cimconautomation
Prelude: In the wake of sensor enabled devices, pervasive digitization, big data platforms and large viable analytics combined with artificial intelligence acceptance took automation diaspora into a different level. Though there are several tools catering to different markets, sizes and verticals, a simple, scalable, actionable and affordable solutions are yet to mature in the present market.
Introduction to Our Solution: Our in-house solution caters to complete data engineering life cycle that begins with cumulating sensor data into data lakes, pre-processing and data preparation, apply ML and AI algorithm wrappers catering to several business cases and showcase the results in interactive dashboards
Analyze and diagnose the historical equipment data that has logged several component errors such as overheat, hoist, and break faults. Accordingly, predict and raise the relevant flags and alerts intimating the stakeholders for quick and timely actions
Cranes operational data gathered from various sensors across geo locations was ingested into AWS storage
Custom ARIMA models Built toforecast diverse faults across several bins
Predict the imminent faults of different components
The solution used ARIMA algorithm to predict the overall fault volumes as well as location and machinery specific faults
Generated proactive alerts for each machinery highlighting the possible event such as hoist or brake failure
Effective planning of maintenance schedules, shipment of spare parts, and service engineer visits
Reduce maintenance/downtime delays and thus improve overall utilization by 7%
Proactive alerts based on sensitivity and severity (RAG) status
“Solution was developed across 10000+ machinery assets and the predictive models were able to generate accuracies upto 85% in fault prediction diagnostics”
As a part of this section, we will be looking at monitoring Pump house and its efficiency, prediction of faults (pre alarm conditions), KPI (Power Vs Water distribution) and demand analysis, leveraging AI and IoT giving both Industrial Solution Deep Dive as well as detailing about the Application stack leverages. The section would include the following:
Industrial Solution Deep Dive
Use of technology in the infrastructure
Pump Energy Reporter Module
This affect was seen system wide when implemented for a customer…
Intelligent Remote Terminal Unit is connected with various field sensor wired or wirelessly Field sensors connected with iRTU for different parameters monitoring are e.g
iRTU will connect via. GPRS (or various wireless communication technology NB-IOT, LoRa Wan, etc.) with Master Control station SCADA software (WebSCANET) and WebSCANET will send data through API or OPC-UA to ICCC software.
ICCC software can have below integration:
Values in Tabular form and Online trends of following parameters:
Values in Tabular form and Online trends of following parameters:
As a part of this section, we will be looking at tracking Oil and Gas pipe line monitoring system leveraging AI and IoT giving both Industrial Solution Deep Dive as well as detailing about the Application stack leverages. The section would include the following:
Industrial Solution Deep Dive
O&G Pipe lines are laid underground or above ground in kms of length. The pipe line carries costly and hazardous fuels with high pressure. Small cracks, corrosion causes leakage in the pipe line which may incur loss to the Company and at the same time may have huge loss on environment / human hazards.
As a part of Integrity management of these pipelines, the foot patrolling of ROU (Right of use) of the pipeline needs to be monitored to avoid any Third party activity resulting into leak or fire.
The ROU monitoring activity is set on the basis of class location(population zones) through which pipe line is passing.
Based on the current scenarios, O&G companies are making physical survey of the system at the Test Lead Points for pipeline corrosion monitoring installed @ 1-1.5 km distance near Pipe line path and Right of Use (ROU) for physical condition monitoring of pipeline.
Manual survey are being carried out at different time interval monthly or bi-monthly on 200 to 400 km of distance and report are to be fed into the existing software by surveyor.
The foot patrolling will be on Daily & Monthly basis as required.
Typical areas where the monitoring has been done manually and cause the chances of errors:
Lack of Technology Awareness & Adoption
Use of technology in the infrastructure
Get your TR Status, Mode of Operation, Real Time Voltage, Current and PSP on your mobile Handset.
This use case describes how ‘Edge Computing’ can apply not just to cater very high end, large infrastructure and complex processing applications but also very useful for small to medium scale applications as widely in demand by today’s fast growing industry world. With ‘Pump House Monitoring’ application example, it demonstrates various advantages the water utility sector can gain over conventional solutions.
Water Pump House / Pumping Stations are mechanism that can be used to transport water from one site to another usually from its source to consumer e.g. supply water to canals, circulate water in treatment systems, supply water to residential areas etc. Few important parameters like pump motor input power supply, its power consumption, water flow, water pressure, time scheduled or demand based pump on & off control etc. are to be taken care for its smooth functioning so that to meet demand-supply in efficient manner. Again, this can be remote site set-up so all such monitoring & control need to be done remotely from utility’s back office (control station) over wireless / wired network connectivity.
Conventional solution utilizes below components -RTU or PLC
This is how Conventional Solution manages basic application. All required sensors / peripheral devices are wired to RTU / PLC, data logged into local memory, data processing, data sent to utility control station over cellular or Ethernet connectivity. It can log and generate power fail or any pre-set threshold limit alert messages as well for supply voltage fluctuation, overload trip etc. Store history data during connectivity loss. For any maintenance activity or fault recovery, operator needs to visit site and take corrective actions.
Though it can manage basic application in simple manner, it has few limitations as well.
High Network dependency to get real time alerts. This can be critical if user needs to take immediate corrective action in response and hence may increase system downtime.
Operator visit becomes must for any system level diagnosis & maintenance activity in case efficiency loss reported. Such is not always favorable for the far remote sites or if located at high altitude, hilly area etc.
Wired connectivity with limited interface options for all peripherals installed inside or outside pump house premise that can lead to reliability issues.
No premise security, so theft threat. If needs to build this feature, requires additional system solution with IP Cameras & dedicated server including integration efforts to user control room in real-time manner.
Lack of preventive maintenance mechanism leads to high maintenance cost/failure recovery. To have this feature added in conventional system, need to add specific sensors along with pump, have added interface channels at RTU/PLC end, data capturing, logging and transporting mechanism which again demands for high end RTU/PLC solution, reliable connectivity for large data transport, software solutions/cloud components with data analytics for preventive maintenance. All these means more dependencies and cost addition.
Edge Computing is computing that’s done at or near the source of data, instead of relying on the cloud/server to do all complex analytics work. With this it is more efficient to cater data latency, bandwidth and security related issues hence attractive feature to have for any real time monitoring & control application solution. To have this feature, it demands for certain capabilities in control system solution depending on complexity of tasks involved with targeted application.
Leveraging this for pump house monitoring application, here we list out some of key features/components example to integrate with device solution or say build ‘Edge Computing Platform’
Required Components –
Diagram here shows how edge computing platform can replace any conventional system solution.
With Edge Computing and Analytics tools implemented with Edge Platform, data processing can be faster, responsive action can be taken in real time, overall system monitoring and data analysis for end user becomes simpler as conclusive notifications they receive in alert form. All achieved with minimal system components that enhances system reliability and optimizes solution cost.
Welcome to WordPress. This is your first post. Edit or delete it, then start writing!