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Simplex Mission Critical Systems are comprehensive, integrated, project-matched fuel management systems for diesel and turbine generators used in critical applications demanding the highest reliability, such as data centers, public safety and security nodes, transportation hubs and other applications where utmost dispatch dependability is essential. The core of the Mission Critical Systems includes a proven line of industrial products engineered for the maximum amount of redundancy (valves, pumps, controls, PLCs, power supplies, probes, level sensors, etc.). The scope spans from the point of fuel delivery to the facility to the engine fuel pump, potentially covering every aspect of the system except basic infrastructure, such as pipe and bulk supply tanks.
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- Control: PLC based dual, redundant PLC system with auto-poling and auto backup reversion, internal modem with ethernet and MODBUS communications capablity.
- Fully Networked: Network operation of all elements and network interface to BMS.
- UL Listings.
- Tank Construction: Double-wall.
- High Level of Redundancy: Redundant PLC controllers, dual power supplies, back-up level sensors, dual elements wherever possible, layered alarm systems, and full manual backups.
- Pipe Fittings, Pipeline Sensors and Valves: Ferrous construction, socket-welded or flanged mounting.
- Pumps: Cast iron construction, flanged fittings.
- Conservative materials selection and application.
- Industrial control devices.
- Comprehensive Services: Design and submittal consultation, start-up, operator training, commissioning, and fast-response service.
| Master Control Panel |
UL508 listed industrial control panel. Type 4, wall mountable, hinged, lockable and gasketed access door. Finish painted dark gray polyurethane enamel over epoxy primer. White interior.
PLC Based Control System: Dual, redundant PLC system with auto-polling and auto backup reversion, Internal modem, and ethernet and MODBUS communication capability.
Mimic type control panel with one-line schematic overlaid on systematic alarm and switch panel.
Dual power supply with preferred source relay; normal, fail indicators and alarms.
Master alarm audible signal with silence pushbutton.
Master indicator press-to-test pushbutton.
Fuel storage tank control panels (2): Return valve open, closed, tripped indicators; main tank selector pushbuttons, 1-2; VPump control (2): selector switch, auto-off-manual indicators; tank auto switchover at low using external input from UST monitoring system; and duplex pump alternator.
Remote valve control relays with synchronization error sensors.
Industrial, oiltight control devices and LED.
Remote alarm outputs, via Ethernet/MODBUS.
Pump starters for remote pumps. Type 4 enclosed, wall mountable, hinge-open front door, full-voltage, circuit breaker combination motor starter. Control power transformer: HOA switch, Run indicator, power available indicator, and current sensor for interface with system selector panel. |
| Duplex Pump |
Open skidded design with containment, pad mountable, indoor, duplex pump set under control of Master Control Panel. Starters included with pump set or integrated with master panel.
Duplex Positive displacement gear pumps, cast iron body, mechanical shaft seal, machined steel gears construction, typical 45 gpm at 150 psi, 1800 RPM, 7.5 HP, 230/460-3-60v, TEFC direct drive. Flanged inlet/outlet.
Pressure relief valve, integral to each pump.
Duplex type strainer, 3-inch, cast-iron construction.
Vacuum gauge inlet and outlet of strainer, with isolation valves.
Differential pressure switch across strainer with alarm contacts to PLC.
Leak detector in skid containment basin, with alarm contacts to PLC.
Flow switch, each pump, with alarm contacts to PLC.
Fusible link valve on inlet, ferrous construction.
Ball type shutoff valves, each pump in/out, 2-inch and main in/out: 3-inch.
Check valves each pump, cast iron or steel, swing-type, 2-inch.
Main outlet pressure gauge with shutoff.
3-inch flanged main inlet and outlet.
All-welded or flanged construction of piping and devices. All ferrous fittings and devices. Schedule 80. 200psi or greater rated.
Controller: Intended for slaved operation from Master Control Panel. Includes PLC and MODBUS interface for transmission of pump-run signals from remote controller and transmission of alarm indication and pump running indications to remote controller.
Dual power inlet, 460-3-60v, with power transfer relay and power available/connected/fail indicators to MODBUS network.
Pump starters for each pump. Type 1 enclosed, unit mounted, hinge-open front door, full-voltage, 3-phase circuit breaker combination motor starter, with control power transformer, HOA switch, run indicator, power available indicator.
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| Day Tank |
Construction:
Double-wall UL142 tank of required capacity, day tank controller including redundant level sensors, fill control valves.
Controller:
UL508 listed industrial control panel. NEMA4, tank mountable, hinged, lockable and gasketed access door. Finish painted dark gray polyurethane enamel over epoxy primer, white interior.
PLC based control system: MODBUS communication capability; day tank differential level control with critical low level and critical high-level integration; communication with Master Panel; and ultrasonic level transmitter, dual redundant, with waveguides. 4-20mA output.
Mimic type control panel with one-line schematic overlaid on systematic alarm and switch panel.
Dual power supply with preferred source relay; normal, fail indicators and alarms.
Master alarm audible signal with silence pushbutton.
Master indicator press-to-test pushbutton.
Dual level transmitter integration, backup reversion.
Digital display of tank level.
LED alarm indicators with common press-to-test pushbutton.
Remote alarm outputs via MODBUS.
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| Main Tank SmartPump |
Use for filling one or multiple remote bulk storage tanks.
3-inch quick disconnect coupling with check valve and isolation/shutoff valve.
3-inch pipe thread fitting for connection of fill line.
Weatherproof and lockable steel enclosure with leak/spill containment basin and basin hand pump. Painted white. Suitable for pad mounting.
Controller with PLC based and MODBUS compatible control for monitoring, high level detection and control of fill valve of each remote bulk supply tank.
Digital level indicator.
Level transmitters for field/contractor installation.
Fill valve, 3-inch, motorized ball valve for field/contractor installation.
300 GPM transfer pump, including check valve and shutoff valve.
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| Receiving Tank Filtration |
Inserted in the transfer line from the SmartPump to either an intermediate receiving tank of the bulk fuel storage tanks.
No active control.
Principle elements: filter-separator, nominal 300 GPM. 10-micron particulate filtration, 10 PPM water coalescing/separation, inlet and outlet shutoff valves, filter differential pressure gauge and contacts, and water detection sensor and contacts.
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| Main Tank Filtration |
Outdoor, weatherproof, pad-mountable enclosure, also suitable for indoor installation. 2-inch NPT.
On-board, integrated digital controller with MODBUS communication.
Inlet, outlet ball-type shutoff valves.
Check valve.
Pressure/vacuum gauges.
Pressure transducers, flow switches, water detector.
Circulation pump, 10-50 GPM and 0.75 – 5.0 HP.
Filtration elements: strainer, 100 mesh; pre-filter, 5 micron; final filter, 2 micron; and water coalescer, separator, 10 PPM.
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Overflow-Return Tank and
Controller |
Tank:
UL142 secondary containment tank, double wall construction.
Capacity as specified, typically 200-600 gallons.
Pipe fittings, top mounted, per specification requirement, including primary, secondary emergency vents.
Leak sensor.
Gravity inlet fitting from day tank overflow manifold.
Duplex submersible pumps, 30-40 GPM at 20-foot head, 1.5HP; equipped with check valve, shutoff valves and flexible fittings.
Controller:
UL508 listed industrial control panel. NEMA4, wall or tank mountable.
PLC based control system with MODBUS communication protocol.
Differential level control with high level alarms.
Ultrasonic level transmitter, dual redundant, with waveguides. 4-20mA output.
Mimic type control panel with one-line schematic overlaid on systematic alarm and switch panel.
Dual power supply.
Master alarm audible signal with silence pushbutton.
Master indicator press-to-test pushbutton.
Duplex pump starters.
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| Engine Fuel Filter Skid |
Skidded assembly of duplex, canister-type, filter-separators with 3-way, two port selector valve, differential pressure gauge with contacts, hand priming pump, shutoff valves, drip basin.
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| Network Interface Module |
For remote, wall mounted installation, Type 4 enclosed. Use to interface the Simplex Mission Critical System network to generator switchgear or BMS. Includes PLC with MODBUS or ethernet input and either MODBUS/ethernet and/or discrete relay contact outputs. |
Note: The above items are just a sample. The equipment used and specifications are determined by each project.
Simplex Mission Critical Systems are tailor-made for each project. The scope of each system spans from the point of fuel delivery to the facility to the engine fuel pump, potentially covering every aspect of the system except basic infrastructure, such as pipe and bulk supply tanks. Our engineers are experts at building systems that include the critical elements of active control in the delivery, storage, transfer and management of fuel to the engine. Contact Simplex with your job specifications.
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