A smart pump control system was very important for better wastewater handling at an industrial site. Specifically, the project involved automating two tanks with four pumps placed over 150 meters apart with communication problems. This advanced pump control system ensured reliable operation, automatic switching, and efficient wastewater management with little human help.
Client Needs and Challenges
The site had two tanks in a row with big distance and a silo blocking direct communication. Each tank had two pumps that needed coordinated control. The client wanted a reliable automation solution that would manage pump work efficiently while solving the distance problems.
Main System Needs
First, the system needed one control panel for each pump pair. Also, pumps required main-backup setup with automatic change every five working hours. The system also needed water level-based control, variable speed operation, and central monitoring. Finally, the setup needed small space while giving maximum efficiency.
Advanced Technical Solution
Control Panel Setup
We put in two special control panels to manage the pump operations. The first panel had an S7-1200 PLC and KTP400 Basic screen for user control. This setup gave the main brain for the whole pump control system.
Wireless Communication System
To solve the 150-meter distance and view problems, we used Phoenix Contact Trusted Wireless 868Mhz modules. The main module connected to the PLC via RS485 protocol, while helper modules handled remote inputs and outputs.
Pump Drive Connection
We linked two Danfoss FC360 drives to the PLC via Profinet for exact pump control. The second panel also had two Danfoss drives with wireless helper modules having digital and analog input cards.
Level Watching Sensors
We put ultrasonic sensors and float switches on each tank for correct level watching. These sensors gave real-time data for automatic pump control based on water levels.
Important Project Successes
Efficient Pump Work
The system achieved variable speed control and main-backup pump setup. This automation ensured balanced work sharing and longer equipment life.
Reliable Wireless Communication
Smooth wireless communication between the tanks was successfully made. This new solution solved physical blocks and distance limits effectively.
Less Hand Operation
The reliable automatic pump control system greatly reduced the need for hand operation. This improvement raised work efficiency and cut labor costs.
Better System Abilities
The project showed our skill in delivering complex control solutions. This success improves our work in advanced automation systems for wastewater management.
Conclusion: Successful Automation Done
This smart pump control system has changed wastewater management at the industrial site. The complete solution gives reliable automation, efficient pump work, and lower maintenance needs. This project shows IAES’s knowledge in making custom control systems that solve complex industrial problems. With this setup, the client now has better wastewater handling with few work stops.
