Dear readers of the TELEMETRON magazine,
We are giving you another article containing the description of the most interesting application solutions implemented by the CONTROL SYSTEM engineers. Traditionally, this edition is a continuation of publications contained in the issues of TELEMETRON magazine from 2008-2017.
In the latest edition of the article, as in previous years, we would like to present the most interesting and technically advanced implementations launched in 2017, together with our partner companies as well as independently, by an experienced team of CONTROL SYSTEM engineers. We have been consistently focusing on the implementation of topics that require expertise knowledge and many years of experience while remembering that our main goal is to create final high-quality applications that guarantee users that they have received the product they expected.
In 2017, our team implemented applications based on new generation modules, i.e. MT-151 LED/HMI, MT-251 3G and MT-331. The increased resources available in the MT-151 LED/HMI module combined with the high efficiency of a modern processor, floating point numbers and the implementation of protocols allowing communication with external devices through RS-485 and ETHERNET ports, significantly increased functional capabilities. The MT-251 communication gateway in the 3G version and the WELOTEC series TK500/700/800 routers enabled the trouble-free processing of data streams generated in networks containing over 150 telemetry modules. In many applications, the MT-331 module was used, which due to the possibility of working in two power supply modes turned out to be a very interesting device.
The closing balance of 2017 is a total of over 10,200 modules working without failure in Poland and Europe, with application software developed by CONTROL SYSTEM engineers.
In the next thematic blocks, we summarize the most interesting examples of telemetry modules applications.
The application described below uses the multi-processor control structure commonly used in our applications. The MT-151 LED module together with the EX-101 modules performs the control process of pumps and dampers. Each of the three modules is associated with its own application that implements part of the control process. Telemetry modules are connected with each other by RS-485 bus. The electromagnetic flowmeters are also connected to this communication bus. Above is shown the communication scheme.
The diagram illustrates how great potential the MT-151 module provides to both the developers of the control system and the user. In addition to the local visualization, available on the graphic panel mounted on the face of the control cabinet door, the measurement data are additionally transmitted, using the ETHERNET bus, to an integrated, extended BMS system supervising the full technological process on this object.
Additionally, the described solution used the ability of the MT-151 module to send data using GPRS/3G technology to a dedicated, secure database server, which allows our engineers to remote control over the correct operation of the control process without access to the BMS system protected from outside interference.
The MT-151 LED and HMI telemetry modules are currently dominating in pumping station control systems and sewage pumping stations. Over the past three years, our team of developers has significantly expanded the functional capabilities of application software and implemented several spectacular implementations.
In addition to standard applications for pumping stations and sewage pumping stations, our team of engineers carried out more advanced projects for our business partners related to the control of additional devices, e.g. mixers and gate valves. In this type of applications, it was necessary to control the amount of sewage discharged to the treatment plant in an hourly cycle, which forced the use of algorithms with prediction functions and sewage buffer in an additional retention tank and control of the valves operation to empty the tank cyclically.
In the case of fish processing plants, due to the structure of sewage, it was necessary to use additional mixers.
The integrated graphic display, available in the HMI version, enabled the local service staff to visualize the most important process parameters without the need for the additional external graphic panel, costing at least a few hundred PLN.
Thanks to the extended resources of the MT-151 module, e.g. in the case of sewage pumping stations, it became possible to implement in one software module a dehydration pump control as well as an additional fan designed for ventilation of the dry chamber. The possibility of connecting external temperature sensors to the MT-151 module allows for more precise maintenance of the set temperature in the control cabinet. The above extension of functions performed by the MT-151 module minimizes the number of additional elements included in the cabinet’s equipment. As a result, the use of the MT-151 module not only does not increase the costs of implementing the control cabinet but guarantees that the control of additional devices will be implemented by the application software stored in the memory of the MT-151 module, and all required additional information will be transferred to the superior SCADA system.
Proven in the first applications, for this class of facilities, functional capabilities offered by the MT-151 module led to the implementation of subsequent implementations of the process of water flow control in the water supply network, to optimize the costs associated with its management.
On the illustration is shown the example of controlling the operation of two gate valves on the main water pipes in Mielno together with visualization.
The presented examples of applications illustrate the functional possibilities offered by the MT-151 telemetry module, which in such cases successfully replaces a traditional PLC connected to a GSM modem. Integration of process control and data transmission (3G) functions in a single module with the possibility of remote modification of the program in MT-151 significantly reduces the costs associated with running the facility.
Below are flow charts and balance sheets.
The number of implementations of InVentia telemetry modules in applications dedicated to billing purposes is growing rapidly. Our team of engineers prepared in 2017 a dedicated measurement system for gravitational metering of wastewater flow, based on the professional TIDALFLUX 2300F flowmeter from German company Krohne, using the latest measurement technologies. The measuring system includes, of course, telemetry set with a cloud application for the visualization of the measurement process and a billing module. Below is a block diagram of a complete, professional system for gravity metering of wastewater. The system consists of a measuring chamber with a specialized TIDALFLUX 2300F flowmeter, a dedicated measuring and telemetric cabinet, containing, among others, MT-101 telemetry module, and a modern cloud application for the visualization of the measurement process with chart modules for calculating balances.
Above is the screenshot of a cloud visualization dedicated to the TIDALFLUX 2300F flowmeter. In the right part of the window, there is an additional field informing about the level of sensor filling.
For flowmeters dedicated to pressure flows, the appearance of the application automatically adapts to the type of flowmeter.
The graphs below show the modulation of the flow caused by the operation of the sewage pumping station, which presses the sewage into the pipeline in a pulsatile manner.
At the end of this thematic block, an example of the visualization of two measuring chambers with electromagnetic flowmeters with sensors of diameters DN150 and DN200. Measurement data is integrated on one screen for easier analysis.
Measurement in measuring chambers on which there is no 230 V available due to the distance from LV power lines, requires the use of telemetric modules and battery-operated measuring devices, rechargeable batteries, or the use of renewable energy sources. An interesting example can be the reservoir located in the picturesque fields in Zubrzyce.
The water level in this reservoir must be maintained in the upper zone to ensure the continuity of water supply for residents. Information on the current level of water should be sent to the MT-151 module installed on a remote pumping station, where there are two pumps that pump water into the reservoir. For this task, a special power and telemetry cabinet was made. It contains two batteries adapted for cooperation with the photovoltaic panel, MPPT controller and MT-331 module.
Measuring chambers equipped with traditional water meters or battery-operated electromagnetic flowmeters are a category of objects in which the energy saving telemetry modules series MT-331/713/723 should be used.
For the needs of our business partners, a new dedicated measuring system was developed in 2017. It enables the most accurate metering of flows and pressures in clean water pipelines.
In the professional solution presented on the previous page, a modern, specialized electromagnetic Krohne flowmeter WATERFLUX 3070F and the telemetry module MT-713 in a special version, i.e. powered from an external battery pack and equipped with a port for RS-485 digital communication with ModBus RTU protocol support were used. The possibility of digital communication between the WATERFLUX 3070F flowmeter and the MT-713 module allows for sending much more critical measurement and self-diagnostic information to the visualization system than in the case of simple solutions based only on information transfer via pulse and alarm output. In the case of battery-powered flowmeters, it is important to be able to adjust the speed of measurements to the dynamics of the flow of the measured medium. The implemented solution ensures obtaining the optimum ratio between the effective accuracy of the measurement system and battery life. The data logger built-in module MT-713 allows for accurate mapping of instantaneous values of flow and pressure on the graphs in the visualization system.
In the picture below an example of a measuring chamber equipped with a classic water meter and a pressure sensor is shown. By using the functions offered by the MT-331 module, even in such a simple case, important measurement and information data are sent to the visualization system, e.g. opening the measuring chamber, exceeding the permissible water level in the chamber, etc.
In this application, the telemetry module is powered from an AGM type battery, which requires cyclic recharging about three times/year. Thanks to the 2.6 Ah battery built-in the MT-331 module, it is possible to recharge the external battery without having to replace it with another battery during charging.
The application prepared for the user monitors not only the value of the average instantaneous flow and pressure but also informs on an ongoing basis the voltage level in the external battery as well as the estimated time for the next charging.
Below is the visualization of the same object made in a cloud application dedicated to desktop and mobile devices.
In 2017, the process of incorporating hydrophore sets into the visualization systems was continued. In numerous applications, CONTROL SYSTEM included objects with various equipment levels in the structures of visualization systems. MT-151 modules have proved their worth in this area of application. Thanks to the availability of RS-485 communication ports, as well as ETHERNET, it was possible in most cases to establish a digital connection with PLCs and transfer data using the ModBus RTU or ModBus TCP protocols. Below is an example of the visualization of a water treatment station (WTS) containing three hydrophore sets.
To make it easier for the new user to “start the adventure” with telemetry, we offer cloud solutions that allow the implementation of visualization without building a standard dispatcher station equipped with a router.
In the screenshot below is an example of the visualization of the pressure booster system equipped with the Movicon SCADA system.
In 2017, our team of engineers implemented extensive visualization systems based on the Movicon SCADA system. In hardware architecture, InVentia telemetry modules were also used in each of the implemented applications. The presented example confirms the extraordinary flexibility in combining, in one system, various models of telemetry modules with PLC devices.
Below is an application to visualize the described water treatment station with the Movicon SCADA system.
Below, a window presenting the work of the third stage pumps in detail is shown.
On screenshots below, we present the visualization of the next WTS.
Below is an example of a modern visualization application with the SCADA Movicon system, a technologically advanced water treatment station. Data from the PLC controller, which is responsible for the running of the control process, is transferred to the dispatch station via the MT-151 LED module, which is connected by the ETHERNET bus with the PLC controller.
Below is shown the view of the so-called dashboard, which presents the operator with a summary of the most important parameters of monitored objects along with information about current and historical alarms.
To sum up, the features offered by the Movicon SCADA system allow you to create professional and modern applications for visualization and remote control of selected functions of the technological process.
In 2017, visualization systems for wastewater treatment plants were developed using the Movicon visualization system, distributed by AB-MICRO.
On screenshots below and to the side, examples of visualization of several wastewater treatment plants implemented in the SCADA Movicon 11.5 system are shown.
In 2017, we developed more and more sophisticated applications based on InVentia telemetry modules. Further functions added to the firmware of these modules allow our team to implement increasingly complex control systems.
An interesting direction of the InVentia company activity is the implementation of the MQTT protocol in selected telemetric modules that allows data exchange with IoT devices.
To facilitate the implementation of telemetry modules for users who are just starting their “adventure” with telemetry systems, we have developed a modern cloud application that allows free access to process data using stationary and mobile devices.
Consequently, all new visualization systems have been implemented based on the Progea Movicon SCADA system, distributed by AB-MICRO. Last year our engineers gained huge experience in creating complex applications based on the Movicon SCADA system. The Movicon.NExT version is another challenge facing our team.