Stormwater overflow basin
Combined sewer overflow basins and their pumping stations can be monitored remotely around the clock with IoT. Operators see level, pressure and capacity utilisation in real time and keep operations running smoothly even during heavy rain.
Stormwater overflow basin at a glance
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Combined sewer overflow: basins and pumps monitored remotely
In the solution example, the Advanced IIoT Gateway DA50A from Red Lion's FlexEdge edge automation platform replaces a discontinued 3G modem. The Crimson 3.2 software converts up to 300 industrial protocols regardless of manufacturer, connecting the existing S7 controllers and the WinCC SCADA system via OPC UA. Readings such as level and pressure are queried, digitised and visualised. The connection runs over 4G via OpenVPN, and exchangeable radio modules allow a later switch to 5G during operation. For telecontrol, the gateways use DNP3, which sends data cyclically or only when something relevant changes. The devices are ATEX and IECEx certified.
The user is Entwässerungsbetriebe Würzburg (EBW), which collects, treats and discharges wastewater for the city of Würzburg and 16 surrounding municipalities. Its control centre monitors capacity utilisation and energy demand at 70 stormwater pumping stations. With 3G being switched off, remote access to all outstations had to be modernised without immediately replacing controllers and SCADA. FleX Automation from Gaukönigshofen delivered the project under time pressure. The result is a communication solution for 4G and 5G that also supports a later change of PLCs and SCADA.
Combined sewer overflow: frequently asked questions
Which values does CSO monitoring record?
The main values recorded are level and pressure at the basins as well as utilisation and energy demand of the pumping stations. At Entwässerungsbetriebe Würzburg, these operating data from 70 outstations come together in the control centre around the clock. The Red Lion gateways query the values from the existing controllers, digitise them and pass them to the SCADA system via OPC UA.
How are stormwater overflow and retention basins connected after the 3G switch-off?
After the 3G switch-off, basins are connected via modern cellular gateways with 4G, ideally with an option for 5G. In Würzburg, FleX Automation replaced the old 3G modems with Red Lion FlexEdge gateways. Exchangeable radio modules allow a later switch to 5G on site during operation. Remote access is secured via OpenVPN, and the existing controllers remained in service.
Do you need to replace PLCs and SCADA to monitor an overflow chamber remotely?
No, PLCs and SCADA can stay. In Würzburg, the existing S7 and ABB controllers and the WinCC SCADA system continue to operate. The Crimson software on the Red Lion gateways translates between protocols and talks to the SCADA system via OPC UA. If controllers and SCADA are replaced later, Crimson rebuilds the data communication without the need for additional tools.
How can data volumes be kept low when monitoring overflow events remotely?
Data volumes stay low when outstations transmit only when something relevant changes. The FlexEdge gateways in Würzburg use the DNP3 telecontrol protocol, which transmits information cyclically or event-driven and offers data reduction functions. This lowers the operating costs of the cellular connection, while level and pressure still reach the control centre in real time.
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