Over 6000 pumping stations use MT-101 modules!

The MT-101 telemetry module, the leading device in the MT product family, awarded with the

Gold Medal of the AUTOMATICON Fair, has become a standard for professional GMS/GPRS

telemetry solutions across the world. One of the largest areas of application for the MT-101 are

clean water, rainwater and sewage pumping stations, where the module can be used instead of a

conventional PLC controller, GPRS modem, and data logger, ensuring lower costs, higher

reliability and better functional integration. There are now over 6000 pumping stations with

remote monitoring, control and diagnostics provided by MT-101 modules, which reduce costs of

operation and enhance the safety of the facilities and the environment.

In the past, systems for monitoring remote facilities were mainly based on radio transmission. As

GPRS data infrastructure is very well developed this communication platform may be used for

providing high functionality coupled with low costs of operation. The main advantages of wireless

GSM/GPRS systems for remote monitoring and control are:

The MT-101 telemetry module substitutes for a

conventional PLC controller, GPRS modem and data

logger, ensuring lower costs, higher reliability and

better functional integration.

• low costs

• short time of implementation

• no limit on the distance between facilities, insensitivity to terrain features and obstacles

(forests, high buildings)

• no need for complex antenna systems

• and the ability to send instant messages about emergency situations to mobile phones,

e-mails and/or other control systems.

GPRS technology enables direct and secure access to information by means of mobile devices

(mobile phones, PDA devices, tablets, portable computers). Additionally, there are no central

station bottlenecks in the case of complex telemetry systems. GSM/GPRS systems do not require

periodical queries being sent by the central station to remote sites one after another. Instead,

the use of the event-triggered transmission mode, in which a remote device sends out data

automatically in specific situations, enables a quick and simultaneous transfer to the central

system (or to many recipients at the same time) the state changes of remote sites located at any

distance. Even in the case of very large systems composed of hundreds of monitored points. The

attractive rates of GSM/GPRS network, coupled with efficient event-triggered transmissions mean

very low of operating costs.

The on-line monitoring of remote sites helps to optimize process control and the operation of

devices, reduce energy consumption, prevent breakdowns, shorten the time of response to alarm

situations, reduce costs of troubleshooting and significantly reduce the risk of costly damages.

Sample architecture of a control and monitoring system for a pumping station based on MT-101 modules.

Introduction of professional GSM/GPRS telemetry systems is now easier thanks to advanced

devices as the MT-101 module, which is configured autonomously by the user and provides much

broader functionality than an ordinary radio or GSM modem. In contrast to an ordinary

GSM/GPRS modem, the MT-101 has its own inputs/outputs, RTC clock, event logger,

transmission protocol converter, packet router, access control system, processor executing

control algorithms (PLC controller), system for automatic logging in to a GPRS network,

advanced self-diagnostics system, processor for event-triggered GPRS transmission, SMS

sending and making calls. The users are free to configure and program the telemetry modules

using intuitive software tools. It is possible to modify a user-defined configuration and program

and to update the firmware remotely via GPRS. Event-triggered transmission enables precise

monitoring of the operation of a remote facility without generating unnecessary traffic in the

GPRS network. As a result, very low costs of operating the system can be achieved.

In contrast to an ordinary GSM/GPRS modem, the MT-101 telemetry module has its own inputs/outputs, RTC clock, event logger, transmission protocol converter, packet router, access control system, processor

executing control algorithms (PLC controller), system for automatic logging in to a GPRS network, advanced self-diagnostics system, processor for event-triggered GPRS transmission, SMS sending and making calls.

The MT-101 module, widely used to control pumping stations, is provided with optoisolated

inputs/outputs: 8 binary inputs, 8 binary outputs (which can be selectively configured as inputs),

and 2 analog 4-20 mA inputs. The optoisolated serial port, which may be configured to operate

in RS232/422/485 standard, enables the MT-101 to operate as a communication gateway for

external devices and as a local Master mirroring external resource. There is a pulse-counting

function available for each binary input while the two analog inputs have 4 configurable alarm

thresholds, one manually-set threshold, and configurable filtering, hysteresis and deadband

functions. The MT-101 is also equipped with an event logger, diagnostic LEDs, removeable

terminal blocks, casing for DIN rail mounting, and a power supply system accepting wide voltage

range, with auxiliary battery supply. The MT-101 can work as a component of a centrally-

supervised control and data collection system. It can also work in event-driven mode,

autonomously initiating local control, sending input/output states, short text messages with

dynamically changing content, data packets or calling up to a defined telephone number.

Communication by means of SMS queries and SMS control commands are also possible.

Importantly, maximum data integrity and security is always ensured, also for remote control and

configuration.

Control cabinets at pumping stations are equipped with programmed MT-101 telemetry modules. Each

telemetry module has a SIM card of a selected mobile operator with a static IP address.

Our integrators developed attractive solutions, based on the MT-101 and GPRS technology, for

the on-line monitoring and visualization of remote pumping stations. The solutions offer the

capability to:

- monitor over 50 crucial parameters of a pumping station on the basis of correlations

among the monitored parameters;

- record changes in sewage levels, with recording rate adjusted to the pump dynamics;

- fully record the pump work cycles and analyze in detail their work time;

- check whether the telemetry module and measurement devices operate properly;

- check whether the float switches operate properly;

- measure pump electric current consumption, with dynamic sampling;

- measure the instantaneous rate of sewage flow and the total amount of sewage pumped;

- measure energy consumption, analyze energy parameters;

- identify intrusion to section of protected area, embedded function of alarm control unit;

- intelligently diagnose the state of the facility on a current basis – detect any irregularities

in its operation other than standard alarm situations;

- predict and prevent serious failures.

The additional tools built into the system analyzing “in the background” over 50 parameters of

every pumping station inform the operator on a current basis not only about standard failures

but also about other irregularities in the work of a pumping station which are not classified as a

breakdown but in fact require intervention. The use of advanced algorithms analyzing the work

of the pumping station in the background, effectively prevents the occurrence of serious

breakdowns, reducing potential costs of damage and its consequences (compensations resulting

from the damage).

Data from the monitored stations are sent to the operator station in an optimized event-driven

mode, which enables optimizing data transmission costs.

The MT-101 installed in a control cabinet executes an advanced algorithm (over 1000 code lines)

for the autonomous control of the operation of a pumping station. Sending data to the

monitoring system and remote control with the use of GPRS technology is an additional function

of the MT-101.

Usually, the most complex part of the system is a real-time visualization of the pumping stations.

Any SCADA program can be used for the visual presentation of status on a computer display. It

checks periodically whether new data have appeared in a database. Every change of status is

immediately presented on the display. Alarm states are additionally annunciated by sound

messages generated using speakers connected to the computer. Some samples below:

Sample screen of a SCADA visualization system

The current level of sewage in the chamber and electricity consumed by the pumps are displayed against

the tank background.

The SCADA programs for chart generations may work as intuitive presenter of graphic analyses. User may see advanced analysis of current and historical data, event after event. It helps the user to fully diagnose

the causes of irregular operations.

How to identify reliable suppliers of telemetry devices? (Characteristics below are satisfied by MT modules distributed by Signalix)

The right choice of telemetry devices is essential for the efficiency of a GSM/GPRS system,

reliability of monitoring and control, low cost of ownership, and ability to manage an extensive

system without service trips to remote sites. There are many GSM/GPRS devices on the market

with different capabilities, flexibility and reliability. Usually, a solution based on the cheapest

option (e.g. an ordinary GSM modem) turns out to be one of the most expensive due to the lack

of important functionalities, lack of intuitive software tools, lack of remote diagnostics and

remote configuration capabilities, a long time required for implementation and testing, high

operating costs caused by inefficient data traffic and service interventions. A cheap telemetry

module usually means a design not suited for harsh industrial environments, e.g. missing

galvanic isolation of I/Os and communication ports - resulting in high risk of failures caused by

electromagnetic interference, ground loop currents, lightning and electrostatic discharge effects.

Before making a final decision it is worth to check if the vendor has multiyear experience and

competence in GSM/GPRS technology, a certified Quality Management System, extensive

reference base, wide portfolio of different types of products satisfying a variety of different

needs, intuitive software tools for remote configuration, programming and diagnostics of the

telemetry modules, a detailed documentation and tech support team. An open architecture

approach enabling easy integration with preferred SCADA systems, historian and database

software and best-in-the-class IT solutions of other vendors should be an important selection

criteria. Advanced implementation of GPRS technology should ensure: autonomous login to a

GPRS network and session recovery, event-based transmissions, remote diagnostics, remote

update of configuration, an application program and firmware with the highest level of security

(passwords, lists of authorized numbers and IP addresses, data frame encryption). User-defined

application programs and embedded standard communication protocols (e.g. Modbus RTU, M-

Bus) should be supported. A reliable and efficient GSM/GPRS system requires essential technical

features of the telemetry modules, i.e. galvanic isolation of inputs/outputs and communication

ports, configurable filtration, hysteresis and deadband for analog inputs, diagnostic LEDs

presenting current status of inputs and outputs, GSM signal level, activity of GSM modem and

communication port, operation mode of the module, etc.