Kurdistan regional government- Iraq

Ministry of Municipality and Tourism

General Directorate for Water and Sewerage

Introduction
To
Project
Main
Equipment
2016. 04.
30

Training Schedule

Week 1
Monday
1st lecture: introduction to project equipment.
2nd lecture: water chemistry .
Tuesday
1st lecture: treatment plant basics .
2nd lecture: Design &Calculation .
Wednesday .
1st lecture : sequence of operation .
2nd lecture :chemical dosing .

Training Schedule

Week 2
Sunday
1st lecture :MV . LV Switchgears .
2nd lecture : Generators .
Monday
1st lecture : SCADA .
2nd lecture : Lab Test procedures.
Tuesday .
1st lecture : .Pump & valves
2nd lecture :Health & Safety .

..

Introduction To
Project Main
Equipment

..

Primary Pumping Station (P1)

Manufacturer : XYLEM WATER SOLUTION AB

Model No. CT3231.736 455, 170kW
3 in Duty/1 Stand By
170kw, 3 phase 400vac/50HZ
Rated flow =800m3/h @diff head=50m
RPM = 1485
VFD control

Max Starts per hour=8 starts/Hr

Min continuous flow: 360m3 /hr @65m head

..
The control target of primary pumps to maintain the water level in
secondary tanks at predetermined level.

(high-high) level continuous for 5 minutes will shut down all pumps
(high) level for about 1 minutes will allow one pump to be operated
(low )level will allow to start two pumps
(low low )level will allow three pumps to be operated

System with high static head in comparison to friction losses ,any

reduce in pump speed may let the pump to works at low efficiency
point and will not produce the required
proportional flow.
Change of intake water level will dramatically affect the flow .
Speed and number of working pumps will be controlled by the SCADA
to maintain the required flow

..

..

Secondary Pumping Station (P2)

Manufacturer : XYLEM WATER SOLUTION AB

Model No. CP3351.905 650, 375kW
two in duty/one standby
Flow and head (rated):1200m/h @64m
Minimum flow: 1100 m/h @65m
Power: 375kw
Reduced voltage soft starter.

Max starts/hour: 8
Type: submersible

..

The control target of secondary pumps to maintain the water level in

the GRIT
REMOVAL CHAMBER
HH Level will stop all pumps (P2 A/C/E) at 765m altitude
Just above the limit H

(at 764m altitude) ) one duty pump will start .

Below the L level (at 762m altitude)) all pumps will run.
Low Water level in secondary water tank will switch off all pumps .
Soft starter . voltage ramping, current limiting will let the pump
accelerates with
suitable time matching the opening time of
the mechanical discharge check valve
On stopping , the DECEL program will decelerate in predefined time to
reduce
hammering, immediately opening the by bass
contactor letting the thyristors to slowly reduce pump torque till full
stoppage, the deceleration ramp time must be adjusted To reduce
check valve slamming and reduce motor heating during operation at
low voltag, the stopping of pumps will utilize the breaking function

..

Grit Removal
2 TRAVELLING BRIDGES.
5 Motors each ( 2 travelling ,2 Scraper ,
1 cable reel )
Traveling distance: 16 meters
Bridge span: 11.6m
Treatment capacity each bridge :43.
1m3/cycle
Capacity time: 28min
Cycles per day: (25-40) cycle
Duty: 2 duties
Forward speed: 1.2m/min
Reward speed: 1.2m/min

Raw Water Pump Station (P3)

Manufacturer : KSB
flow: 1122m/hour

Head: 205m.

Mode of operation: 3 pumps 2 running / 1

standby

1100KW @3.3KV fixed speed 1490 RPM,

50HZ

FLA 225 A, locked rotor current 1460

AMPS.

M.V SOFT STARTER .

Service factor 1.15, continues duty

operation S1

pumps
.. P-3 B/D/F will deliver the raw water to the flash mixer in treatment plant
Control of operation will be the level 30-LIT-602 in final treated water tank (P4)

Communication through SCADA

The level indicator in the local panel will be programmed for four threshold levels
(LL,L,H,HH) set points .

At rising water level

less than low level (at 748m altitude): this will initiate the operation of two pumps in
parallel, first pump start immediately and after 5 minutes the second pump will
start, time interval can be changed
upon request to achieve practical
sequence .

High level (750m altitude)set point will stop one of the running pumps if high level
signal is consistence for more than 2 minutes.

high high (752m altitude)level will stop all the pumps if this alarm set point
remain consistence for more than two minutes.
Pumps operation on running hours:
Based on weekly period interval, SCADA will calculate the running hours of each
pump Based on run status from the PLC (RTU)

Start stop intervals

To prevent the pump from exceeding the number of starts per hour limit.
Recommendation is two cold /one hot consecutive starts time(15-40 )min for
motor to cool down after full load running . PLC program will disable
successive starts within the above mentioned limits .

Time can be adjusted depending on thermal protection ANSI 49 in soft

starter and reducing the starting current limit to suitable value.

..

Raw Water Pump Station.

The local control panel can issue the start/stop to the pumps through The check valve
Manual operation from LCP also protected for high motor temperatures, low water level etc
The RTU will issue the automatic control in case of both the MCC and LCP are in remote pos.
Soft starter will be connected to the RTU through RS-485
Normal starting
Voltage ramp acceleration with suitable ramping time, the initial start voltage (20%-30%), curr
ent limit around 350% of FLA
The ramp timing (up to 120sec) to be adjusted with check valve time delay set by MC 2001P Ro
ss valve panel
Pump will start first after set time ( 20 seconds) the check valve start to open providing that the
pressure switch at the discharge of the pump reach the set value .
The hydraulic actuated check valve will take few second to be fully open ,
If the valve fails to fully open ( sensed by the limit switches on the check valve ) the pump will st
op.
When the valve is fully open the pressure switch at the pump discharge will be disabled during t
he filling period.

Raw Water Pump Station

Normal pump stopping

Using the Decel ramping (less than 60sec)`,with 30%, voltage this will issue braking
on the motor

This timing matched with check valve 95% closure time adjustment ,through de ene
rgize of normal solenoid valve S3 in check valve, to reduce the sudden change in pres
sure which causes hammering
Coasting shutdown
Emergency shutdown,
power failure
pump running in reverse
PLC will send signal to MC2001P to start emergency command to de-energize both
two way solenoid valve S2 and the normal stop three way valve S3 of the check valve
, closing will be immediate to prevent damage to the pump, hammering may occur i
n such cases.

Raw Water Pump Station.

Pump and valve system failures:

A- starting failure: system fail to start when

valve failure: if after elapsing of set opening time the valve fail to full open and limit switch fail to
send full open signal. The control panel will normal shut down the pump.

pump failure: during start period no detection of pressure at the discharge end measured by pr
essure transmitter , expired time TD set in MC2001P, normal shut down will be performed.

B- Running failure: pump will shut down during pump normal running .

Whenever valve open position is failed to be detected

during power failure the emergency shutdown will be activated.

loss of pressure at the pump discharge below set point.

electrical reset through selector switch in MC2001P to zero position.

C- Electrical trips:

over currents ANSI 50, 51 ,low current detection ANSI 37,winding temperature high

bearing temperature high,number of starts/ hours,power failure,reverse rotation,phase

ltage and current unbalance

loss, vo

Raw Water Pump Station

Local control panel:

PLC based control panel
No automatic operation, All governed by the RTU (SCADA)
only start/stop commands and alarms for the raw water pumps.
The local control panel is for local operation and monitoring operating conditio
n.
Measurement and protection are included in the LCP.
1.
2.
3.
4.
5.
6.
7.
8.

Water level treated water tank.

Water level in grit removal tank.
Pump discharge pressure.
Motor winding and bearing temperature .
Pump start/stop and trip.
Check valve opening failure.
Running hours .
Delay times between starts.

..

Flash Mixer

Manufacturer : MIXTEC North America

Motor Spec
Motor Kw/HP 15/20

Speed 1460
The flash mixer tank volume/flow rate input will
determine the detention time, the retention time
will be reduced by the rapid mixing in range of
(about 60 sec).

..F

Flow rate control setting:

The flow rate of raw water to flash mixer measured by (30-FIT-101),

will be totalized in SCADA , and used to determine the amount of
Chemicals to be added ,the flow rate will be averaged to eliminate the
high frequency flow variation, this will control the required dosages set
points

When no flow rate the SCADA will stop the flash mixer after
predefined time (less than 60sec)

The SCADA will transmit the value of flow (FIT-101) to

1. Alum control panel

2. Chlorinationcontroller (pre and middle) chlorination

..

CLARIFLOCCULATORS

Manufacturer : WESTECH

focculator &clarifier diameter 38m

flocculation chamber diameter=14m
side water depth=7.8m
Raw water inlet flow=1150m/h
Settled water flow=1135m/h
Sludge outlet flow 120m/hr
Flocculator numbers=2

..

Overload control:

Each motor starter equipped with overload protection.

Torque switch with two steps (alarm and shut down trip) for the main rake
driver.
The torque control is an electro mechanical device to protect the drive and
mechanism from overload caused by the extreme torque built-up due to
variation of unusual operating conditions

The drive unit protected from excessive loads

Alarm is set to (75-100)% of the normal torque (135,000-180,000)NM

..

Gravity Filter
The rapid gravity filter consists of six basins
each with :
Surface media area: 45.14m

Filter rates: (7.7-8.4) m/hr

Filter basin capacity=(7.7-8.4)x45.14 is up to
378m/hr per
basin

Filter media depth is 900 mm (dual media) as

sand and
anthracite

Water depth about 6.3m above filter media

Each filter controlled by separate control panel .
5 motorized valve for each compartment .
Level transmitter ,turbidity meter ,DP cell for

..

Back wash Pumps

Model: VIT-FFFM
Pump Type : VIT - Short Set Lineshaft . Turbine
Pump
Pump operation speed RPM 1475
Motor Hp : 99.100 HP
Flow : 4966 USGPM
Head :66.40 ft
Voltage 400 V

..

Filter System Block Diagram

..

Treated Water Pump Station.

Manufacturer : KSB
flow: 1042m/hour

Head: 185m.

Mode of operation: 3 pumps 2 running / 1

standby

900KW @3.3KV fixed speed 1488 RPM,

50HZ

FLA 188.3 A, locked rotor current 1224

AMPS.

M.V SOFT STARTER .

Service factor 1.15, continues duty

operation S1

..

Chlorination Building

CHLORINE DOSING & ANALYZER LOC

ATION

..

Alum Building

..

Polymer Building