Plad Equipment’s dual and triple pump systems are widely used for pressure boosting but when it came to programmable logic controllers, (PLCs) it tended to buy from different suppliers and integrate the system in-house.
This multi-supplier approach had led to system integration problems in the past, so when ABB approached Plad to talk about its ongoing development of a new modular 'water library' of PLC software - which features a large range of relevant pump control and data collection functions – it struck a chord.
ABB based in Zurich, Switzerland proposed a new pump control solution based on the continued use of ABB's ACS550 variable-speed drives, but with control provided by the AC500 PLC. To demonstrate the effectiveness of the drive and PLC combination, ABB developed a flexible control program which utilised many pump control functions from the development version of its water library software.
Master software package It was clear to Canada-headquartered Plad that this option offered flexibility, allowing it to configure one master software package for dual or triple pump systems, as well as selecting other operational parameters required for different types of high-rise building water pressure boosting.
ABB's example design also provided a number of technical advances over Plad's own previous control system arrangements. The use of Modbus RTU networking eliminated equipment cabling and simplified system assembly.
The ABB PLC’s high level function block library for communications also simplified data exchange with the ABB drives, speeding control development and simplifying maintenance tasks on Plad systems.
The proposed control solution proved so attractive that Plad has now adopted ABB PLC and drive systems for all of its pumping systems for the building market. "We are pumping specialists first, so standardisation on a single control systems supplier makes a lot of sense. It means we sidestep any potential system integration problems.” said Robert Delisle, director of Plad Equipment.
“However, the key deciding factor in choosing ABB as our supplier was its willingness to act as a technical partner and provide in-depth support.
“If a user needs new functionality we can always call on ABB experts to discuss or help us implement a change. This partnership allows us to focus most of our technical resources on our core pumping technology and applications know-how - and I believe it will help expand our business."
Strong relationship
"Having a strong relationship with a customer makes it easy for us to invest our own time - to ensure our products are used in the most efficient way, and to use our control systems expertise to help clients meet new challenges," added Patrice Bélec, a PLC product specialist with ABB Canada.
Pumping systems used for water pressure boosting in high rise buildings can be configured in many different ways depending on factors including the water pressure available, the size of the building, the spaces available for risers and equipment such as valves and break tanks on higher floor levels. As a result, Plad offers a broad range of pumping systems with many configuration choices such as the ability to have dual or triple pumps to meet differing demand, variable speed operation and local or remote instrumentation.
Systems are also typically assembled on small skids, which allow a great deal of flexibility over the size and shape of the finished system. The combination of the proven ACS550 drives and AC500 PLC adds flexibility and connectivity to an already energy efficient operation. This allows simple maintenance and ensures future requirements can be built in with minimal engineering efforts by a PLC engineer.
The AC500 also acts as the central interface for several pumps or ACS550 drives to the system's CP600 HMI panel, enabling open interaction, monitoring and visualization of single pumps, as well as the whole pump-set configuration.
