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We Build, Program & Install Municipal Control Panels

MurCal Municipal has been automating engine and electric motor driven pumps for 50 years. Our municipal division was founded on the principle of developing efficient solutions to many of the control issues facing modernized water and sewage pumping stations, including flood control, sewage lift, well pumping and water booster applications.
Simply put, every municipality has problems and issues that are unique - and we approach each municipality as such. As a result we've compiled a vast library of proven control strategies. For example, a certain control strategy will automatically cycle the lead engine, throttle multiple engines as one, run engines at the most efficient speed for the task, and lockout failed engines automatically while continuing to operate the station. We build rugged, industry proven, SCADA system compatible control panels from the ground up to meet the specific requirements of the project.

Automation: Efficiency Through Technology

MurCal believes in "efficiency through technology", using automation and remote monitoring. Automation is the use of various control systems for operating stationary internal combustion engines with minimal or reduced human intervention. Automation saves labor and allows for more efficient use of your equipment investment, by saving energy and materials while improving accuracy and precision. The ability to monitor and adjust operating parameters at your facility from a remote location is rapidly gaining favor with operators, allowing for increased productivity while reducing costly downtime.
Our municipal designs include a Central Controller which reads overall station sensors like wet well level, system pressure and flow. The central controller communicates with individual engine controllers and your central office. It determines the least expensive operating mode by deciding which engine to start or by implementing a peak shaving strategy.
To stay in compliance with local laws, we can tailor your system for local Compliance Assurance Monitoring (CAM), by recording key engine parameters. RPM, MAP, MAT, exhaust temperatures and oxygen sensor voltages in and out of the catalyst, and catalyst differential pressure for each engine. This data can be logged at the central controller and in your control room.

 

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Series 600 Control Panel

The Series 600 Controller

The Series 600 Controller is the current MURPHYMATIC® control solution for custom municipal pump control systems. It is applied to pumps with electric motor, VFD, natural gas engine and diesel drives.
The primary feature of the Series 600 Controller is the incorporation of years of experience providing solutions to the unique problems found in controlling pumps in municipal applications, such as:
a) Booster Pumps, Single Well Pumps, and Lift Pumps to provide automatic start/stop and speed control.
b) Multi-Drive Booster Stations, Lift Stations, Treatment Plant pump control and storm drain pumping stations which are required to operate both independently and frequently on battery power alone when commercial power is not available (e.g. during storms).

 

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Series 600 Benefits

•   Our Custom Project Process ensures that the control system will meet the end user's needs.
•   Controls single well pumps, booster pumps, lift pumps, multi-drive booster stations, lift stations, treatment plant pump control and storm drain pumping stations.
•   Password-protected set points.
•   Seamless integration of emission control module (AFRC) with engine controller and SCADA system for local and remote display of key values and alarms.
•   Status and State of each controller indicated both locally and via MODBUS communication to central SCADA system.
•   Installation, Service and Training available from MurCal.

Pump Control Features

Booster Pump Control Features

•   Auto Start and Speed Control based on local system pressure.
•   Remote control/monitoring via SCADA systems using MODBUS RTU communications.
•   Special software routines to control Pre-Lube and Pump Control Valves.
•   Pre-Lube Valve and engine control with adjustable delay and fault sensing.
•   Pump Control Valve control on start and stop where required to control pressure surge.
•   Speed Control for Warm-up, Minimum RPM, Maximum RPM, Engine and VFD drives.
•   PID Speed Control to maintain discharge pressure as required by the application where VFD and Engine Drives are used.
•   Fault annunciation both locally and via MODBUS communication to central SCADA system.
•   Status and State of the controller indicated both locally and remotely to SCADA system.

 

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Single Well Pump Control Features

•   Auto Start and Speed control based on local system pressure.
•   Speed control based on local pressure and/or discharge flow.
•   Remote control/monitoring via SCADA systems using MODBUS RTU communications.
•   Special software routines to control Pre-Lube, Pump Control Valves, Waste/Discharge Valves.
•   Well Pre-Lube Valve control with adjustable delay and fault sensing.
•   Engine Pre-Lube, Warm-Up, Cooldown, Post-Lube.
•   Speed control for Warm-Up, Minimum RPM, Pump-To-Waste RPM, Maximum RPM, engine and VFD drives.
•   Pump Control Valve control on start and stop where required to control pressure surge.
•   Pump to Waste control with valve fault sensing and automatic switch-over to mainline pumping.
•   PID Speed control to maintain discharge pressure or flow as required by the application where VFD and Engine Drives are used.
•   Fault annunciation both locally and via MODBUS communication to central SCADA system. Status and State of the controller indicated both locally and remotely to SCADA system.

Lift Pump (de-watering, flood control, sewage) Control Features

•   Auto Start and Speed Control based on local wet well level.
•   Remote control/monitoring via SCADA systems using MODBUS RTU communications.
•   Special software routines to control Pre-Lube, Pump Control Valves.
•   Pre-Lube Valve and engine control with adjustable delay and fault sensing.
•   Pump Control Valve control on start and stop where required to control pressure surge.
•   Speed control for Warm-Up, Minimum RPM, Maximum RPM, engine and VFD drives.
•   PID Speed Control to flow-match varying flow into wet well by maintaining a preset level or constant speed operation as required by the application where VFD and Engine Drives are used.
•   Fault annunciation both locally and via MODBUS communication to central SCADA system.
•   Status and State of the controller indicated both locally and remotely to SCADA system.

Multi-Drive Station Central Controller

MurCal Municipal's central controllers incorporate an easy to use HMI touchscreen, giving operators a better visual representation of what is going on with their engines. Our signature red and stainless steel panels are synonymous with quality. We build central control and communication with SCADA systems for Booster, Flood Control and Sewage Lift applications. The multi-drive station central controller performs the following:
•   Automatic pump substitution on failure with intelligent pump alternation.
•   Automatic speed synchronization of pumps as multiple engine and/or VFD drives are added based on demand.
•   Control Area Network (CAN) communications between engine controllers to provide instantaneous communication of start commands, speed commands and status between engine controllers and central controller.
•   Emergency operation capability with individual engine controllers able to operate independently, if fault is sensed with the central control system.
•   PID speed control for variable speed drives such as engines and motors with VFD drives.
•   Central controller can act as a Remote Terminal Unit with direct SCADA connection or can communicate with a separate RTU as required by the application.

Most central controller designs employ a 15” high-resolution touchscreen interface which can be customized to meet your unique automation needs, including data logging, alarm management and remote communication.

 

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