Seebach District Waterworks

Seebach District Waterworks

"We were able to add another pump to the system and integrate the analog processing for flow rate and pressure in the easy800. Combined with the MFD-Titan multifunction display, we implemented a powerful visualization system."
— Herman Hofmeister

Background
The Seebach district waterworks, Osthofen, Germany, supplies drinking water from the Osthofen and Bechtheim-West waterworks to a 290 mile long network serving more than 18,000 households. Since the waterworks existing pressure booster was designed with conventional technology, it could no longer be expanded to ensure adequate pressure to meet the system needs.

Challenges
The control cabinet for the pressure booster housed three pump controls. Two were speed controlled and were connected alternately to a variable frequency drive (VFD), changing over after each stop. This alternate connection of two pumps to the VFD ensured sufficient safety reserves. If one of them was faulty, the other operated without interruption. As a result, the water supply and the required pressure were ensured. At night the small pumps were disconnected. The third pump was activated and deactivated with a soft starter for fire fighting operations.

Making modifications to the existing pressure booster system was not possible because there was no more space in the control cabinet to install additional relays. In addition, there was no space available within the building to install a larger control cabinet.

Solution
While Herman Hofmeister, who is responsible for electrical engineering at the waterworks, was looking for a state-of-the-art pressure booster system, he attended an Eaton MFD-Titan multi-function display workshop. After learning the benefits of implementing an Eaton easy800 control relay/MFD-Titan solution, he recognized that it would not only meet the needs of the waterworks, but also provide significant cost savings and efficiency benefits.

In addition to replacing conventional timing relays, the easy/MFD solution also controls the entire monitoring, fault indication, and closed loop control of the system. The contactors and the timer circuits were easily wired by making parameter definitions in the easy800/MFD-Titan system.

The easy800 control relay and the MFD-Titan are networked together using their easyNET capability. This allows up to eight stations, consisting of either easy800 or MFD-Titan devices to communicate with each other at a maximum distance of 1000 meters. Additionally, all stations can be expanded locally via the easyLink interface, which enables easy control relays and MFD-Titans to be used seamlessly in automation applications with 16 to over 300 I/O points. The MFD-Titan can also be used in a simple pointto-point connection with an easy800 or an additional MFDTitan via serial interface.

Unlike the old booster system, which relied on lights to provide alerts, the new system sends text messages, such as operational and fault messages or a pressure display via the MFD-Titan.

Results
Hofmeister explains, “The Eaton easy800 allowed us to replace our previous timing relays, contactor relays, limit switches, the time switch, and the flow controllers. This not only eliminated the need to mount and wire individual components, but also saved considerable control cabinet space.

“We were able to add another pump to the system and integrate the analog processing for flow rate and pressure in the easy800. Combined with the MFD-Titan multi-function display, we were able to implement a powerful visualization system.”

With the easy800/MFD-Titan pressure booster system, the Seebach waterworks district has reduced its switching device and installation costs and has a system that enables them to make modifications cost effectively to accommodate future needs.