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Pumping Stations - Case Study

Case Study: Taw Torridge - Full turnkey Control System (included MCC’s, PLC’s and Electrical Installation)

Project Description

The Taw Torridge scheme comprises a main works (Cornborough) and 5 remote pumping stations at Bideford, Northam, Yeland, Westleigh and Londonderry Farm.  Working in partnership with BVCL to an agreed Target Cost the contract comprised the design and manufacture of six substantial new MCC/ICA Panels, upgrade of a further existing MCC at Londonderry Farm, configuration of all PLC software, site commissioning and electrical installation works at all sites.  All MCCs supplied under the contract were of conventional Form 4 design to WMES and client specific standards.


The site had a 5.9metre 2000A LV switchboard manufactured to Form 4 Type 3 with a fault rating of 50kA / 1 sec.  The LV switchboard fed the two other MCCs the Aeration and Sludge panels and had ABB manufactured Harmonic Filters incorporated as part of the switchboard.  The Aeration MCC was 13.2m long and rated at 1000A with a fault rating of 25kA / 1 sec. The MCC consisted of 4off 90kW Blowers and 6off 22kW VSDs all 6 pulse with the Harmonic correction being carried out on the LV Switchboard.  The Sludge MCC was 6.9m long rated at 400A with a fault rating of 16kA / 1 sec. The MCC consisted of up to 17 starters.

Remote Pumping Stations

The Pumping stations varied in size and configuration from just backplate and door replacements for new starters at Londonderry Farm P.S. to large MCCs at Bideford. The MCCs ranged from 400A to 1000A with fault ratings of 20kA / 1sec. At Bideford P.S. the MCC consisted of 3off 200kW 6 pulse ABB drives for the 3off transfer pumps. Harmonic filtering was provided to G5/4 compliance. At Yelland P.S. due to building limitations MCS designed a 3.7m back to back 1200 deep MCC to contain 4 off Soft Starts in excess of 30kW – this was done as a value engineering exercise to prevent additional civil works to the building and saved considerable costs to the partnership.

ICA Controls

Modicon PLC’s with remote I/O were used for control and data acquisition of plant items. An Ethernet communications network was adopted, a first for South West Water, which transferred data between the PLC’s, PID controllers, SCADA system, telemetry outstations and pumping stations. The main works PLC, programmed using the Modicon Pro-Worx NXT software, controlled communications with both the remote pumping stations and the 13 dedicated local PID controllers. The PLC also manipulated data for the Paragon SCADA system for scaling, set-point entry and data display.

Electrical Installation

The electrical installation consisted of all cabling to plant equipment, HV transformers and communications links. Cables installed varied in size from 630mm singles to 0.5mm comms links. The installation was tested and inspected to NICEIC standards. All aspects of documentation were provided. E.g. Duct layouts, building services specifications, street lighting specifications, cable schedules, tray work layouts, block cable diagrams.


Dave Reedman Electrical Engineer for BVCL
Ian Aldridge Project Manager for BVCL




I would like to say how well MCS have performed at Cropwell Bishop, following a sucessful FAT test we have completed the SAT sign off on site in 15 days which included 3 days E2E testing over Modbus. Having a fully operational ASP circulating flows...

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