Automatic Pump Control

Author(s): M. E. Rogers
Source: Journal (American Water Works Association), Vol. 43, No. 5 (MAY 1951), pp. 383-
390
Published by: American Water Works Association
Stable URL: https://www.jstor.org/stable/41236388
Accessed: 16-08-2018 03:18 UTC

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 Automatic Pump Control
By M. E. Rogers

A paper by M. E. Rogers, Project Engr., Buüders-Providence, Inc.,

Providence, R.I., presented on September 29, 1950, at the Rocky Moun-
tain Section Meeting, Santa Fe, N.M., by G. E. Reipe, Engr., Builders-
Providence, Inc., Chicago, III.

these days of rising operating costs stallations, but it is the intent of the
and decreasing surpluses, water author to discuss only the principal
works management is on the alert for features and applications of the classi-
ways and means of widening the shrink- fications listed, with but passing refer-
ing gap between income and outgo. ence to combinations.
One of the simpler means of accom-
Pressure Control
plishing this end is to reduce the size
of the operating staff. Not only does The simplest type of automatic con-
a shortage of skilled workers make trol is that offered by a pressure switch
this imperative, but, in addition, sub- installed on the pump discharge line.
stantial savings can sometimes be ef- The switch is set to close the pump cir-
fected by using automatic controls cuit whenever pressure falls below a
wherever possible. predetermined minimum. If the switch
One of the most important applica- is equipped with a differential, the con-
tions of automatic controls within the tact can be made to open when pres-
water works field has been its use in sure reaches a given maximum. This
the control of pumps in water works type
or of system is similar to the well
distribution systems. In view of theknown domestic water supply instal-
present inadequacy of water revenues,
lation in which water is pumped from
savings effected by automatic pump a well or other source into a pressure
control can be very significant. As tank.
an When the tank is full, the pump
added value, automatic control can is
of-shut off and normal supply is ob-
ten function more reliably than manual
tained from reserves until pressure
control. again falls below the desired minimum.
Automatic pump control may be To
di-prevent the pump from starting and
vided into five major categories, accord-
stopping too often, the tank is partially
ing to the actuating factor involvedfilled
in with air which acts as a cushion,
operation : expanding or being compressed to
1. Pressure control maintain pressure within the desired
2. Level control range. Proper air volume is automati-
3. Time cycle control
cally maintained by a pump or other
4. Remote supervision means. Such systems are frequently
5. Pressure-flow control. used in small towns, hospitals and
other institutional or small supplies.
Combinations of these systems mayTheir design has been ably described
be suitable and desirable for given in-by Salvato (1).
383

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 384 M. E. ROGERS Jour. A ¡V WA

The inability of commercial

discharge into an elevated standpipe pres
or
sure switches to tank or into a closed section of betwee
distinguish the
short-lived surges, distribution
when system,control
better and more is n
necessary, and low sensitive
or control
high can pressure
be maintained by pe
riods when it isusing the level of water is
necessary, in thea tank
weak
ness of the pressure rather than
switchthe pressure. This methodsys
control
tem. To guard may against
be applied to faulty oper
an unlimited number
tion caused by surges of pumping andunits and
toprovision
prevent can be t
frequent starting made and
to start or stop the pumps at any
stopping of th
pump, a differential predetermined minimum or be
should maximumestab
lished between the level. Frequently
points it isat
desirable
which to cut t
switch will cut in in theat various
low pumping units at dif-
pressures an
cut out at higher ferent falling levels and either
pressures. to stop
Althou
switches with adjustable differentia
all pumps at a predetermined maximum
are available, the same results can be level, or successively cut out the various
accomplished with a thermal time delay pumps, in reverse order, as the levels
device which will prevent the unit rise.
from starting before a given period of Level control may take two forms,
time and will make its starting at that depending on the distance of the tank
time depend upon whether the pres- or reservoir from the booster station.
sure remains low. Switches which in- If the booster station is close by, any
corporate both time-delay features and type of level-sensing unit may be used :
differential adjustments are also avail-a simple float switch; electronic or re-
able. sistance probes; float, air bubbler or
Pressure control is frequently ap- diaphragm bell-operated indicators or
plied to booster stations supplying ele-recorders equipped with adjustable
vated tanks or sections of distribution contacts. Of these, the direct float-
systems. If the connection is direct operated unit is the most convenient
and there are no substantial draw-offs and reliable, when it can be used. If
between the pump and the pressure elevated tanks or other pipes are situ-
ated nearby, a pressure gage graduated
center or tank, the controls will function
reasonably well. If the distance is in feet as an altitude gage can be con-
great, however, or if there are substan- nected to the standpipe or elevated tank
tial draw-offs, a means must be pro-to indicate the level of the water, and
vided to compensate for pressure drops the gage may be equipped with electric
in the transmission line. Installation of contacts to start and stop the pumps at
a tank-level or pressure telemeter sys- predetermined levels. This method is
tem which will determine line condi- not exact because the Bourdon tube
mechanism yields very little power to
tions and relay the information back
to the booster station offers one solu- close the contacts.
tion to this problem. This and otherIf greater accuracy is required, a
more sensitive time-impulse control
methods will be discussed in greater
detail later in this survey. mechanism, such as the "Chronoflo" *
shown in Fig. 1, can be used. This
Level Control

Where suction is being taken from *A product of Builders-Providence, Inc.,

Providence, R.I.
a ground-level reservoir, and the pumps

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May 1951 AUTOMATIC PUMP CONTROL 385
Provision
system consists of a synchronous may be made for either an in-
motor-
driven cam and a cam follower arm
dicating dial or a chart recorder.
If the tank, standpipe or pressure
which is positioned by the primary
pressure element. Depending oncenter
its is distant from the booster sta-
tion, an electric transmitter must be
relative position, the follower arm rides
the surface of the cam for a giveninstalled
pe- at the tank and a receiver in
the booster station. Transmission may
riod of time during each revolution.
When the follower arm is on the cam, be made over private or leased tele-
an electric contact is made to transmit phone circuits.
a signal the duration of which is directly Only two wires are required for
proportional to the pressure. At thetransmission if power of regulated fre-

Fig. 1. Time-Impulse Type Control Mechanism

A time-impulse control system affords great accuracy of pump control. The trans-
mitter (left) usually consists of a synchronous motor-driven cam and a cam follower
arm which is positioned by the primary pressure element. When the follower arm
is on the cam, an electric contact is mode, transmitting a signal of a duration directly
proportional to the pressure. At the receiving end (right), a pair of synchronous
motor-driven magnetic clutches are alternately energised by the time-impulse signal
to position the receiving element, which in turn controls the pumps.

receiver in the pump room, a pair of quency is available at both ends. Nu-
synchronous motor-driven magnetic merous devices are available for this
clutches are alternately energized byservice, employing resistance, voltage,
the time-impulse signal to position the
current or duration impulses.
receiving element, thus exactly dupli- Special adaptations permit trans-
mission of other functions over the
cating the position of the primary ele-
same pair of wires. Thus, the control
ment at the transmitter. This system is
not affected by normal variations in function may be combined with in-
line voltage, resistance or inductance.
formation on flows, temperatures, and
Synchronization is provided to permitother line conditions. Two methods
the resumption of operations after maya be used for multiple transmission
over a two- wire circuit: simultaneous
power failure or circuit interruption.

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 386 M. E. ROGERS Jour. AW WA

tion head or excessive

transmission, in which fire flows. When
all functions are
sent at the same used
time, and
in conjunction withsequencing
the pressure-
transmission (2),flow in
system,which only
a cam may be installed to on
function may be transmitted at a time,
adjust pressure ranges for different pe-
the several functions
riods of the day following
or week. eac
other in rapid succession.
If leased wire circuits are used,
Remotely Supervised Control rental
is charged by the telephone company
for each circuit mile. In simultaneous It is sometimes desirable to retain
manual control of the operation of
transmission, the charge is based on the
number of functions transmitted multi- pumping equipment or other devices
from some remote station. The ap-
plied by the circuit length in miles.
The sequence method affords substan- paratus which makes provision for such
tial savings as only one functioncontrol
is is known as the "supervisory
control" system and is frequently used
transmitted at a time and the only vari-
able factor is distance. in the control of raw water or deep well
At the receiving end, the controls pumps located some distance from a
consist of adjustable switches set tofilter plant, main pumping station or
govern the pumps as desired. Glass-en-reservoir. The control center or dis-
closed mercury switches afford lesspatcher station used in this system is
difficulty in operation than open con-usually installed in some convenient
tacts. place, such as the filter plant, main
Suitable relays may be interposedpumping
to station or superintendent's
keep high voltages out of the controloffice. Field substations are provided
circuit or to control power in excessin each pumphouse. If the several
of switch ratings. Three-position - are close to each other, a single,
units
"Hand," "Off," and "Automatic"- central field control station may be
switches may be used to transfer con-used. One or more of the following op-
erating results may be obtained, de-
trol for testing or manual operations.
Visual and auditory alarms are avail-pending on particular system require-
able to notify the operator of abnormalments :

conditions. Frequently a "watchman"

1. The starting and stopping of
circuit will be employed to advise the
pumps
operator of power failure at the trans-
2. Reports of the operating condi-
mitter, or of open or short-circuitedtion of the device
lines.
3. Signals of faulty or interrupted
Time Cycle Control operation
4. The telemetering of additional in-
As the name denotes, time cycle con-
trol is that method of control which formation on pressures, flows, tempera-
tures or other factors.
starts a pump or pumps in response
to a predetermined time relationship Various methods are used to accom-
plish the control functions. The sim-
which may be adjusted for seasonal or
weekly variations. Usually, some form
pler systems employ a type of position-
ing or stepping relay in which the
of simple pressure control must be
used with time cycle control to providedispatcher rotates a knob or dial to the
for unusual conditions, such as low suc-desired function and the field station,

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 May 1951 automatic pump control 387

assuming a corresponding orposition,

fixed speeds.per-
The pressure-flow
forms the control function.
system (3) conceived and developed
Other systems employ coded
by Marsden im-is being mar-
C. Smith
pulses similar to those used keted under the name
in the dial"Pressure-
telephone system. Impulses flo" * andmay be
has a wider range of appli-
unidirectional currents of the same or cation than any of the controls pre-
opposing polarities. One such systemviously discussed. Reliable control and
employs a dial for the dispatcher sta-fully automatic operation, not obtain-
tion ; others use push button stations orable by simple methods, characterize
toggle action switches to perform the this system. The equipment is sturdy
following operations in the sequenceand does not depend upon external
indicated : transmission circuits. It is frequently
found to be more reliable than manual
1. Selecting of remote control unit
operation.
2. Starting or stopping of field unit
Many distribution systems, particu-
or other control of its operation
3. Reporting that the operation has
larly those involving outlying areas
been carried out with booster pumps and elevated stor-
age, do not readily lend themselves to
4. Resetting equipment for the next
operation.
simple types of control because of line
friction, large intermediate draw-offs
Control functions of this type are per-and other conditions such as extreme
formed in sequence with great rapidity. variations in flow. The pressure-flow
The equipment may be mounted on a system is designed to cope with such
panel together with other instrumentsproblems.
which provide the operator with aux- At low rates of flow, without elevated
iliary information on pressures, flows, storage, there may be sufficient pres-
temperatures, water levels or other fac- sure available from the source to meet
tors. The units may be operated di-booster district needs. If an elevated
rectly or telemetered ; if the latter, theytank is used, the only function of the
may use the same wires as the controlbooster pump is to keep the tank full
circuit or separate circuits. Auxiliaryfor emergency use. Under such condi-
devices include watchman circuits tions, it would be uneconomical to op-
which warn of line faults, line testingerate the booster pump continuously.
equipment, telephone communication As flow increases, contact is made by
and storage battery and charging equip-the flow meter to energize a pump-
ment for emergency operations. Such starting circuit. If suction pressure is
systems readily pay for themselves adequate, and "area" pressure falls be-
through the savings they make possible low the desired value, the pump will
in freeing personnel for other duties begin to operate and continue to run
but they do require adequate technical as long as both pressure and flow are
personnel for servicing. within the required ranges. If addi-
Pressure-Flow Control tional pumps are available, they too may
be placed on the line by means of addi-
Pressure-flow control is a recent de- tional flow meter and pressure zone
velopment combining both pressure and contacts. To provide extremely close
flow information to control the opera- *A product of Builders-Providence, Inc.,
tion of one or more pumps of variable Providence, R.I.

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388 M. E. ROGERS Jour. AW WA

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 May 1951 automatic pump control 389

control, the pumps discharge should line be vari- level con-

or a minimum
able speed or a combination of or
tact in a reservoir fixed
tank level gage.
and variable speeds. When the
Once a pump haspumps
been started, it will
are no longer required, flow
continue and
to run pres-
as long as the flow re-
sure contacts are opened mains toabovestop
the predetermined
their mini-
operation. Figures 2mum and or 3theshow
pressure the
remains below
characteristics of a the typical
set maximum.pressure
The system may be
control system used with used for single or multiple
elevated stor- pumps of
age tanks. either fixed or variable speeds. Pres-
Pressure-flow control units can be sure-flow control is particularly well
adapted to existing stations or to newsuited to use in a direct pressure sys-

280 i

* - T

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Discharge- 1,000-gpm. units

Fig. 3. Head-Capacity Curves for "Pressureflo" Control

The curves show the head-capacity relationships for the "Pressureflo" control system
illustrated in Fig. 2.

pump stations without raising special tern such as is frequently encountered

structural problems. Provision must in tall buildings and airports. Such a
be made for metering the flow and for system has been designed for the Logan
determining the pressure or level. Al- International Airport of Boston by
though a single meter can be used for Coffin (4).
one or more pumps, several meters may The system can function equally well
be provided on individual pump dis- with ground level storage, elevated
charges, with the flows added for con-tanks or standpipes. Although per-
trol purposes. Some form of initiating mitting the most economical and effi-
control is usually employed; this may cient operation, it nevertheless provides
consist of a low pressure switch on thefor instantaneous handling of peak re-

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 390 M. E. ROGERS Jour. AW W A

of controls, simplicity,
quirements. Economy is sturdiness,
made re- p
liability and flexibility
by smaller storage tank must be con-
require
as the portion sidered.
requiredOften emergency for operation
emer
depends upon controls of this
operation on conventional type.
instal
may be eliminated.
During periods of great Pressure
demand, such
control also permits a wider
as are afforded by firefighting, for ex- a
choice in the location of elevated stor- ample, there can be no compromise
age sites, either to effect economies orwith speed of adjustment and reliability.
to overcome objections by property Perhaps of greatest importance, prop-
owners. Frequently, ground level stor- erly engineered controls permit sub-
age may be substituted for elevated stor- stantial savings in operating costs, a
age at a substantial saving in initial andpoint of vital interest to management
operating costs. Each installation must faced with the problem of increasing
be individually engineered as a knowl- costs.
edge of local conditions is required for
References
selecting pressure and flow ranges and
for determining operating requirements. 1. Salvato, J. A., Jr. Design of Pressure
Tanks for Small Water Systems, Jour.
Summary A.W.W.A., 41 :532 (June 1949).
2. Jester, John M. & Hunderson, John W.
Various types of pump control have Multiple Telemetering Over a Single
been described; these range from sim- Telephone Circuit. Jour. A.W.W.A.,
ple pressure controls to the more elab- 41:9 (Jan. 1949).
orate forms of control which must be in- 3. Smith, Marsden C. A New Automatic
Pressure-Flow Control System. Jour.
dividually engineered. It is not practi- A.W.W.A., 40:1259 (Dec. 1948).
cal to provide a package control system 4. Coffin, George W. Water Supply for
which will suit all conditions and all Logan Airport. Jour. N.E.W.W.A.,
methods of operation. In the selection 64:45 (1950).

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