Sustainable Design and Development of Industrial Automation Controller of Booster Pump using Variable Frequency Drives

Various energy-intensive water treatment areas depend on centrifugal pumps for their water treatment. A centrifugal pump is estimated to be responsible for 90 percent of the water treatment process energy consumption. Automated control scenarios with schedule standby and duty cycles can optimize and reduce energy consumption and increase pump reliability. Using duty and standby pump control scenarios, for example, will increase the system's sustainability, serviceability, and reliability. Additionally, an innovative controller with variable frequency drives can further reduce pump operating costs and save energy which is one of the objectives of current project. A literature survey and a search for a local VFD supplier are the first phases of the graduation project. A computer simulation methodology is used to test the schedule control scenario on the panel assembly table as a proof of concept. In order to construct the controller panel prototype, hardware is either purchased locally or imported from outside the country. As part of the final phase of the project, the controller will be tested on an industrial field using a booster pump set. A portion of the work will be performed in the industrial engineering laboratory, while the remainder will be performed in collaboration with the booster pump dealer. As a final approval concept, the in-field controller panel has been tested and approved for the booster pump application of two centrifugal pumps. The project results have impact of the energy sustainability, serviceability and system reliability. In conclusion, the teamwork recommends continuing the development of the controller scenario for the application of multiple pump units with HMI and incorporating IoT functionality into the controller panel development.