How to Optimize Pump Control: HVAC, Water Management, Oil, Gas, Agriculture
Real-World Automation Success Stories with Integrated PLC+HMI Controllers
Pumps are a crucial element in the design of a broad range of machines and automated solutions. This article reviews actual stories from the field, solutions that incorporate pumps, and demonstrates how these automation professionals streamline complex processes, reduce costs, and optimize these systems. In all of these applications, Unitronics multi-function PLCs and automation software provide the essentials of precise control, monitoring capabilities, and serve the increasing requirements for remote maintenance.
Pasteurize, Process and More—
All-in-One Control |UniStream 15.6”
Soda production requires pumps to move soda through the pasteurization process. Procesteh of Croatia needed a PLC with temperature inputs to control pumps, monitor and control the pasteurization temperature and heat exchangers, and digital I/O to open and close valves and run with multiple different settings to control both the pasteurization and cleaning between pasteurizations. They selected a UniStream 15.6-inch powerful programmable logic controller with HMI panel, CPU and I/O modules for their project, benefitting from the big 15-inch HMI display for easy operator control.
Hotel Vanilla: Enhancing HVAC Efficiency | UniStream 10.4”
Hotel Vanilla, a 17-room establishment with an in-house restaurant in Serbia, sought to maintain consistent indoor temperatures while maximizing energy efficiency. They achieved their goals using a UniStream® PLC+HMI controller with a 10.4” color-touch HMI panel from Unitronics. This all-in-one controller manages the hotel’s HVAC system, automating the operation of pumps and valves to ensure optimal temperature regulation, communicating with remote I/O modules on each floor via CANbus. Room temperature is monitored and turned on and off based on occupation, using fan coil speeds and regulating valves. UniStream also regulates hot water temperatures in the boiler room via 3-way valves and 3-point control, heat pumps start and stops, and the status of the electrical boilers.
The HMI application allows staff to easily adjust settings and monitor system performance in real-time.
Engineer Janko Risojevic explained “the biggest advantage was the intuitive, integrated UniLogic environment for ladder and HMI programming”
Tills Innovations: Automating Custom Water Features | UniStream 1040
Tills Innovations specializes in the design and installation of beautiful custom water features. For a recent large-scale project, Tills selected a UniStream 10.4 PLC + HMI. The powerful, multifunction controller automates the synchronization of water flows and lighting effects, creating dynamic displays via seven feature pumps, two filter pumps, and water top-up valves, along with the chemical dosing and lighting for the feature. UniStream’s 10.4” HMI screen enables remote monitoring, control, and maintenance, via a 3G/4G GPRS router. UniStream’s data tables provide the parameters that adjust the pump’s flow to standardize the water jets to the correct heights.
Lead engineer Andy James reports:
“I have used PLCs for over 20 years, but since using Unitronics, with their large range of choices, I will not need to look for any other PLC manufacturer for any of our many and varied projects.””
PLC Pump Control Makes It Easier To Create Clean, Environmentally Friendly Biogas| UniStream
Greenmove Technologies, a bio-energy company, created a unique technology to convert lignocellulosic mass into biogas more efficiently than was previously possible. A key component of this technology is the UniStream PLC + HMI, which controls the variety of pumps, valves, and sensors in their Greenstep® reactors, which relies on natural fungi to produce enzymes that boost biogas production; using the Greenstep enzyme cocktail results in a 20-30% better yield of biogas. The enzymes produced by the fungi need to be fed into the fermentation process, where the lignocellulose is broken down into biogas under anoxic conditions.
The all-in-one design of the UniStream was a huge advantage for Greenmove’s stand-alone application; they were able to get an HMI, PLC, data storage and remote connectivity in one device with no additional costs for software or utilities.
Process Technologist Jeroen Tideman of Greenmove says:
“Compared to the alternative of an industrial PC, UniStream is cost competitive. UniStream offers the right balance between functionality and simplicity and is therefore an ideal fit for our application. With UniStream we succeed in running our ‘mini-factories’ at customers’ locations.”
Energy Plant Solutions: Pumps & Boilers | Vision1040
Energy Plant Solutions, based in New Zealand, aimed to improve the safety and automation of their package boilers via a cost-effective automation solution that could control all of the functions of the boiler, including feed pumps, pressure control and level control. Since the application included nearly 100 local I/O points, both digital and analog, complex communications, EPS therefore selected a Vision1040, with a big screen to display important information without crowding it, and physical buttons for certain dedicated functions..
The V1040 manages boiler operation, including pump control, temperature regulation, and safety interlocks, while the built-in alarm functions allows operators to respond swiftly to any anomalies, thereby enhancing overall safety. Remote monitoring capabilities further ensured that system performance could be tracked in real-time, facilitating proactive maintenance and reducing downtime.
Justin Butler, EPS control engineer said:
“Working with the Unitronics combined PLC and HMI make other systems feel old fashioned and obsolete. The support from Unitronics, from our local supplier, to email support, to help ideas on the forum, has been absolutely fantastic.”
He also noted that Unitronics PLCs also offer significant savings, because of:
“the development software licensing (it doesn’t get much cheaper than free) and also in the time required to develop the PLC/HMI software.”
Supply and Remote Management of Potable Water
University of Johannesburg’s School of Engineering project was to supply clean drinking water to a remote village lacking reliable electricity.
They used two Unitronics PLC + HMI controllers for this project. A simple Jazz controller automates the water pumps onsite via pressure and flow sensors, powered by solar energy. Configured as a Modbus slave, Jazz transmits the data via GSM modem to a powerful Vision1210 located at the University of Johannesburg, configured as a Modbus Master. The V1210 collects data for pump, power supply and tank. Trend analysis of water pressure shows the village’s water usage over time, tracking allows the team to monitor the pump health and detect any problems before the pump fails. Similarly, they monitor the battery voltage and temperature over time to ensure that the battery is not losing efficiency or in danger of overheating. Via Remote Access, the team monitors system performance and makes adjustments when required.
MSI Tec: Reliable Well Pump Control in Extreme Conditions | V570
MSI Tec, an industrial automation equipment distributor, was tasked with redesigning the control system for the City of Tucson’s well pumps, which operate under extreme temperature variations. They chose the Vision570™ PLC+HMI from Unitronics for its robustness and reliability, as well as its ability to communicate with Tucson’s SCADA. V570s manage the natural gas engines for more than 40 wells, driving the pumps and ensuring stable operation despite ambient temperatures ranging from above 100°F (38°C) to below freezing. The Vision570™ HMI screen provides clear visibility and control, even under harsh environmental conditions, ensuring uninterrupted water supply to the city’s residents.
According to Matthew Cronin, MSI Tec’s engineering manager:
“By combining low cost I/O, communications, PLC functionality, and an HMI in a single package, Unitronics delivered more capability for less money.”
Aqua Interma Engineering: Ensuring Water Purity | Samba, Jazz, Vision430
Aqua Interma Engineering specializes in water treatment systems designed to eliminate microorganisms and ensure water purity. They use Unitronics PLC+HMI+ IO controllers to automate the dosing of chlorine and subsequent testing of residual levels, selecting the controller models from the series that best fits the application: Samba, Jazz, Vision430.
The all-in-one design of the controllers allows them to easily fit into the limited control panel space available. These PLCs allow for continuous measurement of the water being treated and offer data logging and Trends to manage the data being collected, while the HMI user-friendly interface allows operators to easily manage the treatment process, ensuring compliance with health standards and providing safe drinking water to communities.
Engineer Stevo Vojnović says, “among all automation the devices I work with, Unitronics is my favorite. It always delivers more performance than I expect!”
AquaRD Sp. z o.o.: Integrating Control and Communication | Vision130
AquaRD Sp. z o.o., operating in the water and wastewater sectors, require solutions that combine control capabilities with flexible communication options. In a recent application, a VisionV130 PLC+HMI runs a compressor station. A hydrostatic probe measures sewage level and sends 4-20 mA signals to the V130; the PLC displays this data on the HMI, compares it to pre-assigned water levels, and starts and stops the pumps to keep the sewage in the tank at a required level. The Vision130 alternates the operation of the pumps based on the programmed work time to ensure uniform wear on all the pumps. The compressor station can be set to run entirely automatically or in manual mode; operators can view key information about the pumps and compressor status on the integrated HMI panel.
Conclusion
These diverse applications underscore the versatility and effectiveness of Unitronics’ all-in-one PLC+HMI solutions in automating pump systems across various industries. By integrating control, monitoring, and communication functionalities into a single platform, Unitronics simplifies complex processes, reduces implementation costs, and enhances system reliability. The ability to remotely monitor and control operations further adds to operational efficiency, making Unitronics a preferred choice for organizations seeking to optimize their pump applications.
These applications show the versatility and effectiveness of Unitronics’ all-in-one PLC+HMI solutions in automating pump systems. By integrating control, monitoring, and communication functionalities into a single platform, Unitronics simplifies complex processes, reduces implementation costs, and enhances system reliability.
To learn more about the benefits of Unitronics solutions for pump applications—our full range of rugged PLCs & PLC + HMI controllers, VFDs, end-to-end IIoT platform, backed by forever- free software and support:
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