Flow, level & control
WASTEWATER FORCE MAIN PRESSURE CONCERNS ALLEVIATED
WITH VEGABAR 38 A wastewater treatment plant in Florida serves over 630,000 residents who rely on effective wastewater management to live their lives without a hitch. Managing force main pressure to control the speed of pumps via Variable Frequency Drive (VFD) at one of their lift stations is critical to achieve stable operating conditions. A previously installed sensor gave inaccurate measurements which led to unreliable performance and equipment damage.
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FDs adjust the pump’s motor speed based on the pressure readings from the force main. Properly controlled pressure helps protect both the pumps and the force main infrastructure. Without accurate
measurements, high pressures could damage the pipeline or cause leaks, while low pressures could cause cavitation in the pumps. At the B01 lift station, pressure from multiple master stations with high horsepower pumps
caused significant fluctuations. When all master stations were running, high pressures were generated, but when they stopped, low pres- sure became an issue. The high-head pumps at B01 struggled in low-pressure scenarios, which created cavitation that damaged pump impellers over time.
The previously installed sensor frequently provided inaccurate readings or got stuck at certain values, which put the facility at risk for overflows, suboptimal pump performance, and decreased system protection.
A NEW SENSOR SWITCHES THINGS UP
Concerned about ongoing risks, plant operators turned to VEGA for a solution. After a thorough discussion, we offered the VEGABAR 38. This sensor combines a durable, reliable ceramic measuring cell with a switching output.
This cost-effective solution has two parts:
If pressure drops below 16 PSI, the VEGABAR 38 triggers a relay coil, sending a signal to the VFDs to adjust pump speed to 45 Hz—preventing cavitation.
If pressure rises above 16 PSI, the sensor signals the VFDs to increase speed to 60 Hz— optimizing pump performance.
Operators appreciated the VEGABAR 38’s 360-degree LED light ring that gave them process status visual cues at a glance, making moni- toring easy and efficient. Troubleshooting and recalibration have been brought to a minimum. The VEGA Tools app’s remote troubleshooting features via Bluetooth connectivity and our expert field service team are always on standby, ready to resolve issues quickly.
THE VEGA DIFFERENCE FOR FORCE MAIN PRESSURE MEASUREMENTS Choosing the VEGABAR 38 improved system reliability in more ways than one. The precise and consistent measurements prevent overflows, leaks, cavitation, and system damage. The intu- itive 360-degree light ring both saves time and increases process visibility at the same time. Long-term, these improvements stop future cavita- tions from happening and save unnecessary wear on the impellers, reducing the need for constant replacements.
For wastewater facilities, accuracy is the key to protecting their equipment and the communities they serve. And for this wastewater facility, the VEGABAR 38 enables effective systems manage- ment, reduces wear and tear on pumps, saves costs, and most importantly, provides reliable wastewater management for Florida’s residents.
VEGA Controls
www.vega.com
January 2025 Instrumentation Monthly
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