Introduction
Ultraviolet (UV) disinfection systems are critical for ensuring pathogen-free water in many industrial, municipal, and commercial applications. However, their operation is often plagued by issues of unplanned downtime, lamp failure, and overheating, which compromise water safety and increase maintenance costs. This case study describes the successful transformation of this major UV-based industrial water treatment facility after the implementation of Terra M.
Terra M, our all-in-one IoT water controller, automates consistent disinfection, gains multi-level system protection, and achieves significant operational efficiency.
The Challenge
The client’s existing UV system relied on separate, non-integrated components for control and monitoring, leading to several critical challenges:
- Safety Risk and Downtime: The lack of real-time predictive maintenance features resulted in sudden lamp failures and system shutdowns, causing water quality risks and costly, unscheduled downtime.
- Manual Monitoring: Monitoring of critical parameters like flow, temperature, and power fluctuation was manual and reactive, leaving the system vulnerable to damage from overheating and dry runs.
- Inconsistent Disinfection: Without a unified, automated control system, maintaining consistent water quality near the UV system was difficult, potentially reducing the UV lamp’s effectiveness and lifespan.
The Solution
Terraconnect deployed the Terra M IoT Controller as the central management system for the UV disinfection unit. The solution integrated AI-enabled features to transform the system from a reactive maintenance model to a self-protecting, predictive operation.
AI-enabled Predictive Maintenance
Enabled real-time monitoring and integration to avoid unplanned downtime and provide prompt alerts for lamp replacement based on usage and performance tracking.
Multi-Level System Protection
Implemented automatic shut-down for overheating, a pre-activation flow check to prevent dry runs, and protection against power surges/dips, guaranteeing a comprehensive safety solution.
Automated Water Quality Management
The Terra M maintained stable water quality through automated controls, ensuring the water was optimally conditioned for consistent and effective disinfection.
Reduction in Unscheduled Downtime
The AI-enabled predictive maintenance feature significantly reduced the frequency of sudden system failures due to unpredictable lamp burnout or component overheating.
Decrease in Maintenance Response Time
The prompt alerts for lamp failure and system anomalies, delivered via the dedicated mobile application, drastically cut the time required for maintenance teams to identify and resolve issues.