Skanderborg Forsyning (Utility) reduces two WWTPs’ iron dosing by 55% & 44%

In a new partnership with Bionic System Solutions, Fors A/S, a large Danish utility company, has integrated BSS Analytics for the remote monitoring of a pumping station. Leveraging sensor data and advanced algorithms, the utility company has enhanced its operational control, enabling proactive fault detection and overflow prevention.

A solemn responsibility

With responsibility for water, wastewater, district heating, and waste management services for approximately 194,000 customers across Holbæk, Lejre, and Roskilde, the utility undertakes a vital societal function. This duty entails a solemn responsibility. Security of supply is, therefore, not merely an objective but a fundamental requirement, necessitating high levels of operational stability.

However, operational stability is a state that may be threatened by mechanical wear, technical disturbances, and unforeseen events. Such irregularities can induce unscheduled downtime and, in extreme cases, disrupt daily life and impair industrial productivity. These hazards can be challenging to detect. For instance, foreign objects may become lodged in water pumps, causing the rotor to operate without effectively conveying wastewater. This condition results in the flooding of the pumping station, leading to overflows within the sewer network and potential environmental contamination.

To reduce the risk of unexpected errors and enhance the surveillance of the pumping station, Fors A/S has recently initiated a project in collaboration with BSS. This project involves utilising sensor data for remote water pump monitoring and management.

”For us at FORS, we use it as extra security for monitoring. It is a requirement from the authority if our normal SRO/Monitoring fails. Then we had to find a system that could issue an alarm independently of our own. To ensure that there is no overflow into the fjord."
Morten Kasper, Team Leader – Pump Stations Team, Fors A/S.

From reactive to data-driven maintenance

BSS Analytics is a decision support platform that operates as a digital monitoring system, issuing alerts prior to the exceeding of user-defined threshold values and ISO standards. Rather than conducting routine inspections of ordinarily functioning water pumps, BSS Analytics delivers data-driven recommendations and enables the scheduling of proactive maintenance interventions at optimal times, thereby minimising operational disruptions.

By integrating sensor technology with analytical software, BSS Analytics establishes real-time data correlation with the asset conditions by employing advanced algorithms to analyse and detect subtle irregular patterns.

For example, the early detection of bearing wear prompts BSS Analytics to generate configurable alerts tailored to customer specifications. Additionally, the platform provides tools for root cause analysis, including spectrograms, analytical charts, and visualisations. Additionally, BSS Analytics also enables extractions of data as well as the generation of operational reports, and documentation.

As part of the collaboration with Fors A/S, BSS has developed a customised remote monitoring system and adapted it to the specific operational requirements and needs of the utility company. This system monitors, among other parameters, the adherence of the water pump to established operational patterns.

Under normal conditions, the pump periodically activates for short durations multiple times per hour to facilitate water extraction. If a pump remains inactive for a period exceeding one hour without scheduling, an alarm is generated. Conversely, the system also activates an alarm if the pump operates continuously for more than one hour, which may indicate a malfunction preventing wastewater conveyance. In both scenarios, operational personnel can verify the alarms through their respective systems and, upon confirmation, initiate corrective measures to prevent overflows.

Future-proofing innovation

The collaboration with BSS has granted Fors A/S operational reassurance by enabling earlier detection of anomalies. Through the identification of minor irregularities in real-time, the utility can initiate proactive responses to prevent issues from escalating into unexpected outages or overflow events. Furthermore, the deployment of additional sensors supplied by BSS facilitates continuous performance monitoring.

Although the collaboration is newfound, the anticipated benefits include a reduction in manual control inspections, decreased maintenance expenditures, and enhanced resource efficiency.

By implementing BSS Analytics as a digital monitoring system, Fors A/S has advanced towards a data-driven paradigm, wherein sensors and algorithms not only identify anomalies but actively contribute to their prevention.