Enhancing Water Treatment Efficiency with NewElec’s Advanced Pump Protection and Control Systems

Industry Trends in Water Treatment

Water treatment plants are embracing digitalisation through the integration of the Industrial Internet of Things (IIoT) and smart meters, which enable real-time monitoring and control of processes. These technologies help improve operational efficiency by providing deeper insights into system performance and supporting proactive maintenance. Unlike traditional systems, NewElec’s solutions stand out by offering advanced automation and communication tools through its “Why Wait to Automate™” initiative, with features like 32 NewCode Relays communicating to a single PLC or HMI. These relays integrate seamlessly with Programmable Logic Controllers (PLCs), supporting communication protocols such as Modbus-TCP, Profibus, Modbus, Ethernet-IP and Profinet, making NewElec’s systems more adaptable and scalable than many competing technologies. Key trends include:

Digital Water Management

The integration of the Industrial Internet of Things (IIoT) and smart meters is transforming water treatment plants by enabling real-time monitoring and control of processes. These technologies boost operational efficiency by offering in-depth insights into system performance and facilitating proactive maintenance. With Newelec’s free Front-end Software you have real-time access to actual readings, live statistical data, spectrum analyser, event and fault records, test screens, data recorder and an audit tool beneficial to the maintenance team in generating operational reports.

Energy-Efficient Technologies

There is a growing focus on implementing energy-efficient solutions to lower operational costs and minimise environmental impact. Variable frequency drives (VFDs) and intelligent automation panels are being widely adopted to optimise pump operations, including dewatering pumps, aligning hydraulic performance with specific demands and ensuring energy-efficient usage. Newlec’s LA series Relay can easily be fitted below a VSD insuring safe operation.

NewElec’s Feeder Protection Relay further promotes sustainability by enabling on-site solar energy integration, connecting solar systems to the grid for reduced energy costs. Additionally, the KG or KH Relay, featuring Bluetooth communication, allows for remote configuration and monitoring up to 10 meters away using a smartphone and a free configuration and control App available in the Google Playstore, providing enhanced safety and convenience without requiring physical access to control panels.

Modular Water Treatment Systems

Modern water treatment plants increasingly prioritise flexibility and scalability to meet diverse and evolving demands. Modular systems offer the advantage of easy expansion and customisation, allowing plants to adapt efficiently to changing water treatment requirements.

NewElec aligns with this trend by offering a comprehensive range of pump control systems designed for modular water treatment setups, including those utilising dewatering pumps. Our advanced solutions, such as the 32 NewCode Relays, seamlessly integrate with modular systems, enhancing flexibility and control. With communication protocols like Modbus-TCP, Profibus, and Ethernet-IP, NewElec’s systems ensure reliable data exchange across all modules, enabling smooth scaling as operational needs evolve.

Additionally, NewElec’s water pump protection solutions, like the Feeder Protection Relay, support sustainability by integrating solar energy with modular systems, reducing energy costs and environmental impact. For water treatment plants looking to grow or adapt, NewElec’s technologies provide the reliability and scalability needed for efficient expansion and customised system performance. Explore more of our pump control and protection solutions at NewElec.

NewElec’s Advanced Pump Control Systems

NewElec offers a range of advanced pump control systems designed to meet the unique challenges of water treatment plants. Our MA-Series, KD-Series, and KE-Series relays provide robust solutions for pump motor protection, ensuring that pumps operate efficiently and safely under various conditions. These systems offer features such as real-time monitoring, automatic fault detection, and advanced diagnostics, which are essential for maintaining the integrity of water treatment processes.

10 Benefits of Advanced Pump Control Systems

Real-world examples in the Water Works Sector

Case Study: Smart Water Management in Various Applications with NewElec’s Advanced Pump Control Systems

NewElec’s advanced pump control systems have been successfully integrated into various water treatment facilities for example; Erwat, Magalies Water as well as Rand Water with the NewCode relay used as a preferred Protection Relay at Zuikerbosch Pumping Station, providing robust solutions for managing pump operations. These systems are instrumental in reducing downtime, optimising energy usage, and ensuring a consistent and reliable water supply. This case study elaborates on how these systems have significantly improved the efficiency and reliability of water treatment processes.

Challenges facing Water Treatment Facilities:

South Africa has built a substantial wastewater management industry that comprises of approximately 2000 treatment plants, extensive pipe networks, and pump stations, transporting and treating an average of 7 589 000 kilolitres of wastewater on a daily basis however many have been non–functional for many years due to lack of maintenance on equipment was reported in 80% of the plants.

Water treatment facilities face numerous challenges, including the need for efficient pump operation, energy consumption management, and maintaining a consistent water supply. Traditional pump systems often struggle with issues like downtime, high energy usage, and frequent maintenance requirements. NewElec, a leading provider of motor protection relays and control systems, has developed advanced solutions to address these challenges.

Solution:

NewElec’s pump control systems were deployed in several water treatment plants to enhance operational efficiency. These systems feature advanced monitoring and control capabilities, enabling real-time data collection and analysis.

The key components of NewElec’s solutions include:

• Safe operation with Variable Speed Drives (VSD’s): These allow precise control of pump speeds, reducing energy consumption by matching the pump operation to the actual demand.
• Harmonic Suppression Circuits: These circuits minimise nuisance tripping and ensure reliable operation even under high starting currents.
• Integrated Monitoring Systems: These systems provide continuous data on pump performance, allowing for proactive maintenance and fault detection.

Results:

The implementation of NewElec’s advanced pump control systems led to several significant improvements in the water treatment facilities:

• Reduced Downtime: By utilising real-time monitoring and advanced fault detection, the facilities experienced a significant reduction in unscheduled downtime. The systems could predict potential failures and initiate preventive measures, ensuring continuous operation.

• Optimised Energy Usage: The VFDs and other energy-efficient components reduced the overall energy consumption of the pumps. This not only lowered operational costs but also contributed to the environmental sustainability of the water treatment processes.

• Enhanced Reliability: The robust design of NewElec’s systems ensured reliable performance under various operating conditions. The integration of harmonic suppression circuits and other advanced features minimised operational disruptions and extended the lifespan of the equipment.

• Consistent Water Supply: The improved reliability and efficiency of the pump systems ensured a consistent and reliable water supply. This was critical for maintaining the quality and safety of the treated water.

Optimise Your Water Treatment Plant with NewElec’s Solutions

NewElec’s advanced pump control systems are revolutionsing water treatment technology, providing precise control, enhanced reliability, and ease of operation. By integrating these innovative systems, water treatment plants can significantly boost efficiency and achieve operational excellence, ensuring a consistent and safe water supply. With a proven track record across diverse applications, NewElec’s solutions optimise system performance, reduce energy consumption, and protect vital equipment.

Leveraging cutting-edge technology and intelligent design, NewElec empowers plant operators to maintain long-term reliability, efficiency, and cost-effectiveness, ensuring the continued success of water treatment facilities.

Manufacturer Support

NewElec offers full support, from initial assessment, commissioning to ongoing maintenance, ensuring water treatment plants maximise operational efficiency and reliability. Our expert team offers assistance throughout the entire process, from initial assessment and system customisation to installation, training, and ongoing maintenance. This support ensures that water treatment plants can maximise the benefits of our advanced pump control systems, achieving long-term operational efficiency and reliability.