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Overview

Water Transfer Pumping Automation

The SCADALink PumpMate water transfer pump automation system includes the following functionality:

  1. Pump safety shutdown (pressure, leak, communication, level shutdowns)
  2. Pump interlocking
  3. Pump startup & shutdown sequencing
  4. Inlet and outlet pressure control
  5. Flow control
  6. Level control
  7. Alarm dialing
  8. Data logging and reporting
  9. Remote monitoring and control

True Automated Control of Water Transfer Pumping Systems

The flexible and automated  functionality of the PumpMate for pump interlocking, sequencing, pressure, and flow control sets it apart from other pump monitoring systems on  the market. 

PumpMate allows fully automated control of water transfer pumping systems from a single pump up to network of 20 pumps and operates both on diesel and VFD (AC) pumps.  Integration is not restricted to a specific manufacturer or controller allowing flexible selection of pumps used in a system, and allows backup pumps to be replaced as required.  All configuration can be done on the color touch screen HMI.

Control and Automate up to 20 Pumps in a System

Water Transfer Pump Automation

Pump Setup – Control Diesel and VFD (AC) Powered Pumps

Water Transfer Pump Automation

Pressure Control Allows Stable Pipeline Operation

Water Transfer Pump Automation

 

 

 

Startup / Shutdown Sequencing

Pump Start & Shutdown Sequencing

Pump strings are typically started sequentially, starting at the source pump and onto down-steam booster pumps until the pipeline is stabilized.  This  allows for a steady rise in pipeline pressure to a preset set point and ensures that booster pumps are primed before they run.  This prevents pipe sections from entering a state of vacuum.   On shutdown it is best to stop downstream booster pumps first back towards the source pump, or to stop all pumps at the same time through interlocks.

Startup and shutdown sequence are configured in part by setting interlocks as shown on the following pump interlock screen.  A pump interlocked with a permissive pump will shutdown if the permissive pump is turned off.  Pump start sequence is configured by engaging the auto-start and configuring the local inlet pressure set-point.  Once the inlet pressure reaches the desired set point the pump will automatically start and maintain the preset inlet pressure.

Pump Interlock Screen

Water Transfer Pump Automation

 

Pressure and Flow Control

Pressure and Flow Control using PID Control

Pump speed  in controlled by adjusting the RPM on Diesel Pumps and Frequency of VFD output.

PumpMate offers the following PID control modes:

  • Inlet Pressure Control
  • Outlet Pressure Control
  • Flow Control

Inlet Pressure Control on booster pumps enables optimal pumping operation. This PID control automates booster pumps to react to changing conditions.  On a pump string with booster, under PID control,  the operator can use the source pump to control the flow of the complete system. The rate may be changed by adjusting the speed of the source pump. An increase in outlet pressure at the source pump will increase inlet pressure of the subsequent booster pump and accelerate the transfer, and a decrease in outlet pressure at the source pump will decelerate the transfer.  The booster pumps react accordingly to maintain the inlet pressure setpoint.  Inlet Pressure PID control enables the booster pumps to maintain a desired transfer rate by maintaining a preset inlet pressure.

Inlet Pressure Control has output pressure override.  This means a pump will not exceed a maximum set point to chase the desired inlet pressure therefore protecting your pipeline.

With Inlet Pressure Control on booster pumps the entire pipeline can be adjusted by a single operator from any single point along the string without any additional operators either at, or traveling between the pumps.

Trend Screen showing Inlet PID Control

Water Transfer Pump Automation

PID Control Setting Screens

Water Transfer Pump Automation

 

Level Control

Automated Level Control

The PumpMate System incorporates the ability to perform automatic level control in “pump-up” or “pump-down” applications. more…Remote Pump Monitoring and Control System

For automated Level Control, the PumpMate system controls the speed of the source pump.  In Pump strings with booster pumps, the booster pumps will maintain inlet pressure allowing the source pump to control the pipeline flow. The PumpMate systems supports control of both diesel or VFD pumps within the same string.

When more than one level sensor is utilized for monitoring a group of tanks,  a single level sensor or the max level of up to ten tank sensors can used as the level input. This ensures that there is no tank overflow. In pump-down applications the minimum level is used as the level input when more than one sensor is used.

PumpMate’s automated level control can be used to control the level in frac tank batteries,  pits, or C-rings.  Testing has shown the PumpMate can maintain the level to within inches of a set point with multiple pumps in use.

Long Distance Pump Control

With the PumpMate wireless network the source pump that is controlling the flow can be a long distance from the operator controlling the string.  We have applications over 15 miles between pumps or a repeater tower.

Frac Tank Level Control

Use of automated level control with the PumpMate systems can assist operators in maintaining the fluid level of the tank battery at the frac site preventing overflows and low tank levels that may delay operations or cause an environmental issue.  Automated level control eliminates the need for the transfer company to have as many employees and vehicles on each string.

 

 

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