REMOTE COMMAND AND CONTROL PUMP SYSTEM

Abstract

The present disclosure relates to water transfer control systems, and more particularly, to apparatuses and systems for centralized monitoring and control of multiple mobile pump control units located at remote pump sites.

Description

BACKGROUND

In various applications, it is desirable to transfer water from one or more water sources, which may be remotely located, and to deliver the water to one or more other sites. For example, in fracking operations, it is typical to locate multiple pumps at different sources of water in a geographic region subject to fracking, to enable the water to be pumped from those water sources to the site of a fracking operation. The pumps are often located at various remote sites within the geographic region.

SUMMARY

In applications where it is desired to pump water from one or more remote water sources to a destination site, monitoring and control of the remotely located pumps may be difficult, as the pumps may be dispersed throughout a geographic region. Disclosed herein are apparatuses and systems for providing centralized monitoring and control of multiple mobile pump control units located at remote pump sites. In one aspect, a mobile pump control unit may comprise a chassis with wheels for mobility. The chassis may house mechanical plumbing, including at least one pump inlet manifold in fluid communication with a suction port, and at least one pump outlet manifold in fluid communication with a discharge port and recirculation port. The at least one pump inlet manifold may be adapted to connect to an inlet of a pump disposed at a pump site, to receive an inlet flow of water via the suction port, and the at least one pump outlet manifold may be adapted to connect to an outlet of the pump to receive a flow of water discharged from the pump. The mobile pump control unit may also comprise a plurality of valves disposed within the mechanical plumbing to direct the flow of water from the at least one pump outlet manifold to the discharge port and the recirculation port; a plurality of sensors disposed within the mechanical plumbing to measure characteristics of water flowing through the mechanical plumbing; and a control unit configured to independently control the plurality of valves and the plurality of sensors. The control unit may further comprise an interface to enable connection to a control panel of the pump at the pump site. The mobile pump control unit may also comprise communications circuitry coupled to the control unit and configured to communicate with a mobile command center and with other mobile pump control units in a geographic area, wherein the mobile pump control unit may receive commands from the mobile command center for controlling the plurality of valves and the pump at the pump site and may send information concerning the pump and the water flowing through the mechanical plumbing of the mobile pump control unit to the command center or other mobile pump control units.

In another aspect, a remote water transfer command and control system may comprise a plurality of pumps, a plurality of mobile pump control units, and a mobile command center. Each mobile pump control unit may be configured to connect to at least one pump of the plurality of pumps, monitor and control the at least one pump connected to the mobile pump control unit, direct an inlet flow of water to the at least one pump, receive a discharge flow of water from the at least one pump, direct a flow of water from the mobile pump control unit, and monitor characteristics of the water flowing into, and out of, the mobile pump control unit. The mobile command center may be in communication with the plurality of mobile pump control units. The mobile command center may be configured to monitor and control the plurality of pumps, the plurality of mobile pump control units, and the water flowing into, and out of, each mobile pump control unit.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Description of Illustrative Embodiments section. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Furthermore, the claimed subject matter is not constrained to limitations that solve any or all disadvantages noted in any part of this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of illustrative embodiments, are better understood when read in conjunction with the appended drawings. For the purpose of illustration, the drawings show exemplary embodiments of various aspects of the invention. The invention, however, is not limited to the specific instrumentalities disclosed in the drawings. In the drawings:

FIG. 1A is a schematic diagram of a remote command and control pump system according to an aspect of the present disclosure.

FIG. 1B is an enlarged section illustrating a mobile pump control unit and pump shown in FIG. 1A.

FIG. 2A is a top view schematic diagram of a mobile pump control unit according to an aspect of the present disclosure.

FIG. 2B is a front view schematic diagram of the mobile pump control unit shown in FIG. 2A.

FIG. 3A is a top view schematic diagram of a mobile pump control unit according to another aspect of the present disclosure.

FIG. 3B is a front view schematic diagram of the mobile pump control unit shown in FIG. 3A.

FIG. 3C is a side view schematic diagram of the mobile pump control unit shown in FIG. 3A.

FIG. 4 is a schematic diagram illustrating an exemplary network configuration of a remote command and control pump system shown in FIG. 1A.

FIG. 5 illustrates an exemplary computer interface at a mobile command center for monitoring and controlling a mobile pump control unit.

FIG. 6 illustrates an exemplary computer interface at a mobile command center for a gauge display for pumps connected to a mobile pump control unit.

FIG. 7 illustrates an exemplary computer interface at a mobile command center for an alarm set up screen associated with a mobile pump control unit.

FIG. 8 illustrates an exemplary computer interface at a mobile command center for an alarm display screen associated with a mobile pump control unit.

FIG. 9 illustrates an exemplary computer interface at a mobile command center for a water reservoir associated with a remote command and control pump system.

FIG. 10 illustrates a schematic of a computing environment according to an aspect of the disclosure.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

FIG. 1A is a schematic diagram of a remote command and control pump system 100 according to an aspect of the present disclosure. System 100 may comprise a mobile command center 106 (e.g., Supervisory Control and Data Acquisition (“SCADA”) trailer), multiple remotely located pumps 120a, 120b, 120c, 120d, and multiple remotely located mobile pump control units 110a, 110b, 110c. FIG. 1B is an enlarged view of a remote pump 120 and mobile pump control unit 110 in system 100.

Referring to FIG. 1B, each mobile pump control unit 110 may comprise a chassis that contains one or more of mechanical plumbing, control, monitoring, and communication components. The chassis may further comprise wheels for mobility and necessary fittings to be towed behind a vehicle (e.g., a trailer). Alternatively, the chassis may comprise a skid or Conex box. The mechanical plumbing may comprise pump inlet manifolds 114a, 114b, pump outlet manifolds 115a, 115b, a suction port 111, discharge port 113, recirculation port 112, conduit, and valves 116a, 116b, 116c, 116d that enable the mobile pump control unit 110 to connect to one or more pumps 120 at a pumping site and to control the flow of water from the pump(s) to a destination, such as a water storage reservoir.

Monitoring sensors may be disposed within the plumbing of the mobile pump control unit to enable monitoring of various characteristics of the water as it flows through the plumbing of the mobile control unit. These monitoring sensors may comprise sensors to measure the suction and discharge temperature, the suction pressure for each pump, and the discharge pressure and flow rate of the water flowing out of the pluming provided on the mobile pump control unit. Each mobile pump control unit 110 may also comprise a programmable logic controller (PLC) 118, also referred to as a control unit, that provides overall control of the sensors, valves 116a, 116b, 116c, 116d, and other components of the mobile pump control unit 110. The PLC 118 may comprise an interface 119 that enables the mobile pump control unit 110 to connect to a control panel/interface 126 on the pump(s) 120 deployed at each pump site. The interface 119 may enable the mobile pump control unit 110 to be able to connect to a variety of different types and sizes of pumps. Via this interface, the mobile pump control unit 110 (via commands from the mobile command center 106) may monitor and control aspects of the pump 120 (e.g., on/off, motor speed (RPM), fuel level).

Referring to FIG. 1A, the mobile command center 106 and each mobile pump control unit 110a, 110b, 110c, may comprise communications components 107, 117a, 117b, 117c. These components may comprise one or more of radios, directional antennas, omnidirectional antennas, and the like that enable wireless communications among the mobile command center 106 and the mobile pump control units 110a, 110b, 110c. For example, the communications components 107, 117a, 117b, 117c may be configured to implement, for example, one or more of a 900 MHz radio link, a Wi-Fi network, a satellite connection, or a cellular connection between the mobile command center 106 and the mobile pump control units 110a, 110b, 110c. Via such communications, the system 100 may allow the centralized monitoring and control of the sensors, valves, and other components of the remotely located mobile pump control units 110a, 110b, 110c, as well as, the individual pumps 120a, 120b, 120c, 120d connected to the respective mobile pump control units 110a, 110b, 110c.

The system 100 may also comprise one or more water storage reservoirs, such as storage tanks 108a and 108b. The one or more water storage reservoirs 108a, 108b may also comprise communication components 109 that enable wireless communications between the mobile command center 106 and one or more water storage reservoirs. The mobile command center 106 may thereby monitor and control the water level in the one or more water storage reservoirs.

Exemplary uses may include connecting multiple pump sites to draw water from multiple remote water sources or locations 130a, 130b, 130c and to transfer the water via pipelines 140a, 140b, 140c, 150 to a destination for use in fracking, fighting fires, or any other application requiring the delivery of water from multiple water sources to one or more destination sites. In a situation in which multiple pump sites need to be up and running relatively quickly, but perhaps for a temporary duration, the system 100 may make it easier to transport the mobile pump control units 110a, 110b, 110c to the various pump sites, hook up to the pumps 120a, 120b, 120c, 120d, and quickly provide centralized monitoring and control of the pump sites via the mobile command center 106.

FIG. 1B illustrates features, equipment, and components at a representative pump site in system 100. Each pump site may comprise at least one pump 120, a mobile pump control unit 110, and a water source 130. The pump 120 comprises an inlet 122, an outlet 124, and a pump control panel 126. Pump control panel 126 may comprise a LOFA control panel. As discussed above, the mobile pump control unit PLC 118 may comprise an interface 119 that enables the mobile pump control unit 110 to connect to the control panel/interface 126 on the pump 120 deployed at the pump site. Via interface 119, the mobile pump control unit 110 may be able to monitor and control aspects of the pump 120. The interface 119 may be configured to enable the mobile pump control unit 110 to be able to connect to a variety of different types and sizes of pumps. Exemplary pumps utilized in remote command and control pump system 100 include, but are not limited to, 4″×4″, 6″×6″, 12″×12″, 10″×8″, 12″×8″ or 8″6″ centrifugal pumps capable of delivering water or other related fluids at rates of 1,000 to 5,000 gallons per minute (gpm), or the like.

The pump control unit 110 may further comprise a suction port 111, a recirculation port 112, a discharge port 113, pump inlet manifolds 114a, 114b, pump outlet manifolds 115a, 115b, sensors, and valves 116a, 116b, 116c, 116d. The pump control unit pump inlet manifolds 114a, 114b are in fluid communication with the suction port 111, which is in fluid communication with water source 130 via suction line 142. The pump control unit pump outlet manifolds 115a, 115b are in fluid communication with recirculation port 112 and discharge port 113.

In an exemplary operation utilizing one pump 120, pump inlet 122 is connected to pump control unit pump inlet manifold 114a and draws an inlet flow of water from water source 130 via suction line 142 and the pump control unit suction port 111. Pump 120 discharges a flow of water from pump outlet 124, which is connected to pump control unit pump outlet manifold 115a. A user located at the mobile command center 106 may be able to monitor and control the flow of water via the sensors, valves 116a, 116b, 116c, 116d, and other components of the remotely located mobile pump control unit 110, as well as, the connected pump 120. For example, a user located at the mobile command center 106 may send commands to the pump control unit 110 to actuate and adjust valves 116a, 116c, 116d to direct the flow of water from pump outlet manifold 115a to discharge port 113 so that the flow of water is transferred to the desired destination via discharge line 140 and water transfer line 150. The user may utilize sensor readings at the mobile command center 106 to inform control decisions. Alternatively, the user may send commands to the pump control unit 110 to actuate and adjust valves 116a, 116c, 116d to direct any portion of the flow of water to the recirculation port 112, such that some or all of the flow of water from pump outlet manifold 115a is recirculated back to water source 130 via recirculation line 144.

In an alternative application, mobile pump control unit 110 may be used as a Booster or Lift pump station that may enable system 100 to maintain a desired water pressure or to achieve specific water delivery rates. By way of example, the water source 130 may be a water transfer pipeline (not shown) that may be connected to suction line 142. In operation, pump inlet 122 is connected to pump control unit pump inlet manifold 114a and draws an inlet flow of water from water source 130 via suction line 142 and the pump control unit suction port 111. Pump 120 discharges a flow of water from pump outlet 124, which is connected to mobile pump control unit pump outlet manifold 115a. A user located at the mobile command center 106 may send commands to the pump control unit 110 to actuate and adjust valves 116a, 116c, 116d to direct the flow of water from pump outlet manifold 115a to discharge port 113 so that the flow of water is transferred to the desired destination via discharge line 140 and water transfer line 150. Pump 120 may thereby boost the water pressure or water delivery rates of system 100. Rather than directing the flow of water back to the water source 130, recirculation valve 116c may direct any portion of the flow of water to line 144 that may discharge the water in an area near the booster pump station.

The pump inlet manifolds 114a, 114b and pump outlet manifolds 115a, 115b may be configurable to connect to various sized pump inlets 122 and pump outlets 124. For example, in an application where the pump inlet and outlet manifolds may have a flange sized for a 12 inch pump, adapters may be used to neck down and connect a 10, 8, 6, or 4 inch pump.

One benefit of the disclosed system is that the mobile pump control unit 110 includes the necessary plumbing and valves to allow one or more standard pumps to be deployed and placed in close proximity to the mobile pump control unit 110. The system may also allow for simplified setup and tear down of remote pumping operations. One suction line and one recirculation line may be plumbed to a water source and connected to the mobile pump control unit 110 to support multiple pumps. The system may also allow for automation and remote control and monitoring of the mobile pump control units and various makes and sizes of standard pumps. The mobile command center 106 may coordinate water transfer activities amongst all of the deployed pumps and mobile pump control units. The system may also allow for multi-directional pumping capabilities. Water may be directed to the water transfer line 150 or recirculated back to the source 130 depending on the water delivery requirements at any particular time. Further, the system may allow for safety shutdown based on various parameters, including but not limited to: high/low suction pressure, high/low discharge pressure, low suction and/or discharge temperature, or water reservoir levels.

FIG. 2A is a top view schematic diagram illustrating the mechanical plumbing, valves, and sensors of exemplary mobile pump control unit 200. The mobile pump control unit 200 comprises a chassis 202 that is adapted to house the mechanical plumbing, valves, and sensors. The chassis 202 may have wheels for mobility and necessary fittings to be towed behind a vehicle (e.g., a trailer). The mobile pump control unit may comprise a PLC 204 that provides overall control of the sensors 208, 218, 236, 238, 246a, 246b, 239, valves 224, 234, 244a, 244b, 254a, 254b, and other components of the mobile pump control unit 200. The valves 224, 234, 244a, 244b, 254a, 254b may comprise butterfly valves. Alternatively, the valves may comprise one or more ball valves, gate valves, or globe valves.

The mechanical plumbing may comprise a suction port 210 that is in fluid communication with pump inlet manifolds 240a, 240b via suction conduit 212 and pump inlet conduits 242a, 242b. The suction conduit 212 and pump inlet conduits 242a, 242b may comprise straight, curved, and tee sections of pipe that are joined in a manner to provide a watertight seal. The suction conduit 212 and pump inlet conduits 242a, 242b may have an outside diameter of 12 inches. Alternatively, suction conduit 212 and pump inlet conduits 242a, 242b may comprise an outside diameter(s) of 12, 10, 8, or 6 inches, or any combination thereof, depending on the water transfer application. Suction temperature sensor 218 may be in electrical communication with PLC 204 and configured to measure the temperature of the flow of water through suction conduit 212.

Each pump inlet conduit 242a, 242b may include a pump inlet valve 244a, 244b configured to adjust an inlet flow of water from the suction port 210 to the respective pump inlet manifold 240a, 240b. Each pump inlet valve 244a, 244b may include an electric actuator in electrical communication with PLC 204. PLC 204 may be configured to independently actuate each pump inlet valve 244a, 244b. As such, the mobile pump control unit may operate utilizing one or more pumps attached to pump inlet manifolds 240a, 240b. The pump inlet valves 244a, 244b may comprise two-position open/close valves. Alternatively, the pump inlet valves 244a, 244b may comprise modulating valves that may be adjusted to any desired opening between 0% and 100%. Each pump inlet conduit 242a, 242b may also include a pump inlet pressure sensor 246a, 246b that may be in electrical communication with PLC 204 and configured to measure the pressure of the water in the respective pump inlet conduit. The pump inlet pressure sensors 246a, 246b may comprise a pressure transducer. The pump inlet pressure sensors 246a, 246b may comprise combination sensors configured to measure negative and positive pressure, thereby enabling the sensor to read vacuum during a pump priming operation.

The mechanical plumbing may further comprise a recirculation port 220 and a discharge port 230 that are in fluid communication with pump outlet manifolds 250a, 250b via recirculation conduit 222, discharge conduit 232 and pump outlet conduits 252a, 252b. The recirculation conduit 222, discharge conduit 232 and pump outlet conduits 252a, 252b may comprise straight, curved, and tee sections of pipe that are joined in a manner to provide a watertight seal. Recirculation conduit 222, discharge conduit 232 and pump outlet conduits 252a, 252b may have an outside diameter of 12 inches. Alternatively, recirculation conduit 222, discharge conduit 232 and pump outlet conduits 252a, 252b have an outside diameter(s) of 12, 10, 8, or 6, or any combination thereof, depending on the water transfer application.

Each pump outlet conduit 252a, 252b may include a pump outlet valve 254a, 254b configured to adjust an outlet flow of water from the respective pump outlet manifold 250a, 250b to recirculation conduit 222 and discharge conduit 232. Each pump outlet valve 254a, 254b may comprise a modulating valve that may be adjusted to any desired opening between 0% and 100%, and may include an electric actuator that may be in electrical communication with PLC 204. PLC 204 may be configured to independently actuate each pump outlet valve 254a, 254b. As such, the mobile pump control unit may operate utilizing one or more pumps attached to pump outlet manifolds 250a, 250b.

The recirculation conduit 222 may include a recirculation valve 224 configured to adjust a flow of water from the pump outlet manifolds 250a, 250b to recirculation port 220. The recirculation valve 224 may comprise a modulating valve that may be adjusted to any desired opening between 0% and 100%, and may include an electric actuator that may be in electrical communication with the pump control unit PLC 204. PLC 204 may be configured to independently actuate recirculation valve 224. During operation, recirculation valve 224 may be opened to direct a portion, or all, of the flow of water from the pump outlet manifolds 250a, 250b to recirculation port 220, thereby recirculating the flow of water back to a water source.

The discharge conduit 232 may include a discharge valve 234 configured to adjust a flow of water from the pump outlet manifolds 250a, 250b to discharge port 230. The discharge valve 234 may comprise a modulating valve that may be adjusted to any desired opening between 0% and 100%, and may include an electric actuator that may be in electrical communication with the pump control unit PLC 204. PLC 204 may be configured to independently actuate discharge valve 234. During operation, discharge valve 234 may be opened to direct a portion, or all, of the flow of water from the pump outlet manifolds 250a, 250b to discharge port 220. The discharge conduit 232 may also include a discharge flow meter 239 that may be in electrical communication with PLC 204 and configured to measure the flow of water through discharge conduit 232. The discharge conduit 232 may also include a discharge pressure sensor 236 that may be in electrical communication with PLC 204 and configured to measure the pressure of the water in the discharge conduit. The discharge pressure sensor 236 may comprise a pressure transducer. Discharge temperature sensor 238 may be in electrical communication with pump control unit PLC 204 and configured to measure the temperature of the flow of water through discharge conduit 232.

The mobile pump control unit 200 may further comprise an ambient air temperature sensor 208 that may be in electrical communication with PLC 204. The mobile pump control unit 200 may also comprise vibration sensors (not shown) that may be in electrical communication with PLC 204 and configured to attach to, and provide information about, the pumps that are connected to the pump inlet and outlet manifolds 240a, 240b and 250a, 250b.

FIG. 2B is a front view schematic diagram illustrating the exterior of the mobile pump control unit 200 shown in FIG. 2A. As shown, the mobile pump control unit 200 comprises a chassis 202 that is adapted to house the mechanical plumbing, valves, and sensors (as discussed above). As shown, the chassis 202 may have wheels 203 for mobility and necessary fittings to be towed behind a vehicle (e.g., a trailer). Alternatively, the chassis 202 may comprise a skid or Conex box. The mobile pump control unit 200 further comprises a PLC interface 206 that may enable the mobile pump control unit PLC 204 to connect to a control panel/interface on the pump(s) deployed at the pump site. FIG. 2B also illustrates one arrangement of the relative positions of suction port 210, recirculation port 220, discharge port 230, pump inlet manifolds 240a, 240b, and pump outlet manifolds 250a, 250b. The relative positions of those components may be different in other implementations. The mobile pump control unit 200 may further comprise an ambient air temperature sensor 208.

FIG. 3A is a top view schematic diagram illustrating an alternative arrangement of the mechanical plumbing, valves, and sensors in exemplary mobile pump control unit 300. The mobile pump control unit 300 comprises a chassis 302 that is adapted to house the mechanical plumbing, valves, and sensors. The chassis 302 may have wheels for mobility and necessary fittings to be towed behind a vehicle (e.g., a trailer). Alternatively, the chassis 302 may comprise a skid or Conex box. The mobile pump control unit may comprise a PLC 304 that provides overall control of the sensors 318, 338, 339, 346a, 346b, 356a, 356b, valves 324, 334, 344a, 344b, 354a, 354b, and other components of the mobile pump control unit 300. The valves 324, 334, 344a, 344b, 354a, 354b may comprise butterfly valves. Alternatively, the valves may comprise one or more ball valves, gate valves, or globe valves.

The mechanical plumbing may comprise a suction port 310 that is in fluid communication with pump inlet manifolds 340a, 340b via suction conduit 312 and pump inlet conduits 342a, 342b. The suction conduit 312 and pump inlet conduits 342a, 342b may comprise straight, curved, and tee sections of pipe that are joined in a manner to provide a watertight seal. The suction conduit 312 and pump inlet conduits 342a, 342b may have an inside outside diameter of 12 inches. Alternatively, suction conduit 312 and pump inlet conduits 342a, 342b may comprise an outside diameter(s) of 12, 10, 8, or 6 inches, or any combination thereof, depending on the water transfer application. Suction temperature sensor 318 may be in electrical communication with PLC 304 and configured to measure the temperature of the flow of water through suction conduit 312.

Each pump inlet conduit 342a, 342b may include a pump inlet valve 344a, 344b configured to adjust an inlet flow of water from the suction port 310 to the respective pump inlet manifold 340a, 340b. Each pump inlet valve 344a, 344b may include an electric actuator in electrical communication with PLC 304. PLC 304 may be configured to independently actuate each pump inlet valve 344a, 344b. As such, the mobile pump control unit may operate utilizing one or more pumps attached to pump inlet manifolds 340a, 340b. The pump inlet valves 344a, 344b may comprise two-position open/close valves. Alternatively, the pump inlet valves 344a, 344b may comprise modulating valves that may be adjusted to any desired opening between 0% and 100%. Each pump inlet conduit 342a, 342b may also include a pump inlet pressure sensor 346a, 346b that may be in electrical communication with PLC 304 and configured to measure the pressure of the water in the respective pump inlet conduit. The pump inlet pressure sensors 346a, 346b may comprise a pressure transducer. The pump inlet pressure sensors 346a, 346b may comprise combination sensors configured to measure negative and positive pressure, thereby enabling the sensor to read vacuum during a pump priming operation.

The mechanical plumbing may further comprise a recirculation port 320 and a discharge port 330 that are in fluid communication with pump outlet manifolds 350a, 350b via recirculation conduit 322, discharge conduit 332 and pump outlet conduits 352a, 352b. The recirculation conduit 322, discharge conduit 332 and pump outlet conduits 352a, 352b may comprise straight, curved, and tee sections of pipe that are joined in a manner to provide a watertight seal. Recirculation conduit 322, discharge conduit 332 and pump outlet conduits 352a, 352b may have an outside diameter of 12 inches. Alternatively, recirculation conduit 322, discharge conduit 332 and pump outlet conduits 352a, 352b may comprise an outside diameter(s) of 12, 10, 8, or 6, or any combination thereof, depending on the water transfer application.

Each pump outlet conduit 352a, 352b may include a pump outlet valve 354a, 354b configured to adjust an outlet flow of water from the respective pump outlet manifold 350a, 350b to recirculation conduit 322 and discharge conduit 332. Each pump outlet valve 354a, 354b may comprise a modulating valve that may be adjusted to any desired opening between 0% and 100%, and may include an electric actuator that may be in electrical communication with PLC 304. PLC 304 may be configured to independently actuate each pump outlet valve 354a, 354b. As such, the mobile pump control unit may operate utilizing one or more pumps attached to pump outlet manifolds 350a, 350b. Each pump outlet conduit 352a, 352b may also include a pump outlet pressure sensor 356a, 356b that may be in electrical communication with PLC 304 and configured to measure the pressure of the water in the respective pump outlet conduit.

The recirculation conduit 322 may include a recirculation valve 324 configured to adjust a flow of water from the pump outlet manifolds 350a, 350b to recirculation port 320. The recirculation valve 324 may comprise a modulating valve that may be adjusted to any desired opening between 0% and 100%, and may include an electric actuator that may be in electrical communication with the pump control unit PLC 304. PLC 304 may be configured to independently actuate recirculation valve 324. During operation, recirculation valve 324 may be opened to direct a portion, or all, of the flow of water from the pump outlet manifolds 350a, 350b to recirculation port 320, thereby recirculating the flow of water back to a water source.

The discharge conduit 332 may include a discharge valve 334 configured to adjust a flow of water from the pump outlet manifolds 350a, 350b to discharge port 330. The discharge valve 334 may comprise a modulating valve that may be adjusted to any desired opening between 0% and 100%, and may include an electric actuator that may be in electrical communication with the pump control unit PLC 304. PLC 304 may be configured to independently actuate discharge valve 334. During operation, discharge valve 334 may be opened to direct a portion, or all, of the flow of water from the pump outlet manifolds 350a, 350b to discharge port 320. The discharge conduit 332 may also include a discharge flow meter 339 that may be in electrical communication with PLC 304 and configured to measure the flow of water through discharge conduit 332. The discharge conduit 332 may also include a discharge pressure sensor 336 that may be in electrical communication with PLC 304 and configured to measure the pressure of the water in the discharge conduit. The discharge pressure sensor 336 may comprise a pressure transducer. Discharge temperature sensor 338 may be in electrical communication with pump control unit PLC 304 and configured to measure the temperature of the flow of water through discharge conduit 332.

The mobile pump control unit 300 may further comprise an ambient air temperature sensor 308 (not shown) that may be in electrical communication with PLC 304. The mobile pump control unit 300 may also comprise vibration sensors (not shown) that may be in electrical communication with PLC 304 and configured to attach to, and provide information about, the pumps that are connected to the pump inlet and outlet manifolds 340a, 340b and 350a, 350b.

FIG. 3B is a front view schematic diagram illustrating the exterior of the mobile pump control unit 300 shown in FIG. 3A. As shown, the mobile pump control unit 300 comprises a chassis 302 that is adapted to house the mechanical plumbing, valves, and sensors (as discussed above). The chassis 302 may have wheels 303 for mobility and necessary fittings to be towed behind a vehicle (e.g., a trailer). The mobile pump control unit 300 further comprises a PLC interface 306 (not shown) that may enable the mobile pump control unit PLC 304 to connect to a control panel/interface on the pump(s) deployed at the pump site. FIG. 3B also illustrates one arrangement of the relative positions of suction port 310, recirculation port 320, discharge port 330, pump inlet manifolds 340a, 340b, and pump outlet manifolds 350a, 350b. The relative positions of those components may be different in other implementations. The mobile pump control unit 300 may further comprise an ambient air temperature sensor 308 (not shown) and communications components 317.

FIG. 3C is a side view schematic diagram illustrating the exterior of the mobile pump control unit 300 shown in FIGS. 3A and 3B. FIG. 3B illustrates one arrangement of the relative positions of suction port 310, recirculation port 320, pump inlet manifolds 340a, 340b, and pump outlet manifolds 350a, 350b. The relative positions of those components may be different in other implementations.

FIGS. 1A and 4 illustrate an exemplary network configuration and communications of a remote command and control pump system. Referring to FIG. 1A, the mobile command center 106 and the mobile pump control units 110a, 110b, 110c comprise communications components 107, 117a, 117b, 117c that enable the mobile command center 106 to communicate with the mobile pump control units 110a, 110b, 110c. The mobile command center 106 may directly communicate with each mobile pump control unit 110a, 110b, 110c. Alternatively, the communications equipment 107, 117a, 117b, 117c may enable the various mobile control units 110a, 110b, 110c to communicate with each other and the mobile command center 106, and to pass communications between the mobile command center 106 and a particular mobile pump control unit 110a, 110b, 110c. For example, the mobile command center 106 may not be able to communicate directly with mobile pump control unit 110c due to range limitations of the wireless communications components or the terrain in which the mobile pump control unit 110c is deployed. However, mobile pump control unit 110c may be able to communicate with mobile pump control unit 110b, which is in direct communication with the mobile command center 106. In that event, mobile pump control unit 110b may pass or relay communications between the mobile command center 106 and mobile pump control unit 110c. In one aspect, the communications components 107, 117a, 117b, 117c of the command center 106 and mobile pump control units 110a, 110b, 110c may form a mesh network.

FIG. 4 is a schematic diagram illustrating exemplary communications components of a mobile command center 420 and a mobile pump control unit 410. The mobile pump control unit 410 comprises a PLC 418 and communication components, such as radio 416, omnidirectional antennas 412, and directional antenna 414. The PLC 418 may comprise interfaces 444, 454 that enable the mobile pump control unit 410 to connect to the control panel/interface 442, 452 on the pumps 440, 450 deployed at the pump site. The interfaces 444, 454 may enable the mobile pump control unit 410 to be able to connect to a variety of different types and sizes of pumps 440, 450. Via these interfaces 444, 454, the mobile pump control unit 410 (via commands from the mobile command center 420) may monitor and control certain aspects of the pumps 440, 450, such as on/off, motor speed (RPM), fuel level, and the like. The mobile command center 420 may comprise a towable trailer that may be fitted with a computer or server 428 and communication components, such as a radio 426, omnidirectional antennas 422, and directional antenna 424 to communicate with a mobile pump control unit 410 and to control and monitor the pumps 440, 450 connected to a mobile pump control unit 410 from a centralized location. This location may be within a 1-2 mile distance from the mobile pump control units. In other deployments, the distance between the mobile pump control unit 410 and mobile command center 420 may be smaller or greater. For example, the system may include radio repeaters or additional mobile pump control units to extend the communications range. The mobile command center 420 may enable automation, control, alarming, data visualization and data storage.

The mobile pump control unit 410 and mobile command center 420 may utilize directional antennas 414, 424 to establish a wireless communication link 430. By way of example, wireless communication link 430 may operate on the 900 MHz band. Alternatively, the mobile pump control unit 410 and mobile command center 420 may utilize omnidirectional antennas 412, 422 to communicate via a network 432. By way of example, network 432 may be a local area network (LAN), a wide area network (WAN), a Wi-Fi (802.11) network, a mesh network, a cellular network, a satellite connection, or any combination of the above.

The mobile pump control unit 410 and mobile command center 420 may include antenna masts 413, 423. The mobile pump control unit omnidirectional antennas 412 and directional antenna 414 may be mounted on antenna mast 413. Similarly, the mobile command center omnidirectional antennas 422 and directional antenna 424 may be mounted on antenna mast 423. Antenna masts 413, 423 may be telescoping masts. Antenna masts 413, 423 may be 25 foot telescoping antenna masts.

Alternatively, the mobile pump control unit 410 and mobile command center 420 communication components may comprise a Rajant ME Series Dual Band 900 MHz/2.4 GHz Breadcrumb Wireless Node utilizing a 2.4 GHz Wireless Access Point (WAP). The WAP may utilize High Gain Omni-Directional antennas 412, 422 that may enable communications via a 2.4 GHz Wi-Fi network 432. In addition, the mobile pump control unit 410 and mobile command center 420 may utilize directional antennas 414, 424 to establish a 900 MHz communication link.

In an aspect of the disclosure, a user may utilize a Mobile Field Unit 460, which may comprise a hand held industrial ruggedized tablet, to locally connect via network 432 (e.g., a Wi-Fi network) to a mobile pump control unit 410 and thereby may be able to locally monitor and control the mobile pump control unit 410 and connected pump(s) 440, 450. For example, the Mobile Field Unit 460 may utilize user interfaces, such as exemplary user interfaces illustrated in FIGS. 5-9, to locally monitor and control the mobile pump control unit 410 and connected pump(s) 440, 450.

FIG. 10 is an exemplary computing environment 950 which, for example, may be used to implement a mobile command center computer or server 428 as shown in FIG. 4, or any other aspect of the disclosed systems that require computing. The computing environment 950 is only one example of a suitable computing environment and is not intended to suggest any limitation as to the scope of use or functionality of the presently disclosed subject matter. Neither should the computing environment 950 be interpreted as having any dependency or requirement relating to any one or combination of components illustrated in FIG. 10. In some embodiments, the various depicted computing elements may comprise circuitry configured to instantiate specific aspects of the present disclosure. For example, the term circuitry used in the disclosure may comprise specialized hardware components configured to perform function(s) by firmware or switches. In other example embodiments, the term circuitry can include a general purpose processing unit, memory, etc., configured by software instructions that embody logic operable to perform function(s). In example embodiments where circuitry includes a combination of hardware and software, an implementer may write source code embodying logic and the source code can be compiled into machine readable code that can be processed by the general purpose processing unit. Since the state of the art has evolved to a point where there is little difference between hardware, software, or a combination of hardware/software, the selection of hardware versus software to effectuate specific functions is a design choice left to an implementer. More specifically, a software process can be transformed into an equivalent hardware structure, and a hardware structure can itself be transformed into an equivalent software process. Thus, the selection of a hardware implementation versus a software implementation is one of design choice and left to the implementer.

In FIG. 10, the computing environment 950 may comprise a computer 971. The computer 971 comprises a processing unit(s) 989, which may comprise a general purpose processor, a special purpose processor, a conventional processor, a digital signal processor (DSP), a plurality of microprocessors, one or more microprocessors in association with a DSP core, a controller, a microcontroller, Application Specific Integrated Circuits (ASICs), Field Programmable Gate Array (FPGAs) circuits, any other type of integrated circuit (IC), a state machine, and the like. The processing unit(s) 989 may perform signal coding, data processing, power control, input/output processing, and/or any other functionality that enables the computing environment 950 to operate in accordance with its intended functionality. The computer 971 may further comprise a graphics interface, graphics processing unit (GPU), video memory 960, and video interface. These components may cooperate to display graphics and text on a video monitor, such as monitor 972. For example, the exemplary graphical user interfaces illustrated in FIGS. 5-9 may be displayed by these components on monitor 972. Processing unit(s) 989 and GPU 959 may receive, generate, and process data related to the apparatuses, methods and systems disclosed herein.

In operation, processing unit(s) 989 fetches, decodes, and executes instructions, and transfers information to and from other resources via the computer's main data-transfer path, system bus 951. Such a system bus connects the components in computer 971 and defines the medium for data exchange. System bus 951 typically includes data lines for sending data, address lines for sending addresses, and control lines for sending interrupts and for operating the system bus. An example of such a system bus 951 is the PCI (Peripheral Component Interconnect) bus. A system memory 952 comprises computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) 953 and random access memory (RAM) 990. A basic input/output system 954 (BIOS), containing the basic routines that help to transfer information between elements within computer 971, such as during start-up, is typically stored in ROM 953. RAM 990 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processing unit 989. By way of example, and not limitation, FIG. 10 illustrates operating system 955, application programs 956, other program modules 957, and program data 958.

The computer 971 may also comprise other removable/non-removable, volatile/nonvolatile computer storage media. By way of example only, the computer 971 may include a hard disk drive (not shown) that reads from or writes to non-removable, nonvolatile magnetic media, a magnetic disk drive 969 that reads from or writes to a removable, nonvolatile magnetic disk 984, and an optical disk drive 970 that reads from or writes to a removable, nonvolatile optical disk 983 such as a CD ROM or other optical media. Other removable/non-removable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like. Magnetic disk drive 969 and optical disk drive 970 are typically connected to the system bus 951 by a removable memory interface, such as interface 965. The drives and their associated computer storage media discussed above and illustrated in FIG. 10, provide storage of computer readable instructions, data structures, program modules and other data for the computer 971.

A user may enter commands and information into the computer 971 through input devices such as a keyboard 981 and pointing device 982, commonly referred to as a mouse, trackball or touch pad. Other input devices (not shown) may comprise a microphone, joystick, game pad, satellite dish, scanner, or the like. Alternatively, monitor 972 may be configured as an input device, such as a touchscreen display that may enable a user to enter commands and information. These and other input devices are often connected to the processing unit 989 through a user input interface 966 that is coupled to the system bus, but may be connected by other interface and bus structures, such as a parallel port, game port or a universal serial bus (USB).

Referring to FIGS. 4 and 10, the computer 971 may utilize a network interface or adapter 967 to connect to a wired network (not shown), a wireless network, such as network 432, or to establish a wireless communication link, such as wireless communication link 430. For example, computer 971 may be used to implement a computer or a server 428 located in a mobile command center 420. The computer or server 428 may utilize a network interface or adapter 967 and communications components, such as radio 426 and omnidirectional antennas 422, to connect to network 432. Alternatively, the computer or server 428 may utilize a network interface or adapter 967 and communications components, such as radio 426 and directional antenna 424 to establish a wireless communication link 430. Via network 432 or wireless communication link 430 the computer or server 428 may establish two-way communications with a mobile pump control unit 410, and thereby the computer or server 428 may send commands to, and receive information from, mobile pump control unit 410. By way of example, a computer or server 428 may receive information from sensors and valves associated with mobile pump control unit 410, and pumps 440 and 450. The computer or server 428 may display the information via a computer interface, such as exemplary computer interfaces 500, 600, 700, and 800, on a monitor or display attached to computer or server 428, such as monitor 972. Alternatively, a user may enter commands and information into the computer or server 428 to control the valves associated with mobile pump control unit 410, and to adjust settings for pumps 440 and 450, and thereby control and direct a flow of water from the pumps 440 and 450, and from the mobile pump control unit 410.

FIG. 5 illustrates an exemplary computer interface 500 at a mobile command center for monitoring and controlling a mobile pump control unit. Interface 500 may, for example, be displayed on the monitor or display 972 in FIG. 10. A user may utilize the interface 500 to monitor and control various aspects of the pump control unit, the one or more pumps connected to the pump control unit, and the water flowing through the pump control unit. Interface 500 shows a clear indication of how the flow of water may be flowing through a respective pump control unit. As shown, the interface 500 may comprise a display for the ambient air temperature, the suction water temperature, the discharge water temperature, the discharge pressure, the suction pressure for each pump, the flow rate of water discharged from the pump control unit displayed in gallons per minute (GPM) and barrels per minute (BPM), and the total amount of water discharged from the pump control unit displayed in gallons and barrels. The interface 500 may also comprise a display showing the motor set speed for each pump and may provide buttons to independently raise and lower the motor set speed for each pump. In addition, the interface 500 may display the status of valves in the pump control unit and may enable a user to open/close two-position valves and to adjust the position of modulating valves between 0% and 100%. As shown, the interface 500 may enable a user to monitor and control the suction valve, pump inlet manifold valves, pump outlet manifold valves, the recirculation valve, and the pump control unit discharge valve. Each mobile pump control unit monitored and controlled by the mobile command center may be associated with its own computer interface 500. In the exemplary interface illustrated in FIG. 5, mobile pump control unit “PCU-1” is configured with both pump inlet manifold valves open, both pump outlet manifold valves open 100%, the pump control unit discharge valve open 100%, and the recirculation valve closed. The pump control unit is discharging 1,850 gallons of water per minute and a discharge pressure of 85 pounds per square inch (PSI).

FIG. 6 illustrates an exemplary computer interface 600 at a mobile command center for a gauge display for pumps connected to a mobile pump control unit. Interface 600 may, for example, be displayed on the monitor or display 972 in FIG. 10. A user may utilize the interface 600 to monitor various aspects of the pumps connected to each of the mobile pump control units. The gauge display may vary depending on the connected pump and connected pump control panel. As shown, the interface 600 may comprise a display for each pump motor speed, actual torque, oil pressure, oil level, oil temperature, fuel pressure, fuel level, fuel temperature, fuel rate, battery voltage, alternator amperage, coolant temperature, and coolant level. Each mobile pump control unit monitored and controlled by the mobile command center may be associated with its own computer interface 600. The interface illustrated in FIG. 6 shows exemplary operational values for various parameters of the pumps 1 and 2 connected to mobile pump control unit “PCU-1”.

FIG. 7 illustrates an exemplary computer interface 700 at a mobile command center for an alarm set up screen associated with a mobile pump control unit. Interface 700 may, for example, be displayed on the monitor or display 972 in FIG. 10. A user may utilize the interface 700 to set various values that may trigger alarms based on information received from the sensors associated with a mobile pump control unit. As shown, the interface 700 may enable the user to set alarms for low suction temperature, low discharge temperature, low discharge pressure, high discharge pressure, as well as low suction pressure and high suction pressure for each pump connected to the pump control unit. In addition, the interface 700 may allow a user to override low suction pressure and high discharge pressure alarms. The interface 700 may also allow a user to override an alarm associated vibrations switch. Each mobile pump control unit monitored and controlled by the mobile command center may be associated with its own computer interface 700. The interface illustrated in FIG. 7 shows exemplary operational values and alarm set points for various parameters of pumps 1 and 2 and mobile pump control unit “PCU-1”.

FIG. 8 illustrates an exemplary computer interface 800 at a mobile command center for an alarm display screen associated with a mobile pump control unit. The interface 800 may display alarms for the various parameters configured in the exemplary computer interface illustrated in FIG. 7. Each mobile pump control unit monitored and controlled by the mobile command center may be associated with its own computer interface 800. For example, a monitor or display 972 in FIG. 10 may display computer interface 800 for multiple pump control units at one time. As such, a user at the mobile command center may easily monitor and control multiple pumps and pump control units dispersed over a large geographic area.

FIG. 9 illustrates an exemplary computer interface 900 at a mobile command center for monitoring and controlling various components of a water reservoir associated with a remote command and control pump system. Interface 900 may, for example, be displayed on the monitor or display 972 in FIG. 10. Interface 900 may provide a collective overview of all water storage reservoirs/tanks currently being monitored and controlled by the mobile command center. For example, if a tank is active, it may be displayed to a user with the tank number and tank data, which may include alarms for a high level warning, low-level warning, high level shutdown, and low level shutdown. For each tank, the user may be able to enter alarm setpoints, such as when to indicate a high level warning, low-level warning, high level shutdown, or low level shutdown. A user may also be able to enter a tank water level setpoint indicating a water level that the system will automatically attempt to maintain. In a multi-tank set up, a PLC may evaluate the highest tank water level to maintain the water level setpoint and monitor the high level shutdown. The interface illustrated in FIG. 7 shows exemplary operational values for tank levels and set points for a high level warning, low-level warning, high level shutdown, and water level.

The foregoing description is provided for the purpose of explanation and is not to be construed as limiting the invention. While the invention has been described with reference to illustrative embodiments or preferred methods, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Furthermore, although the invention has been described herein with reference to particular structure, methods, and embodiments, the invention is not intended to be limited to the particulars disclosed herein, as the invention extends to all structures, methods and uses that are within the scope of the appended claims. Those skilled in the relevant art, having the benefit of the teachings of this specification, may effect numerous modifications to the invention as described herein, and changes may be made without departing from the scope and spirit of the invention as defined by the appended claims.

Claims

1. A mobile pump control unit comprising:

a chassis, the chassis housing:

mechanical plumbing, including at least one pump inlet manifold in fluid communication with a suction port, and at least one pump outlet manifold in fluid communication with a discharge port and recirculation port, wherein the at least one pump inlet manifold is adapted to connect to an inlet of a pump disposed at a pump site, to receive an inlet flow of water via the suction port, and the at least one pump outlet manifold is adapted to connect to an outlet of the pump to receive a flow of water discharged from the pump;

a plurality of valves disposed within the mechanical plumbing to direct the flow of water from the at least one pump outlet manifold to the discharge port and the recirculation port;

a plurality of sensors disposed within the mechanical plumbing to measure characteristics of water flowing through the mechanical plumbing;

a control unit configured to independently control the plurality of valves and the plurality of sensors, the control unit further comprising an interface to enable connection to a control panel of the pump at the pump site; and

communications circuitry coupled to the control unit and configured to communicate with a mobile command center and with other mobile pump control units in a geographic area,

wherein the mobile pump control unit may receive commands from the mobile command center for controlling the plurality of valves and the pump at the pump site and may send information concerning the pump and the water flowing through the mechanical plumbing of the mobile pump control unit to the mobile command center or other mobile pump control units.

2. The mobile pump control unit of claim 1, wherein the plurality of valves includes a recirculation valve and a discharge valve, wherein the discharge valve directs the flow of water to the discharge port and the recirculation valve directs the flow of water to the recirculation port.

3. The mobile pump control unit of claim 2, wherein the recirculation valve and the discharge valve are modulating valves that the control unit may independently adjust to an opening value between 0% and 100%.

4. The mobile pump control unit of claim 1, wherein the plurality of valves further comprises at least one pump inlet manifold valve configured to adjust the inlet flow of water from the suction port to the at least one pump inlet manifold.

5. The mobile pump control unit of claim 4, wherein the at least one pump inlet manifold valve is a two-position valve that the control unit may independently adjust to an open or closed position.

6. The mobile pump control unit of claim 4, wherein the at least one pump inlet manifold valve is a modulating valve that the control unit may independently adjust to an opening value between 0% and 100%.

7. The mobile pump control unit of claim 1, wherein the plurality of valves further comprises at least one pump outlet manifold valve configured to adjust the flow of water discharged from the at least one pump outlet manifold.

8. The mobile pump control unit of claim 7, wherein the at least one pump outlet manifold valve is a modulating valve that the control unit may independently adjust to an opening value between 0% and 100%.

9. The mobile pump control unit of claim 1, wherein the plurality of sensors includes one or more of a pressure sensor, a temperature sensor, and a flow meter.

10. The mobile pump control unit of claim 1, further comprising a vibration sensor in contact with the pump disposed at the pump site, the vibration sensor in communication with the control unit, wherein the mobile pump control unit may send information from the vibration sensor to the mobile command center or the other mobile pump control units.

11. The mobile pump control unit of claim 1, wherein the control unit comprises a programmable logical circuit (PLC).

12. The mobile pump control unit of claim 1, wherein the communications circuitry comprises a radio coupled to an antenna.

13. The mobile pump control unit of claim 12, wherein the antenna further comprises one or more of a directional antenna and an omnidirectional antenna.

14. The mobile pump control unit of claim 1, wherein the control unit communicates with the mobile command center via one or more of a wireless communication link and a network.

15. The mobile pump control unit of claim 14, wherein the network further comprises one or more of a local area network (LAN), a wide area network (WAN), a Wi-Fi (802.11) network, a mesh network, a cellular network, and a satellite connection.

16. A remote water transfer command and control system comprising:

a plurality of pumps;

a plurality of mobile pump control units, each mobile pump control unit configured to: connect to at least one pump of the plurality of pumps; monitor and control the at least one pump connected to the mobile pump control unit; direct an inlet flow of water to the at least one pump; receive a discharge flow of water from the at least one pump; direct a flow of water from the mobile pump control unit; and monitor characteristics of the water flowing into, and out of, the mobile pump control unit; and

a mobile command center, the mobile command center in communication with the plurality of mobile pump control units, wherein the mobile command center is configured to monitor and control the plurality of pumps, the plurality of mobile pump control units, and the water flowing into, and out of, each mobile pump control unit.

17. The system of claim 16, further comprising a water reservoir, the water reservoir configured to be in fluid communication with the plurality of mobile pump control units.

18. The system of claim 17, wherein the mobile command center is configured to control the plurality of mobile pump control units so as to direct at least a portion of the flow of water from each mobile pump control unit to the reservoir.

19. The system of claim 17, wherein the water reservoir further comprises at least one storage tank.

20. The system of claim 16, wherein the command center and plurality of mobile pump control units communicate via one or more of a wireless communication link and a network, the network further comprising one or more of a local area network (LAN), a wide area network (WAN), a Wi-Fi (802.11) network, a mesh network, a cellular network, and a satellite connection.