Lighting and Wastewater Controls Smithfield Foods Engineering.

Lighting and Wastewater Controls

Smithfield Foods Engineering

Lighting Controls

Smithfield Foods Engineering

Did you know:

In some industries, lighting accountsfor more than 60% of a facility's electrical bill and 40% of the total energy bill in the US. Add indirect costs, such as increased loads on Cooling systems and increased maintenance, and the total can be even higher.

How do you change this?• Zone Controls – Controls system that can be programmed to shut down areas that are not in use to save energy.

• Motion Sensors – device that will turn on the system upon detection of motion in the area. When no motion is detected for a preset time, the system is turned off.

• Emergency lighting controls – In the event of a power outage, the lighting system have a built in batteries that will keep the lights on, allowing personnel to see.• Power Monitoring – This software system will monitor specific electrical connections and database the data for reports or for future reference.• Ambient light sensor – A sensor that will detect the amount of light in a room and use presets values to dim the lights or increase the light. These systems can save you a sizeable amount of energy over time.• Examples of lighting opportunities:Areas in the plant that have 400W or Higher fixtures, T12 Fluorescents.

Examples of Lighting Technologies• LED: Light Emiting Diode

• Pro’s: good efficiency, long life, and good quality of light.• Con’s: Can be more expensive than other technologies.

• T5 Fluorescents: • Pro’s: good efficiency, average life, and good quality of light, Good fit for high ceilings.• Con’s: Cost is average, are not a good fit for freezer applications.

• T8 Fluorescents: • Pro’s: good efficiency, average life, and good quality of light, Good application for office or low to average ceilings.• Con’s: Cost is average, not a good fit for freezer applications.

• Induction Lights: • Pro’s: good efficiency, extremly long life, and good quality of light, designed for freezer applications.• Con’s: retrofit kit doesn’t always work with standard fixtures, be careful to not buy the cheapest units on the market, most are made in china and are cheaply made.

• LEP: Light Emitting Plasma • Pro’s: Long Life 30,000 hrs plus, Color rendering index up to 94, Dimmable to 20%, Rapid Start, Digitally Controlled, and up to 16,000 Directional Lumens.• Con’s: No retrofit kits on the market for existing fixtures, Technology is expensive, Not avalible widespread in the US yet.

Waste Water ControlsSmithfield Foods Engineering

Levels Of Control

As a general operational philosophy, all plants should have five different functional levels of control.

•Equipment Control – is meant for maintenance and troubleshooting only.

•Local Control – provides automatic and manual control of processes.

•PLC Control – controls the system’s automatic processes.

•SCADA Control – provides access to the PLC’s automatic process, alarming, historical data, and trending.

•Plant Monitoring Control – provides a means to send data to a SQL server, also publish the data via a website for remote monitoring, and monitoring via smart phones.

Where do I begin???

• Electrical Equipment Standards – The equipment and uses should comply with the Smithfield Electrical Standards Document, NEC, and NFPA-70. Examples: Flow meters, Thermocouples, PH probes, level sensors, etc.

• Automated Controls – The automated controls are recommended over manual control. The automated controls provide a level of constant operation that manual controls cannot.

• Wireless Components – Wireless controls can reduce installation costs by eliminating the need to run cable to remote locations. Keep in mind that some installations may require repeaters to increase signal strength.

• SCADA, OEE, MES Packages – all will assist operations in system control and efficiency, these system can collect data, store the data, alert operation with alarms via direct means or email, and publish live or historical data via the web or smart phone.

• Examples of equipment: PLC Controllers, HMI’s, VFD’s, Sensors, Floats, PH Meters, Data Acquisition Software.

Example of a controls layout

Continuous On:Constant Speed

Continuous On: Variable Speed

200 gpm @ 30 psi

200 gpm @ 30 psi

Frac Tank

Frac Tank

PP # 1

60-115 gpm

PP # 2

400 gpm

New RecirculationLine 4"

ControlValve

Solenoid Isolation

Valve

100 gpm

60 - 115 gpmVariable

DAFEmergency

Flow

DAF

Acid / CausticFeed Point

pH Probe

Increase Suction Line to 6"

Martin City Equalization, pH Control and DAF Feed Layout

Pressure Gage 0-90 psi

UltrasonicLevel Gage

Operation:1. pH Probe to pH meter; controls acid and caustic feed pumps to maintain pH of 6.0 – 8.0 (alternatively, PLC controlled)2. Level gage to PLC to control PP#1 DAF variable feed rate from 60 – 115 gpm to maintain Frac Tank level at 20-80% volume.3. Level gage to PLC to control PP#2 DAF Isolation Valve – open at High/High Alarm (90% full). (NOTE: Pressure on recirculation line maintained at > 30psi to allow emergency DAF feed when isolation valve opened.)4. PP #2 operated at 300 gpm (or higher if needed) to mix the Frac Tanks, provide a pH neutralization feed point, and provide emergency feed to DAF if needed to prevent Frac Tank overflow.

Tanks Cross-Tied

Frac Tanks – Top Fed from Rotary Influent Screen

6"

Tapered6" to 4"

Reducer

6"

Questions:Lee Casey

Controls and Automation Engineer Smithfield Foods Corporate Engineering

111 North Church St Smithfield, VA 23430 Phone: 757.356.6712 Mobile: 757.604.2550

Fax: 757.356.6718 [email protected]