ICP DAS’s Lift Station Monitoring Solution: Ensuring Reliability in Urban Sewer Systems
Deploying the ICP DAS WinCE PAC and I-87K Series High Profile I/O Expansion Modules has established a monitoring system for five lift stations located outside a wastewater treatment plant.
The WP-8441 acts as the main controller, with the I-87040W module receiving data from equipment like pumps, motors, and valves, the I-87017ZW module collecting water level and pressure readings, and the I-87057W module managing field equipment control. The NAPOPC DA Server software centralizes this data and transmits it to the SCADA system, enabling seamless system integration.
Introduction:
Water is an indispensable resource in our daily lives. To ensure citizens have access to clean water, governments worldwide have established urban sewer systems to convey domestic wastewater to treatment plants for purification, promoting the sustainable use of water resources.
Lift stations play a pivotal role in sewer systems. Because sewer pipes rely on gravity flow to transport wastewater, intermediate lift stations help elevate water levels to create height differentials, continuously driving water flow and overcoming topographical obstacles such as hills, subways, and rivers.
ICP DAS has implemented an automation and monitoring solution for Taiwan’s largest wastewater treatment facility—the Bali Sewage Treatment Plant in New Taipei City—covering five lift stations. Industrial-grade controllers collect critical data from various equipment within the lift stations, perform logic operations, and monitor devices such as pumps, motors, and valves. This data is transmitted in real-time to the SCADA system in the central control room, allowing management to remotely monitor lift station status, greatly improving equipment management efficiency and operational stability.
Smart Monitoring System for Lift Stations: The Hidden Hero of Urban Wastewater Conveyance
Lift stations are generally installed as either wet-well or dry-well types. In wet-well designs, the pump is submerged in wastewater, while in dry-well designs, the pump is kept in a separate chamber, isolated from the wastewater. The equipment typically includes one or more pumps, motors, check valves, screens, and grit removal devices.
The WP-8441 WinCE 5.0 PAC serves as the core controller for lift stations with its compact design, multiple communication interfaces, and four I/O expansion slots. It operates with high-performance I-87K Series Serial Bus I/O Modules that support the DCON communication protocol—specifically, the I-87040W Isolated DI Module, I-87017ZW Voltage/Current AI Module, and I-87057W Isolated DO Module—to monitor essential equipment within the well.
Equipment Monitoring
The I-87040W Isolated DI Module features a 32-channel wet contact digital input and supports both sinking and sourcing configurations. It also provides intra-module isolation, with protection up to 3750 VDC.
In this setup, the I-87040W receives status data from equipment, such as the operating status and runtime of pumps and motors, and the status of check valves, which prevent pumped wastewater from flowing back into the well. This data is then transmitted to the WP-8441 WinCE 5.0 PAC via the DCON communication protocol for processing and control.
Equipment Control
The I-87057W Isolated DO Module receives commands from the WP-8441 WinCE 5.0 PAC via the DCON communication protocol and controls the activation and deactivation of motors and pumps through its digital output channels.
Key features of the I-87057W include 16 open collector digital output channels, each with a maximum load current of 100 mA, and 3750 Vrms intra-module isolation.
The I-87057W provides sinking output wiring with protection against over-voltage, overload, and short-circuit conditions. Additionally, users can set the ‘Power On Value’, ensuring that the module enters the preset output state when power is first applied or restored, thereby enhancing the stability of the lift station control system.
Water Level and Pressure Monitoring
The I-87017ZW Voltage/Current AI Module is responsible for receiving data from liquid level gauges installed in wastewater wells. Maintaining a minimum water level is crucial to prevent odor release and to cool down the wet-well pumps, while controlling the maximum water level is necessary to prevent overflow. When the liquid level is detected as too low or too high, the data is transmitted via DCON to the WP-8441 WinCE 5.0 PAC, which then controls the operation of motors and pumps through the I-87057W Isolated DO Module.
Additionally, the I-87017ZW Module receives pressure readings from pressure gauges. If the pressure reaches the preset maximum limit, the pump automatically stops; when the pressure drops to the preset minimum limit, the pump resumes operation.
The I-87017ZW Module features 10 differential or 20 single-ended analog input channels with sampling rates in both normal mode (10 Hz) and high-speed mode (50 Hz). It also includes robust protection features such as 4 kV ESD protection, 3000 VDC intra-module isolation, 4~20 mA open wire detection, as well as overcurrent and overvoltage protection, ensuring excellent resistance to noise interference in industrial environments.
Subsequently, the WP-8441 WinCE 5.0 PAC transmits data to the central SCADA system via Modbus TCP. When any critical data reaches preset upper or lower limits, the SCADA system triggers real-time alerts for management. Additionally, notifications can be sent to relevant personnel via email or mobile devices, enabling immediate on-site inspections and troubleshooting.
The WP-8441 WinCE 5.0 PAC, equipped with a PXA270 CPU (520 MHz) and running on the Windows CE.NET 5.0 operating system, offers multiple communication interfaces, including Gigabit Ethernet, USB, RS-232, and RS-485, enabling fast and seamless integration with other devices.
NAPOPC DA Server: Integrating Monitoring Systems Across Five Lift Stations
The NAPOPC software used in this application is a free OPC DA Server that supports ICP DAS I/O products. As an industrial process control and data access standard, OPC DA is built on Microsoft’s OLE COM (Component Object Model) and DCOM (Distributed Component Object Model) technologies. The NAPOPC Server offers a comprehensive set of standard OPC DA objects, interfaces, and methods, enabling seamless process control and data exchange with other software systems.
In this case, the NAPOPC DA Server facilitates equipment monitoring and data exchange across five lift stations. Designed for compatibility with both PCs and PACs, the system centralizes equipment data, making it readily accessible to multiple SCADA systems for streamlined integration. This approach not only reduces the load on individual equipment serving multiple SCADA systems but also enhances overall system stability and reliability.
The NAPOPC DA Server offers multi-threaded communication, significantly enhancing the speed of data collection from equipment. Users can also customize the communication interval to match the specific polling frequency needed for each device, ensuring optimized performance.
During each device’s idle period, the NAPOPC DA Server can be set to automatically detect modules and create a corresponding Device/Group/Tag data structure. This function supports ICP DAS’s DCON I/O modules, as well as I-7K, I-8K, I-87K, and RU/USB-87Pn remote I/O modules. For devices that are offline, users have the flexibility to manually configure the NAPOPC to build the same data structure.
Win-GRAF Solutions: Streamlining System Integration for Greater Efficiency
As the WP-8441 WinCE PAC has been discontinued, we recommend using the WP-8428-CE7 Win-GRAF PAC as an alternative. Data exchange with the WP-8441 required a more complex communication method. In comparison, the WP-8428-CE7 Win-GRAF PAC allows users to set local variables to ‘Public’ directly in the Win-GRAF software, enabling other PACs to easily read or write local data. This feature simplifies data exchange between PACs significantly.
The WP-8428-CE7 Win-GRAF PAC is a Soft-Logic WinPAC equipped with a robust Cortex-A8 CPU (1.0 GHz) running on the Windows CE 7.0 operating system. It features VGA, USB, dual Ethernet, RS-232/485 communication ports, and four I/O expansion slots, compatible with I-8K Series Parallel Bus I/O Modules and I-87K Series Serial Bus I/O Modules.
The WP-8428-CE7 Win-GRAF PAC supports the Win-GRAF software (IEC 61131-3 standard) for developing logic control applications and also supports M.S. VS 2008 (VB .NET, C#) for HMI and data management application development. It enables data exchange with Win-GRAF applications, making application design more convenient and practical.
Moreover, the WP-8428-CE7 Win-GRAF PAC includes a built-in Dual Watchdog Timer. The Module Watchdog automatically restarts the CPU if the internal firmware encounters an issue, while the Host Watchdog monitors the communication between the module and the host. Administrators can set a ‘Safe Value’ as a fallback mechanism if the I/O module fails to receive commands from the host within a specified timeout period. When activated, the module reverts to a predefined safe output state—either continuing or halting operations as needed. This feature enhances the reliability and stability of lift station control systems, meeting high industrial demands for secure communication and on-site safety.
Win-GRAF is a powerful PLC-like soft logic development software compatible with Windows 7/8/10 and newer versions. It adheres to the IEC 61131-3 standard, supporting PLC programming languages such as Ladder Diagram (LD), Function Block Diagram (FBD), Sequential Function Chart (SFC), and Structured Text (ST). Additionally, Win-GRAF Workbench facilitates multi-task programming, enabling users to develop applications that can be downloaded and executed on all ICP DAS PAC series devices that support Win-GRAF.
With Ethernet ports (LAN1 and LAN2), up to 32 ICP DAS Win-GRAF PACs can exchange data. Win-GRAF uses event-triggered data binding for data transmission, which is more efficient than traditional polling methods. Additionally, users can configure redundant data binding through the software. If one network connection fails, the backup network takes over automatically to maintain continuous data exchange. This feature significantly enhances the reliability of the lift station monitoring system.
When users need to make minor revisions to the program without halting its operation, Win-GRAF‘s ‘On-Line Change’ feature enables online troubleshooting and monitoring without interruptions, providing users with great convenience.
Benefits:
1. The I-87040W 32-channel Isolated DI Module and the I-87057W 16-channel Isolated DO Module are equipped with LED indicators for each channel, making it easy for personnel to monitor the status of each channel. Additionally, both modules feature 4 kV ESD protection, effectively shielding against communication disruptions caused by noise in industrial environments.
2. By using the I-87040W Isolated DI Module to track the operating time of each pump, management can estimate the amount of sewage pumped and schedule maintenance or component replacements accordingly, thereby reducing the risk of unexpected pump and motor failures.
A significant decrease in pumped sewage may indicate excessive wear on components, impeller blockages, or damage. Staff can assess the conditions through trend charts in the SCADA system and take appropriate action.
3. When the I-87017ZW Voltage/Current AI Module detects unusually high pressure readings, it may indicate an accumulation of excessive sludge or debris in the lift station’s outlet pipe. In such cases, cleaning personnel can be scheduled to remove the obstructions, preventing pipe blockages and sewage backflow.
4. The NAPOPC DA Server Series supports various operating systems:
- NAPOPC_ST DA Server: For PCs with Windows XP/7/10 OS
- NAPOPC_XPE DA Server: For PACs with Windows WES OS
- NAPOPC_CE5 DA Server: For PACs with Windows CE.NET 5.0 OS
- NAPOPC_CE6 DA Server: For PACs with Windows CE.NET 6.0 OS
5. The NAPOPC_CE5 and NAPOPC_CE6 DA Servers feature an efficient active data transmission mechanism, allowing PACs to send data to SCADA systems at high speeds. This ensures seamless communication and real-time updates. In emergencies, the PACs quickly transmit critical data to the central SCADA system, providing timely alerts for management personnel.
6. The WP-8428-CE7 Win-GRAF PAC features a redundant power design with dual power inputs. In the event of a power failure in one source, the system will automatically switch to the backup power source, ensuring enhanced reliability for the lift station control system.
Additionally, the WP-8428-CE7 supports relay outputs that can be connected to visual and audible alarm devices. When the backup power is activated, the alarm will sound, alerting maintenance personnel to prepare for repairs.
7. The WP-8428-CE7 Win-GRAF PAC supports a wide range of communication protocols, including Modbus TCP/IP master and slave, Modbus RTU/ASCII master, Modbus RTU slave, DCON, and HART master. This ensures seamless compatibility with devices from various manufacturers.
8. The WP-8428-CE7 Win-GRAF PAC enables multiple-language support—including English, German, French, Russian, Korean, Spanish, Italian, Simplified Chinese, and Traditional Chinese—providing a user-friendly interface for customers worldwide.
9. The WP-8428-CE7 Win-GRAF PAC runs on the Windows CE 7.0 operating system, offering hard real-time capabilities, high-performance deterministic control, and a user-friendly windowed display and operating environment.
10. Using the Win-GRAF Workbench development software, users can set local controller variables to ‘Public,’ allowing PACs at the other four lift stations to read or write local data, which enhances system integration efficiency.
Conclusion:
ICP DAS PACs, together with ICP DAS I/O modules, form control systems that fulfill diverse requirements and endure harsh environments. PACs (Programmable Automation Controllers), PLCs (Programmable Logic Controllers), and IPCs (Industrial PCs) are commonly used controllers in industrial automation, with PACs offering distinct advantages:
1. Functionality: PACs combine the reliability of PLCs with the flexibility of IPCs, supporting complex calculations and large-scale data processing. They also offer various communication protocols, facilitating seamless device integration.
2. Application: PACs are ideal for applications demanding high flexibility and scalability, such as large-scale factory automation systems and a wide range of monitoring systems.
3. Flexibility: PACs are highly adaptable, easy to program and expand, and support multiple open standards and communication protocols.
A lift station failure can bring numerous issues: sewage may backflow into upstream pipes and overflow from manhole covers, leading to strong odors that negatively affect residents’ quality of life. Additionally, if sewage enters rivers or streams, it can damage the ecosystem by depleting oxygen levels, resulting in fish deaths and indirectly affecting irrigation water for farmers.
ICP DAS’s lift station monitoring solution uses PACs and I/O modules to continuously monitor the operational status of pumps, motors, and check valves. The PACs send data to the SCADA system, enabling remote monitoring and data analysis. This allows for timely scheduling of equipment maintenance or well cleaning, effectively reducing the risk of unplanned downtime.
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ICP DAS was established in 1993 and strongly focuses on innovation and the enhancement of industrial automation technology. ICP DAS continuously endeavors to develop a comprehensive selection of products ranging from remote I/O controllers, distributed I/O modules, I/O data acquisition boards, programmable automation controllers, industrial communication modules, web-related products, motion control systems, SCADA/HMI software to automation solutions for applications critical to energy management, motion automation, smart factories, intelligent buildings, and smart cities. Our ambition is to provide a wide range of high-quality products and versatile applications, together with prompt and efficient services, that can be implemented to assist in the continued success of our clients worldwide.