H.E.R.P.S — Sensor & Control System
Volume 19 — Automation Layer (Full Dimensions Blueprint)
Hybrid Energy Recovery Pump System (H.E.R.P.S)
System Overview — Sensor & Control Architecture
Volume 19 defines the complete automation layer for the H.E.R.P.S hybrid pump platform. This includes pressure, flow, temperature, vibration, RPM, generator output, oil level and ambient sensors, along with PLC control logic, communication networks, cabinet layout, wiring diagrams and alarm parameters.
- Inlet Pressure Sensor (PI‑01)
- Discharge Pressure Sensor (PI‑02)
- Differential Pressure Sensor (PI‑03)
- Flow Meter (FT‑01)
- Temperature Sensors (TT‑01, TT‑02)
- Vibration Sensor (VS‑01)
- RPM Sensor (RS‑01)
- Generator Output Sensor (GS‑01)
- Oil Temperature Sensor (OT‑01)
- Oil Level Sensor (LS‑01)
- Ambient Temperature Sensor (AT‑01)
- Control Cabinet (CC‑01)
Sensor Mounting Details (Typical)
- Pressure Sensors: G 1/4”, HEX 27
- Temperature Sensors: G 1/2”, 50 mm insertion
- Vibration Sensor: M8 Bolt
- RPM Sensor: M12 × 1.25
- Flow Meter: Ø18, Ø120, Ø208
Control Cabinet Layout
- Dimensions: 1000 × 1600 mm
Component List
- Main Power Switch
- HMI — Main Control
- 10” Touch Screen
- I/O Modules
- PLC Controller
- 24 VDC Power Supply
- Data Logger
- Alarm Horn
- Circuit Protection
- Battery Backup Unit
- Cooling Fan
Sensor Specifications
| Sensor Type | Tag | Range | Accuracy | Signal | Power |
|---|---|---|---|---|---|
| Pressure Transmitter | PI‑01 to PI‑03 | 0–25 bar | ±0.25% FS | 4–20 mA | 24 VDC |
| Flow Meter | FT‑01 | 0–250 m³/h | ±0.5% FS | 4–20 mA | 24 VDC |
| Temperature Sensor | TT‑01, TT‑02 | 0–250°C | ±0.5°C | 4–20 mA | 24 VDC |
| Vibration Sensor | VS‑01 | 0–50 mm/s | ±1% FS | 4–20 mA | 24 VDC |
| RPM Sensor | RS‑01 | 0–3000 RPM | ±1% FS | Pulse | 24 VDC |
| Generator Sensor | GS‑01 | 0–500 V | ±0.5% FS | 4–20 mA | 24 VDC |
| Oil Temp Sensor | OT‑01 | 0–150°C | ±0.5°C | 4–20 mA | 24 VDC |
| Level Sensor | LS‑01 | 0–100% | ±1% FS | 4–20 mA | 24 VDC |
| Ambient Temp Sensor | AT‑01 | 0–50°C | ±0.5°C | 4–20 mA | 24 VDC |
System Wiring Diagram (Signal Layout)
- Field Sensors → Junction Box (JB‑01)
- JB‑01 → PLC (Siemens S7‑1500)
- Signals: 4–20 mA, Digital, Pulse, 24 VDC
- Communication: Ethernet
- Outputs: HMI, Data Logger, Alarm Horn, Status Lights, Control Relays, V/F Motor Drive, Generator Exciter
Control Logic Flowchart
- System Start → Read All Sensors
- If parameters out of limits → Alarm + Protective Action
- If parameters normal → Optimize Pump & Turbine Operation
- Monitor & Log Data → Continuous Loop
Communication Network
| Item | Description |
|---|---|
| Network Type | Industrial Ethernet |
| Protocol | PROFINET / MODBUS TCP |
| Data Output | PLC → HMI / Cloud |
| Remote Access | Yes (Secured) |
| Interface | 10” Touch Screen |
| Data Logging | SD Card / Cloud |
| Alarms | Email / SMS / HMI |
Cable Specifications
| Cable Type | Use | Size (mm²) | Shield | Distance (m) |
|---|---|---|---|---|
| Instrument Cable | Sensor Signals | 2 × 2.5 | Yes | 100 |
| Power Cable | 24 VDC | 4 × 2.5 | No | 50 |
| Ethernet Cable | Communication | 4 × 2.5 | Yes | 50 |
| Motor Power Cable | Motor Drive | 4 × 25 | No | 20 |
| Generator Cable | Generator Output | 4 × 25 | No | 20 |
| Grounding Cable | Earthing | 1 × 10 | No | 10 |
Alarm & Shutdown Parameters
| Parameter | Warning | Trip / Shutdown |
|---|---|---|
| Discharge Pressure | >20 bar | >25 bar |
| Inlet Pressure | <1 bar | <0.5 bar |
| Oil Temperature | >80°C | >100°C |
| Vibration | >10 mm/s | >20 mm/s |
| RPM | >3600 | >3800 |
| Flow Rate | <120 L/min | <100 L/min |
| Oil Level | <20% | <10% |
Engineering Notes
- All sensors IP65 or higher
- All cables shielded for noise protection
- System designed for 24/7 continuous monitoring
- PLC programmed to IEC 61131‑3
- All components and conduit trays labeled
- Integrates with master blueprint for Volume 19
Blueprint Access & Licensing
Volume 19 of the H.E.R.P.S Sensor & Control System is part of the complete engineering blueprint package available exclusively through BlueprintsMarket.com.
Contact Blueprints Market for licensing, integration support or enterprise‑level deployment.
