HOSS PUMP SYSTEMS FULLY AUTOMATES CUSTOMER’S REMOTE SWD SITE
KODIAK drive automation saves operator thousands in site trips.
This Permian-based Commercial Disposal Operator was constructing a saltwater disposal site in a remote area of west Texas. A constant onsite presence would not be necessary or cost-effective. Its remoteness would mean a site trip to check on operational status would take several hours.
THE PROBLEM:
For simplicity and efficiency, the Operator needed a single vendor to install a remote control system that would give them full operational data, alarms and valve controls to let them solve most onsite issues without a long trip.
"We really appreciated the HOSS team’s willingness to understand our control and monitoring needs and for the way they diligently worked with our team to see the project to completion.”
The system also needed to have a simple and informative user interface available onsite and
for remote users.
THE PROCESS:
In most cases a company building an SWD would have chosen vendors like HOSS to install pumps, VFDs, tanks and other components.Then they would use a separate provider for the automation system.
One might ask how HOSS, whose main products are horizontal pumps and VFDs, also was asked to supply automation for this facility.
When the Operator inquired about pumps and PLCs, the HOSS representative began explaining the wide variety of functions available from their Kodiak Drive system. The client asked if HOSS could use the Kodiak Drive to automate the entire site, saving them development time and the cost of bringing another vendor onsite.
HOSS engineers studied the client’s instrumentation specifications, operational schematics and other information, concluding that they could expand the functionality from just the HPS to include the entire system.After three weeks of modifications to the KODIAK PLC and to the HOSSBasin Trak monitoring system interface, the installation was scheduled.
THE RESULTS:
HOSS installed the industry’s first HPS VFD/PLC system designed to fully control site operations.
Benefits include:
- Reduced cost by eliminating the need for a third-party automation vendor
- Cloud-based monitoring, including full operations visibility for incoming water, valve control and historical trending
- Alarm and shutdown callouts, including emails and SMS messaging to operator and HOSS
- Tank level monitoring on saltwater and oil storage
- Detailed local graphical touchscreen HMI showing all operational information
- Elimination of site trips except on the rare occasion when a physical repair is needed, improving efficiency and safety
Conclusion
HOSS operated the site manually during the break-in period to make sure everything was in order. During that time the customer reported adding additional wells that increased the SWD flow from 4,000 BWPD to 10,000 BWPD, with everything operating smoothly. The Operator plans to further increase flow to 14,000 BWPD. Upon switching the site to full automation, operations continued smoothly. The customer reported flow rates ranging from 6,000 BWPD to more than 17,000 BWPD as needed, with the automation handling inflow rates successfully, requiring no intervention.
