PUMPS AND PUMPING SYSTEMS
Clearing the way for big savings
The Retroflo RPC_2000 Pump Control System has been winning plaudits from across the UK water
industry thanks to its ability to resolve the traditional blockage, consent and energy efficiency issues that
have been plaguing problematic wastewater pumping stations all around the country
T
he RPC_2000 has been in an area of natural beauty, the station
successfully installed at pumping has been of concern to Northumbrian
stations operated by Northumbrian Water due to the risk of discharges as a
Water, Scottish Water, United Utilities and result of pump blockages.
South West Water, where it has lived up to During the first 12 month period from
its billing by delivering a vast reduction in installation of the Retroflo system at
blockages and reactive maintenance call- Skinningrove, in excess of 1000
outs while reducing energy costs and successful Pre-Blockage Detection
carbon emissions through the more routines were implemented, all of which
efficient operation of pumps. returned the pumps to optimum
Understanding that every pumping performance. This meant that no
station is different goes some way to operator/maintenance intervention was
explaining the philosophy behind the required to remove blockages from the
Retroflo system. The RPC_2000 was The RPC_2000 Retroflo system combines intuitive hardware pumps. The pumps were also regularly
specifically designed to control pumping
and software components and is operated through an
inspected during this initial period and a
easy-to-use touch-screen interface
stations as a whole, rather than just the massive improvement regarding the
individual components within them. cleanliness of the impellor was observed.
Through continuous dynamic monitoring of The introduction of the Retroflo pump
the pump characteristics over a range of control system has not just maintained
wet well levels and pump speeds, the consents by reducing blockages but has
system is able to use the full range of dramatically reduced energy costs for the
pumping data available to optimise the station. By initiating pump reversal cycles
performance of any given pumping station. on detection of partial blockages and
With the onus on the water industry returning the pump to optimum operating
to reduce emissions and protect the conditions, the improved pump
environment from spillages and combined performance equates to a 12% decrease
sewer overflows, Retroflo’s station-wide in power during normal operation. At
solution is more than proving its worth. Skinningrove this has resulted in a savings
At pumping stations across the UK it has of 0.45p every 12.2 seconds based on
ensured consent security using the Pre- costs to pump m
3
. This, coupled with the
The RPC_2000 has been specifically designed to be easily retro-
Blockage Detection, Intelligent Flushing
fitted in existing installations. The system monitors pumping
savings from no call-outs, meant the capital
Cycles, and Periodic Efficiency Testing
stations as a whole rather than just the component parts
expenditure of installing the system was
features to dramatically reduce blockages repaid within the first 12 months.
and optimise pump performance. Blockages are a common and costly problem
at wastewater pumping stations due to the Energy and emissions efficiencies
Figures do the talking gradual build-up of debris on pump impellers. The energy efficiencies produced at the
The figures produced speak for themselves, During this gradual build-up pumps operate Skinningrove station represent the minimum
with a minimum 12% reduction in energy inefficiently, which eventually leads to a reduction in power consumption, but
consumption. This, combined with almost no blockage, resulting in time consuming and efficiencies recorded at other stations across
reactive maintenance call-outs, means that costly call-outs. Retroflo’s RPC_2000 uses its the UK point to opportunities for even greater
utility companies can expect a return on CAPEX patented Pre-Blockage Detection function to savings. At South West Water’s Ilsham Valley
within 12 months of installing the system. detect debris build-up and remedy the problem Pumping Station the introduction of Retroflo
The RPC_2000’s adaptability to unique before it becomes a blockage. technology has resulted in a 27.1% reduction
pumping station conditions is best exemplified in absorbed power through reduced
by looking at the individual features and how Savings at Skinnigrove blockages, cleaner wells and the optimisation
they interact with the system’s station-wide Prior to fitting the RPC_2000 Northumbrian of pump performance.
monitoring solution as a whole. While many of Water’s Skinningrove Sewage Pumping Station Ilsham Valley pumping station had a history
the problems in pumping non-constant fluids was neither economical nor efficient, despite of pump blockage problems that proved costly
are common, the idiosyncrasies of any given relatively new pumps and VSDs. Frequent and time consuming to clear. Additionally, the
pumping site affect the cause and frequency pump blockages meant numerous reactive station’s pumps often ran for extended periods
of blockages and the resultant power usage maintenance call-outs to unblock the pumps. while partially blocked, leading to extremely
and maintenance costs. Located on the North East coast and situated high electrical energy costs. Originally all four
34 Water & Wastewater Treatment November 2009
Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56