Automation of condensate stations. Automatic control system for condensate pumping station designed to control the level of condensate in the condensate tank to ensure the necessary conditions for the flow of technological processes.
Work algorithm
In operating mode, the system maintains the level of condensate in the tank at the level set by the operator. The smoothness of this process is regulated by a frequency converter. It influences the current performance of the working pump in order to keep the level setpoint (balance of liquid inflow and outflow). If the performance of the working pump is not enough, then the backup pump is connected (peak operation). It works until the level in the tank reaches the standby pump off level. A level drop below the lower alarm limit stops the pumps until the condensate rises above this level.
The working and standby pumps are rotated periodically to equalize the running hours of the devices. In the event of an emergency with the pump, the system automatically switches to the backup.
During operation of the unit, according to the readings of the pressure sensors behind the filters, their contamination is monitored. If the pressure is below the minimum allowable threshold, the filter is considered contaminated and the unit switches to the reserve line.
The unit is protected from operation with a closed valve after the pumping group. If no fluid flow is registered during operation, the system stops due to the “Valve closed” alarm. In the case when the length of the condensate drain from the condensate tank has a significant length, the line may freeze during a shutdown of the system. Therefore, when the unit is in the "Stop" mode and the temperature in the tank drops below an acceptable level, a warning alarm is activated with a recommendation to drain the condensate line.
The system consists of a control panel and peripheral sensors of technological quantities (pressure, temperature, level):
Automation of condensate stations. Functions and capabilities of the control system:
- condensate level control according to the developed algorithms;
- switching to a backup pump in case of a malfunction of the main one (according to the state of the pressure sensor after the pumping group);
- connection of a backup pump at peak load;
- rotation of the main and standby pump for even hours of operation;
- control of the tank condition (according to the readings of the level and temperature sensors);
- indication, registration of emergencies and response to them;
- automatic or manual mode of operation with registration of the fact of mode change;
- accounting for condensate consumption (hourly, daily consumption);
- displaying the necessary information about the process on the LCD touch screen;
- possibility of data transmission via industrial network for dispatching (Ethernet, Modbus-TCP protocol).