Velim Ecological Solutions in collaboration with Green Solutions, has developed the technology for IIoT based Sewage Treatment Plants (STPs). IoT technology and its application in the industrial scenario offers a host of operational advantages. Foremost among them is the facility to remotely monitor the operation of the STPs over the Internet, even though the plant itself may be located at the outskirts of human settlements. This can greatly mitigate human exposure and frequent travel issues.

We present here a live demo of a IIoT-based model plant which incorporates some of the features of a typical STP. The demo plant is a scaled down version which includes two pumps and its associated control panel. This would be a single module of a full-fledged functional STP.

Description: In this plant, there are two pumps, each of 1HP rating. They are labelled as Pump-1 and Pump-2 respectively in Figure 1.
They can be run alternately as in a typical STP. They can be run in “Auto” mode without human intervention or in “Manual” mode.

The pumps pump water from one tank to another alternatively. Water-level controllers are also installed.

The pump motors are protected by individual overload relays and the system has phase failure protection. In addition, there is a mode selector switch to select between auto and manual mode.

There is a selector switch to select between Pump1 and Pump2 in Manual mode. In the Auto mode, the pumps are run in a cyclic fashion, running alternately. In each cycle, the ON state is triggered by a timer. Thereafter, a water-level controller turns off the pump when the delivery tank is full.
The block diagram in Figure 1 consists of an electrical block which provides electric power and electrical protection and switching circuits for the pumps. This electrical block takes care of the regular plant operation. From this block two sets of signals are obtained-

a. Power consumption and power factor and
b. Control/status signals

The signals sent to respective signal processing blocks. The power signals are processed by analog processing block and the control signals by a digital signal processing block. The analog and digital data are then combined in the IoT block and uploaded to the cloud via the networking block. The dashboard described here displays the data received from the cloud.
a. Analog – The following analog data is available: Power consumption in each phase of a given motor and the corresponding power factor.

b. Digital- The digital signals in binary form indicate the status of the safety controls as well as which motor mode is selected. In the auto mode, the timer ON/OFF status is also read. The pump ON/OFF status is also displayed. Thus, altogether, eight control/status signals are displayed in binary fashion. The complete list of all available signals is provided in a later section.
The dashboard is available for remote viewing. As already explained, the dashboard has distinct sections for the analog data and digital data. A snapshot of the dashboard in operation is provided in Figure 2. It may be divided into several sections which are explained in Figure 3.

Here the various sections of the dashboard are marked off by red boxes. They are then labeled alphabetically as A, B, C D and E respectively.

The various sections are explained below.
Section A : (Text Box)

Indicates the status of the dashboard itself. It has the following entries

  • CONN – when the dashboard connects to the data server
  • DISCONN – when the dashboard disconnects from the data server
  • IDLE – when no data is being received
  • UPDATING – when the data is being received and the screen is being updated
Section B : (3 Dials)

Indicates the power being consumed by the active pump. The two pumps are driven by two 3-Phase motors respectively, each rated for 1 HP.

The dials in this section show the actual wattage (real power) in each phase of the pump that is currently running.
Section C : (Trend Chart)

Graph style display of the data in section B but as a chart of power values in the Y-axis and time scale in the X-axis.

The 3 phases are indicated by multicolour plots of red, yellow and blue respectively
Section D : (Power Factor)

The power factor of the currently running motor is displayed.
Section E : (LED style display)

Binary signals which give a view of all the relevant control signals that define the state of the system. The details are as follows:

• PHASE FAILURE – Phase failure relay , a protection device
◦ Safe- green
◦ Tripped-red

• MOTOR MODE – whether the motor operation is automatic (timer controlled ) or manually controlled
◦ Auto -green
◦ Manual -red

• MOTOR 1 STATUS, MOTOR 2 STATUS currently running motor
◦ On-green
◦ Off – dark

• TIMER 1 STATUS , TIMER2 STATUS – Which timer is currently operational
◦ On-green
◦ Off – dark

• OLR1 STATUS, OLR2 STATUS – Overload relays which are protection devices
◦ Safe- green
◦ Tripped-red

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Geographic location:

The plant and associated electronic and network modules are currently stationed at the outskirts of Coimbatore city, Tamilnadu, India. The dashboard can be viewed in any location where Internet coverage is available.

Contact us for Live Demonstration.