The project: Supplying Stadtlohn with sufficient water pressure
Stadtlohn’s utility SVS-Versorgungsbetriebe was struggling with fluctuating water pressure. At peak load times, water supply could no longer be guaranteed. Following a pressure drop of approx. 1 bar lasting over 3 hours, the decision was finally taken to redesign the clean water pumping station at the Stadtlohn-Hundewick waterworks. An additional objective was to achieve energy savings for the clean water pumps.
The customer: SVS-Versorgungsbetriebe
SVS-Versorgungsbetriebe provides the public energy and drinking water supply for the towns of Stadtlohn, Vreden and Südlohn (hence the name SVS), which are located in the western Münsterland region in the northwest of North Rhine-Westphalia. As well as providing electricity, natural gas and fibre-optic lines, SVS-Versorgungsbetriebe delivers an average of 2.9 million m³ of water per year to the local population as well as to industry, trade and agriculture via a network of pipelines stretching over 472.2 km.
The challenge: Optimum water transport in confined spaces
The supply networks Stadtlohn and Südlohn lacked sufficient drinking water reserves. When quantities of around 400 – 440 m³/h were required, pressure dropped to 32 mWC and the clean water pumps were unable to transport the required quantity, despite the head of 42 mWC being clearly below their design point which at the time was known to be 54 mWC. The redesign also had to account for the extremely limited space available in the waterworks, which ruled out most horizontally installed pumps on the market.
The solution: Proven pumps with state-of-the-art control technology
The engineering company H2U was entrusted with the task of performing a fault analysis and developing a new plan. An extensive review of the performance data and an energy efficiency analysis of the waterworks yielded the following insights: The system lacked redundancy, offered unfavourable efficiencies and could not cope during high-demand periods as the pumping station was not designed for flow rates of more than 60 m³/h – even though these occurred 15% of the time.
The engineers decided to modify the piping and flow rates, with the work being carried out by the company A+H Anlagentechnik. The following factors were of primary importance: The system needed to become more flexible and energy efficient while offering a higher level of redundancy. In the Multitec V, KSB was able to offer a very efficient pump with frequency inverter (FI) which can also be operated via the latest high-tech interfaces. In addition, the pump can be installed vertically and thus fit perfectly into the confined space available. From a cost-benefit perspective, this was the best solution on the market.
The entire waterworks now employs KSB SuPremE® motors controlled by frequency inverters. The water flow rates of the pumps controlled via frequency inverters can be read on the PumpDrive display. The frequency inverters can be operated very easily by means of a multi-line display and can also be set via Bluetooth using a smartphone. Using KSB SuPremE® motors also delivered the desired energy savings. Here, the frequency inverters are additionally used to calculate the pumped flow rates, removing the need to purchase electromagnetic flow meters.
The cooperation of all parties involved went so well that KSB has already converted another waterworks in Vreden to using KSB SuPremE® motors, PumpDrive 2 and KSB Guard.
Figures I Data I Facts
End user: SVS-Versorgungsbetriebe
- 2x Multitec V
- 3x Etanorm
- 5x PumpDrive
- 5x PumpMeter
- 5x KSB Guard
Horizontal volute casing pump, single-stage, with ratings and main dimensions to EN 733, long-coupled, back pull-out design, with replaceable shaft sleeves / shaft protecting sleeves and casing wear rings, with motor-mounted variable speed system. With KSB SuPremE, a magnetless synchronous reluctance motor of efficiency class IE4/IE5 to IEC TS 60034-30-2:2016, for operation with the KSB PumpDrive 2 or KSB PumpDrive 2 Eco variable speed system without rotor position sensors. Motor mounting points in accordance with EN 50347, envelope dimensions in accordance with DIN V 42673 (07-2011). ATEX-compliant version available.
PumpDrive 2/PumpDrive 2 Eco
Modular self-cooling frequency inverter that enables continuously variable speed control of asynchronous and synchronous reluctance motors by means of analog standard signals, a field bus or the control panel. As PumpDrive is self-cooling, it can be mounted on a motor, on the wall or in a control cabinet. Up to six pumps can be controlled without needing an additional controller.
System for monitoring the condition of pumps: Sensors on the pump record vibration and temperature data, which is processed in the KSB Cloud. Information on the pump's condition can then be accessed via smartphone or computer. Easy to retrofit on pumps during operation. Components of the KSB Guard system: KSB Guard kit (comprising sensor unit and transmission and battery unit) and KSB Guard gateway. Access via the KSB Guard web portal www.ksbguard.net (computer) or the KSB Guard app is required to retrieve operating data. Data from up to 40 pumps can be transmitted via one KSB Guard gateway.