Opti-Pump Products

Abstract

This report is a review of the OptiPump Pump Performance Measurement and Maintenance Decision Support System. features and İZSU stations, the preliminary studies we have done and the structure planned to be established contains information.

Introduction

OptiPump Pump Performance Measurement System is specially designed for pumps, providing online assessment based on predetermined parameters. It is a software developed specifically for pump stations, displaying the Station Performance of pumps and pump stations. It can be used by local and central users, as well as on all smart devices, including mobile devices, through internet access if required. User-based authorization allows the establishment of different hierarchical structures in the operating entity, enabling the creation of user-specific screens (dashboard) and permissions. Performance information can be instantly reported thanks to the reporting feature. Additionally, customized report formats can be prepared to meet the specific needs of the business. The advanced data validation system ensures data retention over many years. As a result, OptiPump will be a significant part of the organization's institutional memory.

Due to the continuously changing operating conditions in a pump, predicting the system's performance is quite challenging. In OptiPump, performance measurement is made independent of the operating conditions and presented to the user in comparable Key Performance Indicator (KPI) parameters. With OptiPump, users can track performance degradation values for each pump and total pump station over many years and compare current performance with historical data.

In addition to displaying performance degradation, OptiPump provides the user with the Impact-Analysis and Economic Analysis features. These features allow users to see the possible causes of performance degradation, their impact on system output and power consumption, and ultimately their associated costs. The Economic Analysis module facilitates maintenance planning by determining the break-even point between maintenance costs and additional costs caused by system failures. Moreover, the Economic Analysis module serves as an important assistant in conducting feasibility studies for the acquisition of new pumps, motors, and other equipment.

Furthermore, these features simplify the determination of optimal maintenance intervals and effective Maintenance Planning, both on equipment and system levels. Additionally, OptiPump provides a "measurable numeric value" for the impact of any maintenance or improvement activity on pump performance. This way, the effect of maintenance on pump performance can be clearly observed.

To set up and operate the system, the signals provided by all the necessary devices and equipment must be transferred to a Server. These signals, along with the existing signals of the system, are configured as inputs to the OptiPump software through a Database. If the software is deployed on a Server that is open to the external internet, secure access to the software can be achieved through various authorized methods.

In addition to the signals present on the pump, the OptiBOX system, which includes additional "Bearing Temperature" and "Vibration" sensors, can be mounted on the pump and used in the OptiPump system if requested by the user. With OptiBOX, OptiPump's Impact-Analysis capability is strengthened, enabling the identification of pinpoint failures and providing predictive maintenance recommendations to the user before an actual failure occurs. The Maintenance Management Support Module aims to increase the effectiveness of scheduled maintenance and repair activities and reduce costs related to labor, travel, spare parts, etc. OptiPump is a customized system for each pump, so each installation is considered a separate project, and the following steps are followed to set up the system:

1. Evaluation of Pump Design and Operation data
2. Evaluation of Pump and Pump Station Piping Diagrams
3. Evaluation of Measurement Devices
4. Installation of the Database System in the facility
5. Implementation of the Performance Module
6. Installation of OptiBox devices
7. System Testing
8. Commissioning and Training

The main modules that make up the system, as well as the benefits provided by the system components, will be explained in the following sections.

2 OPTIPUMP PUMP PERFORMANCE MEASUREMENT MAIN MODULES

2.1 OPTİPUMP PUMP PERFORMANCE MEASUREMENT MODULE

OptiPump Pump Performance Measurement Module operates based on a performance measurement and maintenance recommendation system supported by powerful mathematical models. It consists of modules specially prepared for all equipment found in pumps and directly affecting the system output. The entire software is developed by our software team as a "Decision Support" software. OptiPump Pump Performance Measurement Module allows monitoring pump performances online, identifying deteriorations in performance and their potential causes, and assisting in determining the Optimum Standstill Time for maintenance through the economic module. The pump module compares the performance values of a pump under operating conditions with the design conditions at the initial commissioning of the pump. Efficiency and Head are used as the performance criteria for the pump in this module. The working data from the field, along with the pump-specific performance curves and calculation algorithms embedded in the module, are used to calculate the current performance values of the pump. Then, the module compares the current performance values with the reference conditions to reveal the deterioration values of the pump. This enables:

  • Online visualization of the pump's energy consumption under current operating conditions, allowing the calculation of additional energy consumption costs caused by the pump.
  • Long-term (up to 10 years) operation data can be tracked through data validation and filtering.
  • Adjustment of pump maintenance intervals based on degradation and differences in Key Performance Indicators (KPIs).
  • Continuous monitoring of data from field sensors and early detection of potential "mechanical, hydraulic, and electrical" faults through generated warning signals, facilitating "Predictive Maintenance" implementation.
  • Identification of possible problems and their causes through the Impact-Analysis module, leading to minimal maintenance requirements.
  • Evaluation of data from the field, cleansed from contaminants and changing conditions, through the "Data Validation and Filtering" feature.
  • Calculation of the "Replacement Periods" for pumps through the Economic Analysis Module.
  • Continuous monitoring of vibration and bearing temperatures with OptiBox installation, enabling the early detection of faults.
In the OptiPump Pump Performance Monitoring System, the following signals listed in Table 1 are monitored.
Table 2.1. Parameters Required for Pump Performance Calculation
Measured Parameters Description
Q Pump flow rate
P2 Pressure at the pump inlet
P1 Pressure at the pump outlet
RPM Pump rotational speed (for variable speed pumps)
W, U (V), I (A), cos Φ Power analyzer
Tyatak, Vyatak Bearing temperature and Vibration (provided with OptiBox)

2.2 STATION MODULE

The station module is the main screen where the results calculated in pump performance modules are displayed on a station basis. OptiPump system allows evaluation of pump station performance based on equipment and the performance criteria when pumps operate together, and it also presents all relevant information about the station on a single screen. Within this scope, the main screen of the software displays general performance values from all pumps, real-time information, sudden changes, and performance losses related to signals to the user. Thus, ranking of pumps that work efficiently in stations can be established, and the use of pumps with the lowest energy consumption can be ensured for energy savings. The screen provides graphical and numerical presentation of pump performances for comparison.
In addition to monitoring the KPIs of pumps and station-specific KPIs, OptiPump provides monitoring of fault signals determined by OptiPump on a station basis. Furthermore, through the Maintenance Management Support module, tracking of scheduled predictive/preventive maintenance activities can be achieved on the screen.

2.3 MAINTENANCE MANAGEMENT SUPPORT MODULE

The Maintenance-Repairs Decision Support system, a separate module of the OptiPump system, ensures the execution of continuous control maintenance within a certain system for equipment-based corrective and preventive maintenance activities to be carried out in pump stations. It is structured with effective planning and reporting content in terms of time, performance, and planning of comprehensive preventive maintenance activities and corrective (failure) maintenance works in equipment and facilities. It provides monitoring of maintenance performance for pump stations and offers "Decision Support" services based on maintenance data. Decision support capabilities for executive management are presented through a Management Cockpit. "Maintenance Schedules" are created to minimize the breakdowns causing system operation to stop and thus optimize the effectiveness of operations across the organization. In the scope of failure and emergency maintenance work, "Work Orders" are opened, and records of work order details are kept. Instant completion of tasks and notifications, and reporting of performed and unperformed duties and notifications are achieved through this module.
Work orders related to "Failure and Emergency Maintenance Requests" are displayed in a suitable structure as "Open, Pending, and Completed" work orders. Processed work orders can be viewed collectively on a single screen in real-time. The "Operating and Maintenance Infrastructure" is provided, detailing the equipment in the operating inventory for maintenance, and computer-based maintenance infrastructure is presented for the realization of any kind of operation and maintenance/repair. Maintenance infrastructure data is processed into the software to produce the maintenance infrastructure in a product tree format. The "Maintenance Types and Modes (periodic, predictive, planned)" specific to each critical equipment are extracted through this module. The Maintenance Management Support Module aims to increase the effectiveness of scheduled maintenance and repair activities and reduce costs related to labor, travel, spare parts, etc. Through predictive maintenance, it aims to maintain pump deterioration at an optimum level continuously and minimize unplanned stoppages and associated losses.

2.4 OPTIBOX

OptiBox comprises the equipment that completes the necessary measurements for the effective operation of the OptiBOX system. OptiBox primarily consists of vibration and temperature sensors that will be installed on pump bearings (bearings). In addition, the infrastructure (devices, cabling, etc.) required for transferring the data to the central server is included in the content of BOX.

3 OPTIPUMP SYSTEM COMPONENTS

The components that constitute the OptiPump system, their duties, and capabilities are summarized in the table below:

4 SOFTWARE FEATURES AND HARDWARE REQUIREMENTS

4.1 SOFTWARE

The OptiPump system is a specialized solution designed specifically for each pump and is installed completely tailored to that pump. Our software is web-based and can be accessed from any computer and mobile devices if authorized. It is developed using the JAVA programming language and does not require any additional license installation. The system operates on any computer connected to the Internet once authorized.

The software consists of the pump module. Performance parameters for this module can be displayed on graphical screens at specified time intervals and summarized in a table. Screens where the reasons affecting the performance of each pump in the software module are listed and where analysis will be conducted are provided to the user. User-based authorization can be configured, allowing users to view only the screens they are authorized to access. Daily backups are taken, and since the backup process is done online, it does not affect the system's operation or slow it down. Maintenance and upgrades of the modules are provided free of charge during the system's warranty period.

4.2 HARDWARE AND NETWORK

The signals required for the OptiPump Pump Performance Measurement Module, listed in Table 1, are integrated into OptiPump by being collected in parallel through SCADA. If the necessary signals are not available in the existing SCADA, the installation of OPTIBOX allows transferring the pump's bearing temperatures and vibration values to the system if requested.

5 PRIVACY

The information presented in this report contains confidential information related to the OptiPump system. None of the information in the report, in whole or in part, can be shared with any third parties for any purpose through any means (electronic or otherwise). Written permission must be obtained from us if such a situation is required.

6 CURRENT SITUATION AND TASKS TO BE PERFORMED IN STATIONS

Based on the inspection conducted on 09.12.2021 at the pumping station, the pump and station numbers, infrastructure, and network equipment are presented below, along with the connection diagram, field photographs, and infrastructure report.

Tahtalı Water Intake Structure Above-Ground Pumps

There are 6 pumps, and 4 of them are currently active. Power analyzers' information cannot be obtained, and pump output pressure sensors are faulty.

There is 1 more booster station with 3 pumps.

Wastewater Booster Stations Above-Ground Pumps

Karşıyaka: There are 5 pumps with 1010 kW each.

Çiğili: There are 8 pumps with 920 kW each.

Gümrük: There are 6 pumps with 320 kW each.

Bayraklı: There are 5 pumps with 420 kW each.


Districts

There are 214 booster stations in the districts, with 538 submersible pumps in these stations. There are over 100 horizontal centrifugal pumps in 30 districts, where it has been learned that SCADA is present.

Sensor Installations: The new Temperature and Vibration sensors are planned to be mounted on the pump bearings. No drilling will be performed during installation, and they will be attached to the pump bodies using special epoxy adhesives.

Data Cabling: Data from the sensors is communicated using the RS-485 communication protocol. Cables with LI2Y(St)CY-PiMF characteristics, which provide this standard, will be pulled through halogen-free PVC spiral pipes and terminated at the ends. Spiral pipes will be pulled through the channels feeding the existing motors to the SCADA panel. Additionally, Cat6 UTP patch cables will be used for communication between the existing SCADA units and the RS-485 converter and GSM modem.

RS-485 - Ethernet Converter: An RS-485 ethernet converter will be installed to enable the transfer of data from the newly installed sensors and the current SCADA control main unit (MTU) to the required Ethernet communication protocol.

* GSM Modem: To allow the analysis software to collect data from the sensors and SCADA system, a *GSM modem will be installed. If there are areas without *GSM signal, alternative communication systems can be considered. The *GSM modem will be an industrial type capable of 24/7 operation. For communication security, support for protection such as IPSec VPN, L2TP, SSL VPN, CA certificate is planned.

*Alternative communication technologies will be used in areas without GSM coverage.

Electrical Cabling: The necessary electrical infrastructure required for the installation of the RS-485 converter and GSM modem will be provided with 3x1mm² TTR cables from the most suitable and closest line.

Our software can be installed on any computer within the scope of the İZSU General Directorate.

The following gains are expected from the work to be carried out in the stations:

  1. Data from the existing SCADA system will be transferred to any desired computer, and the current status of the station will be displayed in real-time.
  2. Efficiency and degradation analyses of the station and pumps will be carried out, showing excess energy consumption, losses, and maintenance needs.
  3. The starting point of the leakage detection system between stations and subscribers will be the stations.
  4. We estimate that it will prevent between 10% to 20% of excess electricity consumption.
  5. Initially, it is recommended to install the system for the Tahtalı station, Karşıyaka Wastewater, and 2 stations from the districts.

Our request from the İZSU Information Processing Center is to provide a computer for data transfer and software installation, along with the necessary security permissions.

The existing SCADA structure will not be touched, and the old system's operation will not be disrupted.