Frequent monitoring of the environmental conditions and equipment at pump stations is important to prevent an unrecognized problem from turning into a disruption in service. The challenge is that most facilities do not have staff available to visit sites and assess conditions around the clock.
However, there is a cost-effective, user-friendly way to keep tabs on conditions at pump stations. What started decades ago as an alarm auto dialer that communicated through a landline, remote monitoring systems are now industrial internet of things (IIoT) devices that use cloud-based technology. They enable operators to see real-time status of all monitored conditions through an app and receive alerts when sensor readings fall out of the desired range.
What Is Remote Monitoring?
Remote monitoring systems alert operators to environmental and equipment changes that can lead to problems. They are installed at both staffed and unattended sites to monitor conditions around the clock. The system consists of a base unit that constantly collects data (like well levels and flow rates) from existing equipment or sensors positioned at key places at the facility. Each monitored condition requires its own sensor input on the base unit. The devices are programmed to detect high or low limits on the monitored sensors.
When a sensor reading moves out of preset parameters, the base unit contacts personnel by phone, email or text. Users can access the data any time via website, app or phone.
Alarm dialers were the first remote monitoring devices. For decades, they were the go-to devices for water facility operators to receive reliable monitoring and alarm delivery from remote pump stations. Auto dialers communicated through a landline and were programmed with a keypad. They were considered dependable because telephone lines usually were not affected by power failure.
However, landline-based systems are changing. The dependable copper telephone lines are no longer the standard in most places since voice over internet protocol (VOIP) systems have come into use. The VOIP systems usually do not work with a traditional auto dialer and are susceptible to power outages.
Both copper phone lines and VOIP systems are unsupervised, which means they do not send a notification if the phone connection is lost. Users can call into their dialer to verify the lines are operational but a line can go down at any time after that check, making the alarm monitoring system useless.
In addition, traditional copper telephone lines are becoming obsolete, expensive and increasingly unsupported by the major telecommunications companies. More importantly, auto dialers cannot provide the level of service expected to meet the demands of the IIoT age. For industrial use today, operators are turning to cloud-based monitoring devices that communicate via internet or cellular connection. These newer systems are more reliable, provide better access to data and are less costly to install and maintain. They also offer data logging capabilities.
Cloud-Based Monitoring Systems
Like the auto dialer, cloud-based monitoring systems consist of a base unit plus sensors and alert users when readings fall out of the desired range. However, the similarities end with these essential functions. Because cloud-based systems are built on IIoT technology, operators can access devices in real time from anywhere in the world to see the current status of all monitored conditions and receive alerts on their mobile device of changes that could indicate a problem.
Cloud-based systems are supported by networks of remote servers that enable them to store vast amounts of data. To ensure data security, providers of these monitoring systems use private cloud services to prevent public access. In addition, the cloud platform is monitored around the clock, and providers use multiple backup server sites across the country to ensure the system is never down.
A cloud-based unit monitors itself by constantly sending a signal to the cloud to confirm the system is online. If the internet connection is lost or there is a cellular communications problem, the system sends an alert to designated users by phone, text or email. Operators do not have to worry about losing data if the cloud connection is interrupted because all information gathered during this time is stored in the device and will be uploaded to the cloud when the connection is restored.
If the pump house locations do not have an internet or Wi-Fi connection, users can opt for a cloud-based monitoring system equipped with a cellular modem. These systems send information to the cloud through a cellular connection. Most manufacturers will package their device with a cellular modem and a battery backup. In addition, they will provide cellular service so there is no need to worry about subscriber identity module (SIM) cards or billing overages—there just needs to be a strong cellular signal at the site.
Monitoring Remote Pump Houses
Cloud-based technology lets users check conditions of multiple water and wastewater locations, access pump runtime and flow reports, check specific equipment status and review alarm history. These systems also log data automatically, which enables operators to analyze trends and improve performance systemwide.
These systems can monitor, deliver alarms and log input/output point data from third-party Modbus sensors, transducers and programmable logic controllers (PLCs). Operators can remotely access the values pulled from Modbus equipment or sensors and integrate the monitoring system into floats, pump alarm outputs, level transducers and other equipment.
Connect external sensors to monitor temperature fluctuations, flow rate, power failure and security breaches.
Data Logging & Retrieving
Industrial IoT technology has transformed data collection and logging—no more chart recorders, logbooks or manual data log entries. A data logger communicates with sensors at a set interval and automatically records data points, dates and times. Cloud-based monitoring systems can store an unlimited amount of data that can be used to help identify trends that can improve pump performance, optimize operations and discover potential problems.
For advanced IIoT monitoring of remote pump stations, it is time to discard the landline and auto dialer alert device for a cost-effective, cloud-based monitoring system. Because facility personnel usually do not visit remote pumping stations regularly, installing a cloud-based monitoring system provides secure 24/7 access to real-time and historic sensor readings. These advanced systems also provide peace of mind because they send an immediate notification when the system detects an undesirable sensor reading, so personnel can troubleshoot to prevent a major malfunction.