The Digital Transformation: IoT & Emerging technologies area of CEPSA, with which GALEO collaborates closely in the design of digital architectures and solutions based on IoT, has recently held an event to bring the IoT world closer to the people responsible for industrial processes.
In the digital HUB of the Energy Park of San Roque, we have been able to bring together professionals from different sectors of the energy sector. CEPSAThe aim is to bring them closer to current trends in digital transformation, such as training and training through virtual reality in simulated industrial environments, the recognition of people and movements thanks to artificial intelligence image recognition algorithms, new trends in the sensing of rotating elements such as pumps or turbines for the alarming of possible failures, how to apply machine learning techniques to incorporate predictive maintenance effectively, or the advantages of additive manufacturing, among others.
In particular, GALEO has taken care of two demonstrators provided by the company BECKHOFF and we have integrated the data from both applications within the IoT platform of CEPSAwhich makes use of managed services from the IoT stack from AWSand finally visualize them using the dashboards web interface of Grafana Cloud.
Below, you can read more in detail about the scope of these two IioT integrations.
PREDICTIVE MAINTENANCE FOR INDUSTRIAL ROTARY PUMPS
The use of vibration sensors for the control and maintenance of rotating elements, so abundant in industries such as the oil & gas sector, is an increasingly widespread practice. When an industrial machine (such as a pump) is in operation, it generates vibration. If we measure these vibrations using, for example, an accelerometer, we will obtain a voltage signal that is proportional to the amount of vibration, as well as to the frequency of that vibration. Therefore, if we perform a real-time Fast Fourier Transform (FFT) and represent the amplitude vs. frequency, we can compare the vibration spectrum of the pump when it is working properly with respect to a spectrum that presents anomalies and detect if we are facing a case of error or possible failure. In the following captures we can see how the characteristic frequencies of the spectra are clearly different in the normal state and in the anomalous state.
Fourier spectrum in normal operating condition
Fourier spectrum in anomalous operating state
This type of condition-based predictive maintenance has been used in the industrial world since the 1990s, but adding to the predictive model other parameters such as the pump’s power consumption, its rotational speed, the power consumed or even external parameters such as temperature or humidity of the environment allows enriching the prediction being much more productive. And the first step to be able to associate many parameters to the same asset is to integrate them all within an IoT platform that allows the ingestion, processing and analysis of all these data from different sources of information.
During the event, we were able to show the attendees how the data from this vibration sensor was recorded by a PLC from CEPSA. BECKHOFF PLC, which in turn had been configured to send the data to the IoT platform of CEPSA GALEO has participated in the development of this platform. Thus, in a practical way, it was possible to see that the data sensed and displayed on the control panel of the demonstrator unit (rotation speed, energy consumption, torque, operating status, etc…) were replicated on the control panel of the demonstrator unit (rotation speed, energy consumption, torque, operating status, etc…). Grafana CloudThe data had been ingested and sent to the cloud where they are stored and processed along with all other data that may be related to the same asset, with refresh times of less than one minute. In this way, using machine learning techniques, a new, more intelligent and predictive model can be trained based on many more parameters.
In the following video of less than two minutes you can see the transition from normal operating state to Error mode in the control panel and how that is replicated to an alarm state in the IoT on cloud platform.
EFICIENCIA ENERGÉTICA MEDIANTE EL CONTROL DE LUMINARIAS O TERMOSTATOS DE REFRIGERACIÓN
In order to show how to improve the energy efficiency of the facilities and thus reduce the carbon footprint, a second demonstrator was set up to control the switching on, switching off and intensity of lighting fixtures using light sensors and consumption meters, as well as to control thermostats of refrigeration systems to monitor the cold chain, change set points or set alarms. In this case, a BECKHOFF PLC was connected to sensorized LED strips that allow light intensity control and wireless thermostats and temperature sensors were also connected, as an example of possible elements of this type of solution. GALEO ha colaborado en la integración de esos datos, que eran enviados desde el PLC de BECKHOFF, dentro de la plataforma IoT on cloud de CEPSA. Once the data is received, it is displayed with a refresh period of one minute in a panel built in Grafana Cloud. The objective of this demonstration was to see an example of the continuous monitoring of these parameters of light intensity, temperature and alarm management from the IoT platform and to understand that all these parameters can be managed, visualized and treated in a centralized way, combining them with other external parameters such as data from weather stations, maintenance plans, hours of use, equivalent energy cost, reduction of carbon footprint, etc…
In the following video you can see the continuous monitoring of light intensity, among other parameters, and how, after a change in light intensity, the IoT platform receives this change and can launch an alarm, or simply counting this change to use it later in the calculations of cost, energy efficiency or environmental impact.
If you want to know more about this type of IIoT implementations do not hesitate to contact us and we will be happy to explain the details and see how we could help you.
Article written by
Dr. Alejandro Junquera Pérez
Delivery Manager en Galeo