Pump station automation for intake, booster and lift stations
Remote start/stop, level-based cycling, VFD and starter integration, equipment protection and energy reporting, so pumping stations run to demand and every kWh is traceable.
From local panels to an automated, monitored station
Pumping is the largest operating cost of most water and lift irrigation schemes, and the largest source of downtime. Stations operated by hand from local panels cannot respond quickly to reservoir levels, cannot balance run hours across pumps, and leave little record of why a pump tripped.
Nebulotix adds a PLC or RTU layer to the station that reads levels, flows, pressures and electrical parameters, controls starters and VFDs to rules agreed with the operator, and reports everything to the Control Centre. Operators keep local manual override; automation adds protection and records.
Our hydraulic engineers review pump curves, system curves and surge conditions before control logic is set, so cut-in and cut-out levels, ramp times and duty/standby rotation suit the actual network.
What is supplied
PLC / RTU panel
Controller with I/O for starters, VFDs, valves and instruments, with local HMI and manual override.
Instruments
Sump and reservoir level (ultrasonic, radar or hydrostatic), electromagnetic flow meter, delivery pressure transmitter.
Electrical monitoring
Multifunction meters on each feeder for voltage, current, power factor and kWh.
Valve automation
Actuated delivery and isolation valves interlocked with pump sequence to limit surge.
Communication
4G, fibre or radio link to the Control Centre and to remote reservoirs for level-based control.
| Item | Typical configuration | Notes |
|---|---|---|
| Controller | PLC or industrial RTU | Make agreed with client or specification |
| Level sensing | Ultrasonic · radar · hydrostatic | Selected for sump geometry and foam |
| Flow | Electromagnetic | Per pump or common header |
| Electrical | Multifunction meter, Modbus | Per feeder / pump |
| Drives | DOL · star-delta · soft starter · VFD | Integrated via hardwired I/O or Modbus |
| Protocols | Modbus RTU/TCP · MQTT · OPC UA | To Control Centre or third-party SCADA |
Typical values. Final selection follows site survey, hydraulic review and the project specification.
Control and protection
Level-based cycling
Pumps start and stop on sump and remote reservoir levels with deadbands to limit starts per hour.
Duty/standby rotation
Run hours balanced across pumps with automatic changeover on fault.
VFD pressure or flow control
Speed set to hold delivery pressure or flow as demand changes.
Equipment protection
Dry-run, over/under-voltage, phase loss, overload and high-temperature trips with alarms.
Energy reporting
kWh per m³ by pump and by day to track efficiency and spot wear.
Event history
Every start, stop, trip and operator action time-stamped for O&M review.
Survey, supply, operate
Survey and design
Hydraulic review, instrument and valve placement, radio coverage study.
Supply and install
Field equipment installed, commissioned and tagged on GIS.
Operate and maintain
Remote monitoring, preventive maintenance and operator training through O&M.
Can existing starter panels be automated without replacement?
In most cases. Control is added through auxiliary contacts and interposing relays, or over Modbus for VFDs and soft starters. Panels in poor condition are flagged during the survey.
Can pumps be controlled from a remote reservoir level?
Yes. The reservoir RTU sends level to the pump station over 4G or radio, and the station starts and stops pumps against agreed levels, with a safe fallback if the link fails.
Do you supply to EPC contractors on government projects?
Yes. We supply and commission the automation package, prepare documentation for tender compliance, and support O&M through the defect liability period.
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Tell us about your scheme
Share location, scale and project stage. An engineer will reply with a scope.