Ingleton WwTW located in the Yorkshire Dales National Park has recently been upgraded to include a duty/standby screening inlet works, two primary settlement tanks, two trickling filters and two humus tanks and a single storm tank.  The Ingleton site was developed by United Utilities in conjunction with KMI Water (Kier Murphy Interserve) as a pilot for a low-cost, high-value solution based upon an "integrated intelligent system"   to    provide   simplified controls with additional facilities and monitoring.  BLACKBURN STARLING were selected

to produce the Motor Control Centre and associate PLC Control system. The speed of communications was an important factor in the choice of products along with the features offered by the components. In conjunction with Blackburn Starling the choice of “intelligent” Motor Protection relay and communications system resulted in the Simocode – DP and Profibus DP solutions from Siemens being selected, to work at a transmission rate of 1500kBit/s, using a shielded twisted pair cable over a maximum distance of 9.6km.

The integration of fuse links, contactors and Simocode – DP relays ensured that the Motor Control Centre met with the latest International Technical Standards – Form 4, Type 3, Type Tested Assembly at 50kA, 1s, (EN 60439:1999, part 1) and provided a Type 2 co-ordinated solution (EN60947-4-1).

A standard PLC with an OP370 Human Machine Interface (HMI) provides automatic control and monitoring of the plant with full diagnostic and manual override control.       

Site wide communications are based on the Profibus DP/PA network and protocol. Distributed S7-400 Series I/O is networked to the Profibus ICA I/O and Remote I/O. The single motor control centre provides “intelligent” interconnectivity between 22 DOL and VSD drives, 27 actuators, level and flow instrumentation networked on either Profibus DP or Profibus PA as shown below. The intrinsically safe PA network provides 'Ex' links to the sludge holding tank area.

All drives utilise the Simocode-DP unit on Profibus-DP network providing comprehensive “intelligent” motor protection and plant monitoring. The single unit, replacing a series of hardware components, offers additional in-built control software functionality. The optimum solution both technically and economically was implemented for each drive by combining standardised, pre-programmed functions with elements such as timers, counters and logical operations.  Detailed diagnostics of all drives are available via a simple “WinSimocode” software package   accessing   each  Simocode-DP   via   the  integrated  PROFIBUS-DP  network,

providing a cost-effective solution for a communications and automation system.  The Motor Control Centre built by Blackburn Starling houses the motor starters and protection devices for pumps and other drives.