Sep 07, 2017

Large Utility Turns to Artificial Intelligence at Major Pump Station

Pump station outfitted with new equipment to solve reliability problem

concertor pump on the site ready for installation
new versus old 10-hp pump
concertor pump on the site

The Genesee County (Mich.) Drain Commissioner, Division of Water & Waste Services (GCDC-WWS) is responsible for the construction and maintenance of the county sanitary sewer collection system and water distribution system. GCDC-WWS owns and operates three wastewater treatment facilities: the Anthony Ragnone Treatment Plant (ARTP), Sanitary Disposal District #3 Treatment Plant and Sanitary Disposal District #7 Lagoons.

Scope

In 2007, GCDC-WWS completed the construction of its Northeast Extension Sewer Project, which split and rerouted some of the system’s flows. The utility began reviewing the current status of ten of its major sanitary sewer pumping stations. Pump Station #8, servicing Genesee and Richfield townships, was among the stations being considered for rebuilding the existing pumps or replacing them with new units.

Pump Station #8 contained two horizontal dry pit and two submersible pumps installed in 1988. GCDC-WWS Operations and Maintenance Department has rebuilt the pumps several times over the years. De-ragging of pumps was part of their employees’ standard operating procedures when running their station routes. When it became time once again to rebuild the pumps, GCDC-WWS opted to look at newer options. It also was desirable for the new pumps to match the actual flow and head conditions required.

Simply rebuilding pumps did not restore them to their original head conditions and flows. In addition, there were longevity considerations between repairs, ongoing ragging problems, spare parts issues and service considerations for the older model pumps.

new versus old 10-hp pump

New versus old 10-hp pump.

Solution

GCDC-WWS no longer wanted to throw good money at old technology, so it turned to its Xylem distributor and supplier Kennedy Industries for answers and a more permanent solution. Pump Station #8 was the perfect place and time to introduce Xylem’s Flygt Concertor, a smart wastewater pumping system that senses the operating conditions of its environment, adapts its performance in real time and provides feedback to pumping station operators.

There are several reasons why Flygt Concertor technology appealed to GCDC-WWS:

  • Interchangeability throughout many of the pump stations reduces the number of spare pumps needed in its inventory. This created the ability, in an emergency, to move pumps from a lower priority station to an immediate priority station by simply resetting the pump parameters.
  • The Xylem Technology with integrated speed control eliminates the need to purchase variable frequency drives, which was also a selling point as this takes up valuable space. Flygt Concertor’s built-in technology saved the county time and money by eliminating the need to upgrade controls.
  • The county was most impressed with Flygt Concertor’s automatic non-clog reverse function. County personnel already were familiar with the reverse function troubleshooting method because they often had to employ it with their current pumps. Concertor’s built-in intelligence of the auto reverse function reduces life-cycle cost dramatically by not having to send personnel out to the station, thus eliminating the inherent danger involved with working with high voltage while switching motor leads around.

The outdated guide rail assemblies were replaced due to extreme corrosion; Kennedy supplied the new rails and the county installed them. Human/machine interfaces were installed for pump feedback, a feature the county did not have with the old pumps at Station #8. Being able to receive and monitor pump running, amp draws, voltage, speed, faults, starts, runtime, daily runtimes, daily kWh usage and troubleshooting suggestions are all value-added features when purchasing the Flygt Concertor.

concertor pump on the site

Concertor pump at the site.

Results

The new pumps began operation in March 2017, and thus far, results have been impressive. There have been zero maintenance callouts. Furthermore, the N-impeller self- cleaning design plus the ability to auto reverse during a “soft clog” has eliminated the need to pull the pumps and clean them on a weekly basis, greatly reducing the risk of personnel injury to the maintenance teams.

On this retrofit project, elimination of the variable frequency drives resulted in a major reduction in both installation and equipment costs. Additionally, the Energy Minimizer functionality of the integrated pump controls significantly reduces operating energy costs.

Flygt, a Xylem brand

Contact

14125 South Bridge Circle

Charlotte, NC 28273

United States

Phone: 203.712.8927

Fax: 203.380.4705

http://www.flygtus.com

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