Datataker have undertaken a project whose primary goal is to develop and construct a Pump monitoring system to monitor temperatures in the bearings of on site pumps. These systems are designed to sound alarm if the bearing in the pumps reach a temperature above a set safety margin.
The Pump monitoring system will communicate remotely through radio modem communications and will automatically shut down the overheating pump. In the report analysis, Remote monitoring stations are separated from the Alarm stations on the basis that they utilise different power supplies.
The primary use of the Pump monitoring system is to manage the remote pumps in order to minimise breakdown and resultant costs. To do this, the Pump monitoring system must be self sufficient.
For self sufficiency, 20W solar panels will be included on the remote monitoring stations and a backup battery will be included in the alarm station. In case of a power failure, the solar panels will be charged by the 24V mains power supply that the Alarm station is connected to.
Monitoring station overview
The two Monitoring stations will be pontoon borne static positions that have the primary purpose of monitoring the temperature of the bearings in the pumps. Their secondary purpose will be to initiate a shutdown of the pump if the temperature exceeds pre-set safety margins.
Each Remote station has the following components:
- 1 x dataTaker DT85 unit
- 1 x Elpro 905U-E radio modem
- 12V, 7.2Ahr batteries
- 1 x 20W solar panel
- 1 x Extension antenna for radio modem
- 1 x Weatherproof casement with relevant outlets for sensors and cabling
- Sensor set (supplied by Ensham Resources)
- Cut-off control cables and connectors
- Relevant mounting bolts/screws
The Remote station will use a 20W solar panel to supply the necessary power to maintain the charge in the battery packs, allowing for testing at one minute intervals. This will allow 1440 tests per day under normal operating conditions.
The power consumption is based on a combination of usage by the modem, the DT85 and the thermal sensors. The power consumption also takes into account the five second power up/power down times of the dataTaker in low power mode.
As the whole monitoring unit is to be sited upon a pontoon, it is recommended that the unit casement be constructed out of powder coated steel compact enclosure providing maximum durability and strength.
Alarm station overview
The goal of the Alarm station is to centralise the system, enabling the user to monitor the Alarm station rather than maintain overwatch on the monitoring stations. In addition to sounding an alarm, upon receiving notice of an overheating pump, the Alarm station will initiate an automatic shutdown of the pump. It will also log and display which pump was overheated, allowing quick response and less downtime of the machinery.
The Alarm station has the following components:
- 1 x dataTaker DT80 unit
- 1 x Elpro 905U-E radio modem
- 1 x Trip-switch with manual re-set
- 1 x Beeper for audible notification of the alarm
- 1 x Flashing light/flashing LED arrangement for visual notification
- 1 x Battery for backup power
- 1 x Extension antenna for radio modem
- Requisite 24V power supply unit and cables
- Weatherproof casement
- Requisite fixture bolts/screws
The DT80 is configured to trigger the alarm and notify the user of which monitoring unit that the alarm originated from, in addition to shutting the pump down. The DT80 will be programmed to display on its display which pump was alarmed and shutoff.
The backup battery exists to provide emergency power to the alarm in case of a failure of mains power and the failure of mains power will not trigger the alarm.
The use of radio modems in all three stations will provide for wireless connection of all the stations. Thus the Alarm station can be sited near a security station or maintenance depot. This will reduce downtime of the pumps as the alarm can be readily acted upon.
Combining the System
The two monitoring stations are linked through radio communications by the
Elpro radio modems. The Elpro radio modems allow monitoring stations to be placed at 1km from the Alarm station.
Following are the total components listing for the three stations:
- 1 x dataTaker DT80 unit
- 3 x Elpro 905U-E radio modem
- 1 x Trip-switch with manual re-set
- 1 x Beeper for audible notification of the alarm
- 1 x Flashing light/flashing LED arrangement for visual notification
- 1 x 24V battery setup for backup power
- 3 x Extension antenna for radio modem
- 1 x Set of requisite 24V power supply unit and cables
- 1 x Weatherproof casement for alarm station
- 2 x dataTaker DT85 unit
- 2 x 12V 7.2Ahr batteries
- 2 x 20W solar panel
- 2 x Weatherproof casement with relevant outlets for sensors and cabling for Monitoring stations and mounting for solar panels.
- 2 x Sensor setup for monitoring bearing temperatures
- 2 x Sets of cut-off control cables and connectors/interfaces
- Requisite fixture bolts/screws