Our team designed the new architectural, mechanical, and electrical systems for the major upgrade to an intake pump station at Missouri American Water’s North Water Treatment Plant. This project replaced the aging switchgear and provided four variable frequency drives with a bypass for the intake pumps. Two of the 300 hp vertical turbine pump motors were replaced with new inverter duty motors. Included with the design was a new pre-cast concrete Intake Building housing all the 480V switchgear, variable frequency drives (VFD), and the PLC/SCADA cabinet. The building was specified as a prefabricated concrete enclosure rated to withstand wind forces up to 180 mph.
The electrical design included modifications to the existing overhead 4160-volt distribution system supplying the pump station. The design provided redundant overhead taps on the existing lines and transition to underground to supply primary switches. Existing 5 kV primary switches and pad mount transformers were tested and relocated to supply the new switchboard. The 480V switchgear was designed with a main-tie-main configuration.
We designed the new PLC/SCADA system that interconnects to the existing plant’s system. A new panel allowed an operator to control the starters and variable frequency drives and valves at the Intake Building or via a remote operator in a remote building on the site. Redundant water source heat pump systems were provided using plant water for heating and cooling the building. Backup emergency ventilation was also included.
Additional design aspects included necessary site lighting, lightning protection for the Electric Building, and an Arc Flash study whereby our team developed all the circuit settings for the switchgear.