation arrangement
10. Cables Layout
Figure 16 Layout of Cables
11. Lighting Arrangement
Figure 17 Layout of light arrangement
CONTROL SYSTEM DESIGN
1. Control System Architecture
2. PLC design.
Figure 18 PLC design.
3. SCADA SYSTEM
Figure 19 SCADA architecture
4. farLink wireless Systems
Figure 20 farLink plan
5. Variable speed drive (VSD)
Figure 21 PLC and VSD I/O configeration.
6. Tank Level Gauge
Figure 22 Tank level gauge.
Figure 23 Installation of the level gauge sensor.
7. FIRE DETECTION AND ALARM SYSTEM OF THE BUILDING
Figure 24 Fire alarm system
7.3.3 Datasheets
Description Unit Data
Rated voltage kV 33
Rated Power MVA 6.3
Output Voltage kV 6.6
1min power frequency withstand voltage kV 95
Number of Phases 3
Number of coils 3
Rated frequency Hz 50/60
No load loss KW 7.04
Load Loss KW 38.07
Impedance Voltage V 7%
No load Current A 0.68
Table 4 HV Transformer datasheet
Description Unit Data
Rated voltage kV 6.6
Rated Power KVA 30
Output Voltage V 400
Number of Phases 3
Number of coils Two windings
No load loss W 100
Load Loss W 600
Impedance Voltage V 4%
No load Current A 2.1
Gross weight kg 305
Table 5 LV Transformer datasheet
Item Unit Data
Rated voltage kV 6.6
Rated current A 200, 400
Rated interrupting current kA 40
Rated main bus bar current A 400, 630, 800, 1250, 2000
Rated vertical bus bar current A 700
Rated short time current kA 40
Insulation AC kV, 1min 20
Insulation BIL KV 60
Control voltage V AC100/110, 200/220V
Table 7 LV Switchboard datasheet
Table 6 HV Switchboard datasheet Jayanga Rajapakse 65

Description ENG30001 ENGINEERING
Unit DataDESIGN ACADEMY
Rated voltage VAC 400
Rated insulation voltage VAC 1000
System 33W/34W
Rated current A 630-5000
Rated short time withstand current kA 50, 65, 75, 85, 100KA
Main circuit withstand voltage V 3500
Control circuit withstand voltage V 1500
Table 8 Cable Layout datasheet
Description Item Data

Rated Power 10KVA
Phase 3
Input Input Voltage 240~400Vac
Input Frequency 50/60Hz 5Hz
Output Output Voltage 110/120Vac or 220/230Vac
Output Frequency 50/60Hz 1%(Battery Mode)

Output Accuracy 10%
Wave Form sine wave
Wave Distortion < 3%
Efficiency >90%
Protection Utility Mode output high/low voltage, overload, short circuit, surge
Battery Mode battery low voltage, overload, short circuit,battery reverse

connection
Buzzer Alarm Battery Mode beeping 4 times continuously Every 30 Seconds
Overload beeping once every second
Battery Low V beeping once every second
oltage
Error continuous beeping
TAGNR DESCRIPTION CABINET l/0 SIGNAL
P1110 infl pomp 1 B1 DI10 pushbutton in
Table 9 UPS datasheet
P1110 infl pomp 1 B1 DI1 pushbutton out

P1110 infl pomp 1 B1 DI2 safety switch
P1110 infl pomp 1 B1 DI3 contactor position
P1110 infl pomp 1 B1 DI4 main current breaker
P1110 infl pomp 1 B1 DI5 control current breaker
P1110 infl pomp 1 B1 DI6 Run signal VSD
P1110 infl pomp 1 B1 DI7 failure VSD
P1110 infl pomp 1 B1 D01 contactor
P1110 infl pomp 1 B1 D02 run VSD
P1110 infl pomp 1 B1 AI speed
P1110 infl pomp 1 B1 AO speed
Table 10 PLC input/output list
Item Description
Description Data
Supply Voltage 440Vac (-15%) to 600V (+10%)
Output Voltage 0 to 600Vac
Capacity up to 20 Mbps
Modulation adaptive, from QPSK to 64 QAM
Interfaces Ethernet/TDM
Operational distance up to 100 km, LOS, NLOS;
Configuration full outdoor, 1+0, 1+1, 2+0, 1.5+0.5
System gain up to 132 dB
Table 11 farLink datashee
Phase 3 Phase
Frequency Range 0-200Hz

Description Data
Motor - Power indicated on name plate 3200kV
Sensor Element: Silicone Diaphragm, Silicone Diaphragm,
Line supply - Line current 24Vdc (20mA)

Wet/Wet
DigitalTransducer
Inputs: Range: 0-200m control functionality
5 Digital Inputs with programmable
Digital Outputs 2 Relays with programmable functionality
Analogue Inputs 2 Analogue Input 0-5V, 0-10V, 0-20mA, 4-20mA
Analogue Outputs Up to 2 Analogue Outputs with programmable functionality
Preset Speeds 7 programmable Speeds
Table 12 VSD datasheet
Linearity and Hysteresis 0.1%
FS Accuracy: 0.1% FS at constant temperature,

0.2% over 35 to 70F range
Overpressure: Not to exceed 2 x full scale range
Resolution: Infinitesimal (Analog)
Power Input 24VDC
Supply Voltage: 20 VAC, 240 VAC
Outputs: Analog output 4-20 mA
Current Draw: Same as sensor output.
Warm Up Time: 10 ms minimum
Weight: 1/2 lb.
Operating Temperature: -40 to +185F Weight: 1/2 lb.
Compensated Temperature Range: 30 to 70F submerged,
Table 13 Tank level gauge datasheet
Date 4th Day of January 2017 ENG30001 ENGINEERING DESIGN ACADEMY
Venue AGCSE 202
Members Ali, Sebastian, Tee, Asanka, Jayanga
Minutes Formed the group and discussed about the initial approach to the project.
Ali: Mechanical
Sebastian: Mechanical (Pump)
Tee: Mechanical (Pipes & Valves)
Asanka: Civil (Structures and geotechnical data)
Jayanga: Electrical & control systems
Date 6th Day of January 2017
Venue AGCSE 202
Members Ali, Sebastian, Jayanga
Minutes Ali: Was organising the team up.
Jayanga: Requirements for the power stations were mentioned. (Access to power)
Sebastian: Submitted a derivation for the pump head respective to the energy
equations.
Civil not represented
Venue Library
Members Ali, Sebastian, Tee, Jayanga
Minutes Ali: Split the work Among the group members.
Sebastian: Looking into pumps.
Jayanga: SLD for HV and LV were submitted and transmitting data using Farlink.
Tee : Research on suitable pipes
The issue of the Civil person not turning up was mentioned.
Venue AGCSE 202
Members Ali, Sebastian, Tee, Jayanga
Minutes Sebastian: Requested details on the Layout of the pipe line and elevation details.
Tee: Submitted a mechanical equipment list required, and requested for further
clarifications on pumps(out/In)
Jayanga: Submitted a proposal on the PLC control system. Working on Switchboard.
Venue Library
Members Sebastian, Tee, Jayanga
Minutes Formed the group and discussed about the initial approach to the project.
Sebastian: Provided details of the centrifugal pump to be used. Gave discharge,
maximum head, maximum flowrate, specified centrifugal pump type and derived
mechanical power required.
Tee: Provided the Valves List and Specification. Have a discussion on the valve for
selection in the drawing to install in our piping system. Simple and it fulfilled the
scope of the project is the main goal. Working on the best material for piping and
further on to design criteria for the overall piping layout. With the provided detail on
pump, the pipe sizing could be calculated.
Jayanga: Design Layout for the LV Cable schedule was announced, and control
instruments were listed.

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ENG30001 ENGINEERING DESIGN ACADEMY

ENG30001 Engineering Design Academy

2 Overview of Proposed Design

First phase: Design life, Environmental requirements, constructability and maintainability,

4.1 Mechanical Engineering Design Summary

4.1.1 Piping Design

Types of Materials used in piping

Plasticized polyvinylchloride (PVC)

Selection of Materials used in piping

Australia Standards for Piping Materials

Metallic material and Non-metallic material

This standard requirement applies specific to pressure pipe:

Figure 1.1 Australian Standard

Australian Standard on Steel pipe

AS 1074 Steel tubes and tubulars for hollow sections

Diagram 1.1: Ideal state

4.1.2 Pump Design

Ruhrpumpen Horizontal Split Case ZW 18x14x32 Pump Source:

4.1.3 Valve Design

Start and stop of flow

Valve List and Specification

diameter is designed from a range

Check Valve The usage of check valve is to

Lift Check valve Life Check Valve usually has a size

Gate valves was designed due to the

Angle Valve Materials- 304 S. S.

Needle Valve Server up to 689.4757 bar

Body design used international

For the gear operators where have 10

Control Valve Actuators Valve Method of Control and

The pressure relief valve (PRV) is a type

up for a process upset, instrument or

Choke Valve Choke Valves are severe service valves

Control Valve A control valve is used to control fluid flow by

varying the size of the flow passage as directed

STD 600 Steel gate valves,

Control Valve Actuators ISA S20.50 Specification Forms for

ISA Guide Control Valves, Practical

Foot Valve AS 1722.1 Pipe threads of

Control Valve Actuators and Positioners

1. Electro-Pneumatic Valve Positioners

3. Direct Acting Actuators

a) More accurate control and position is required.

Electrical Actuators operation and options

Reason on Selecting these valve

4.2 Civil Structural Engineering Design Summary

4.3 Electrical & Control Systems Engineering Design Summary

4.3.1 Power Reticulation

2. Single Line Diagram (SLD)

In addition, a standby pump is proposed to install as a secondary plan for emergency

Alongside, an uninterrupted power system installed with an automatic transfer switch to

Design of the Substations.

3. High Voltage Substation

Figure 2 High Voltage Transformer

Assumption the Rated Pump Voltage 6.6kV.

Figure 3 High Voltage Switchboard

4. Low Voltage Substation

Figure 4 Low Voltage Transformer

Figure 5 Low Voltage Switchboard.

Lighting arrangement is designed to be operated in two different modes, as Regular system

Uninterrupted Power Supply

Further, it operated as a stabiliser on battery mode. Hence, provide adequate protection in

4.3.2 Control System