HCLT Whitepaper: Remote Monitoring of Rotating Equipment using Cloud

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http://www.hcltech.com/engineering-rd-services/overview~ More on ERS

Heavy rotating equipment like compressors, turbines and pumps are more susceptible to mechanical failure than non-rotating equipment. Periodic health monitoring of rotating equipment is necessary to ensure productivity and to extend longevity. Remote health monitoring of rotating equipment by harnessing cloud computing can appreciably reduce the cost. In fact, it offers a dual benefit – remote monitoring compared to monitoring by qualified staff on-premise, and second, use of the cloud to reduce IT overhead. This article describes the benefits to end users of using cloud for remote monitoring of their assets.

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In the process industry, most critical rotating equipment like turbines and compressors are maintained by dedicated systems and by onpremise specialists. In a few safety-critical cases, the systems are made hardware redundant. The health monitoring equipment, too, requires periodic maintenance and software/hardware upgrades. This makes health monitoring of rotating equipment a costly proposition for end users. Only critical equipment is condition monitored (another term for health monitoring), and by and large, other equipment that is not monitored is a frequent source of production loss.

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HCLT Whitepaper: Remote Monitoring of Rotating Equipment using Cloud

  1. 1. Remote Monitoring of Rotating Equipment Using CloudJanuary 2011
  2. 2. Remote Monitoring of Rotating Equipment Using Cloud | January 2011 TABLE OF CONTENTS Abstract ............................................................................................. 3 Abbreviations .................................................................................... 4 Market Trends/Challenges ................................................................ 5 Solution ............................................................................................. 6 Conclusion....................................................................................... 11 Reference ........................................................................................ 12 Author Info ....................................................................................... 12 © 2011 HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
  3. 3. Remote Monitoring of Rotating Equipment Using Cloud | January 2011 Abstract Heavy rotating equipment like compressors, turbines and pumps are more susceptible to mechanical failure than non-rotating equipment. Periodic health monitoring of rotating equipment is necessary to ensure productivity and to extend longevity. Remote health monitoring of rotating equipment by harnessing cloud computing can appreciably reduce the cost. In fact, it offers a dual benefit – remote monitoring compared to monitoring by qualified staff on- premise, and second, use of the cloud to reduce IT overhead. This article describes the benefits to end users of using cloud for remote monitoring of their assets. © 2011 HCL Technologies, Ltd.. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.3
  4. 4. Remote Monitoring of Rotating Equipment Using Cloud | January 2011 Abbreviations Sl. No. Acronyms Full form 1 OEM Original Equipment Manufacturer © 2011 HCL Technologies, Ltd.. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.4
  5. 5. Remote Monitoring of Rotating Equipment Using Cloud | January 2011 Market Trends/Challenges In the process industry, most critical rotating equipment like turbines and compressors are maintained by dedicated systems and by on- premise specialists. In a few safety-critical cases, the systems are made hardware redundant. The health monitoring equipment, too, requires periodic maintenance and software/hardware upgrades. This makes health monitoring of rotating equipment a costly proposition for end users. Only critical equipment is condition monitored (another term for health monitoring), and by and large, other equipment that is not monitored is a frequent source of Periodic onsite maintenance is production loss. expensive, and remote monitoring will go a long way Many end users, ranging from chemical process plant managers to toward reducing the cost of residential houses, have rotating equipment operating without a maintenance health monitoring system in place. They rely on their technicians to perform periodic manual offline maintenance checks to improve reliability. If periodic comprehensive maintenance checks are not performed, the equipment can continue to operate with defects, leading to a potential breakdown. Many times the problems are fixed without determining the underlying cause, resulting in the problem resurfacing within a short time after the repair. Remote asset management of rotating equipment with expert technical advice, at nominal rates, will ensure that all equipment performs as expected. © 2011 HCL Technologies, Ltd.. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.5
  6. 6. Remote Monitoring of Rotating Equipment Using Cloud | January 2011 Solution 1. Dynamics of Rotating Equipment Unbalance, misalignment, Generally, rotating equipment operates from 1,000 to 10,000 looseness and rotor rub are a rpm, and is subject to centrifugal and centripetal forces. In few of the reasons for rotating many cases, they handle fluids (gases or liquids) at high equipment failure that can be pressure and temperature. As they are highly stressed, the detected by condition chances of breakdown are also high. Some of reasons for monitoring equipment breakdown are: o Unbalance - Unbalance occurs when the center-of- gravity of a rotating object is not aligned with its center- of rotation. o Misalignment – a condition where the centerlines of coupled shafts do not coincide. o Looseness – Looseness between a machine and its foundation o Rotor rub - Rotor rub is a slight rubbing condition as the rotor is initially operated. If left undiagnosed, they will wear away the internal clearances until the machine cannot be operated. o High temperature leading to overheating It is important to monitor the health of rotating equipment periodically to prevent breakdown. 2. Condition Monitoring and Asset Management Condition monitoring of rotating equipment is used to prevent failures, as mentioned above, from occurring. It monitors parameters such as vibration, current and temperature to identify potential issues, and quite often can predict the problems in advance, allowing preventive maintenance to be performed. Asset management includes condition monitoring as one of its major modules. Asset management includes a database of equipment specifications, maintenance history, the dates and description of maintenance, a schedule for the next maintenance due, and the ability to raise alerts about the next maintenance due. In some cases, the asset management application can generate work orders to release the equipment for maintenance. 3. Remote Monitoring Remote operation monitoring of rotating equipment is fast, and gaining acceptance worldwide. In remote monitoring, the © 2011 HCL Technologies, Ltd.. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.6
  7. 7. Remote Monitoring of Rotating Equipment Using Cloud | January 2011 sensed data like vibration, temperature, power consumed, the number of starts/stops, and the duration of stops are transmitted to a central server. The data from sensors on the equipment is sent via wired or wireless mode to the server. There might be an intermediate server to acquire data from multiple pieces of equipment using varied protocols such as Modbus, Fieldbus, Profibus, and then provide another interface like OPC to transfer that data to the processing server. Data from rotating The figure below gives a schematic representation of an entire equipment is sent in wired setup – data collection from pumps to server and then on to or wireless mode to data users. The “CIU” cards are modules to transmit data from servers pump to servers in wireless/wired mode. Cloud Infrastructure Internet Firewall WebServer ModBusTCP over GPRS Alternate Communication path GPRS GPRS Bacnet Modbus Profibus CIU 271 CIU 250 CIU 300 CIU 200 CIU 150 The software on the server processes the data and presents it in a consumable format (reports, graphs, alarms, etc.) to equipment operators. It is normal to have web interfaces to © 2011 HCL Technologies, Ltd.. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.7
  8. 8. Remote Monitoring of Rotating Equipment Using Cloud | January 2011 enable remote monitoring. SMS and emails alerts are also provided as add-on features. There are many advantages of remote monitoring over field supervision. o A wide range of rotating equipment – be it turbines, compressors, pumps or fans – can be monitored from a single, centralized location, even if they are spread geographically. Cloud computing is a perfect o The dependence on field technicians to do periodic platform for remote monitoring checking can be substantially reduced by remote monitoring o Remote monitoring can be a solution to aging staff or unavailability of qualified technicians at remote sites o As state-of-the-art analytics are provided, the monitoring becomes accurate and effective. o Remote monitoring can be done by a competent person in another part of world, bringing down the cost of asset management. 4. Remote Monitoring with Cloud Cloud computing is a perfect platform for remote monitoring. The cloud is a shared pool of IT resources, applications, processors, storage and databases. Resources can be dynamically procured to satisfy peaks in demand, and then released when demand subsides. Cloud provides cost elimination through standardization and the reuse of IT infrastructure data centers, taking advantage of low real estate prices, less expensive power supply and the availability of competent resources at a reasonable price. Cloud is elastic in nature – charges are based on usage of hardware and software. At peak loads, more hardware would be put in use to service the user requests than compared to steady state. Accordingly the users are charged. Also there is a “Green Commitment” by efficient resource use. 5. Analysis and Control Monitoring of raw data coming from pumps in the form of graphs/reports, and displaying those alerts based on those values are only the first few steps. With the availability of abundant processing capacity on cloud, computing-intensive applications to interpret the data can be implemented. Examples of such applications are: © 2011 HCL Technologies, Ltd.. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.8
  9. 9. Remote Monitoring of Rotating Equipment Using Cloud | January 2011 o Spectrum Analysis (frequency analysis using Fast Fourier transform) to identify defects after they have surfaced on rotating equipment which is not possible to visualize based on raw data o Model Prediction – Creating a model based on input data within a given timeframe, then using the model output to compare the actual input signal coming thereafter to identify any defect before the defect Remote monitoring will spur manifests into a bigger problem usage of Analytics as a Service o Predict the behavior (probability) of rotating equipment in the immediate future (next few days) to long-term (next few months). This will enable technical personnel to take preventive steps 6. Spurring Analytics as a Service Analytics as a service is a service offering in a cloud environment, wherin the data analysis is handled by another provider. They ensure the data is interprested by the most efficient and accurate algorithim. That means the data from the usual source (vibration analysis or current signal ) will be treated with varied algorithims as they become available. Because the service providers will be working with multiple organizations, they will have the means to provide the optimum solutions for each of the problems they encounter. Remote condition monitoring would in turn spur the usage of analytics as service. End users want an accurate health diagnosis of their equipment. That, in turn, would mean using varied or complex algorithims to solve their problem. 7. Extension to Smart Phones All data available on cloud can be easily viewed on smart phones. The obvious advantage of monitoring on smart phones will be felt by field personnel, who will have access to the data as they perform maintenance activities. They can take a snapshot and send mail to their offices and customers using There are many options to the smart phones. make the cloud a secure place to process data 8. Apprehensions About Cloud Computing The biggest hurdle to remote monitoring of rotating equipment on cloud is to convince end users their data is safe and secure, even though it will be handled by people outside their organization. Many process plant owners are wary of sharing their data outside their premises, as there are many IP © 2011 HCL Technologies, Ltd.. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.9
  10. 10. Remote Monitoring of Rotating Equipment Using Cloud | January 2011 technologies involved. For those end users possessive about their data, or apprehensive about data being misused, the cloud today offers many secure solutions: o Cloud service providers will have the most sophisticated security systems in place as they work with customer organizations, making it highly improbable for hackers to to break through o Data scattering among geographically separated data servers will ensure that not all data is available in a single location. Different locations will implement different security mechanisms (all equally strong), different passwords, etc. o Strong encryption algorithms will ensure even the scattered data will mean little to hackers, even if they were to gain access to such data 9. Economics to End Users and OEMs Remote monitoring will be more economical for more than one reason: o Continuous monitoring will ensure minimal unplanned shutdowns, thereby ensuring productivity. Many process plants bleed due to unplanned shutdowns as a result of improper condition monitoring. o Visits by skilled technical staff from OEM to installation sites are virtually eliminated. For bigger rotating equipment like turbines and compressors, skilled staff are usually flown in from a distant country, and become expensive OEMs of rotating equipment will also benefit from remote monitoring. o They can bring down their warranty cost of equipment by offering remote monitoring (though the remote monitoring will be an added cost to end users) o They are assured of regular income by managing the subscription to services, unlike the one-off sales revenue © 2011 HCL Technologies, Ltd.. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.10
  11. 11. Remote Monitoring of Rotating Equipment Using Cloud | January 2011 Conclusion Remote monitoring of rotating equipment adds value to all stakeholders (end users and OEMs). Continuous monitoring ensures very little productivity loss due to unplanned shutdowns. By offering the services on cloud, end users pay a nominal fee on a monthly basis to have all their rotating equipment insured for health. Due to cloud infrastructure, OEMs will be able to offer added features at very low cost. © 2011 HCL Technologies, Ltd.. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.11
  12. 12. Remote Monitoring of Rotating Equipment Using Cloud | January 2011 Reference 1. Grundfos Remote Management – product flyer Author Info Mahesh Subramaniam, ERS, Industrial Practice, has over 21 years of experience in control systems engineering, software development and IT project management. His current interests include safety-critical applications and condition monitoring. © 2011 HCL Technologies, Ltd.. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.12
  13. 13. Hello, I’m from HCL’s Engineering and R&D Services. We enabletechnology led organizations to go to market with innovative productsand solutions. We partner with our customers in building world classproducts and creating the associated solution delivery ecosystem tohelp build market leadership. Right now, 14,500+ of us are developingengineering products, solutions and platforms across Aerospace andDefense, Automotive, Consumer Electronics, Industrial Manufacturing,Medical Devices, Networking & Telecom, Office Automation,Semiconductor, and Servers & Storage for our customers.For more details contact eootb@hcl.comFollow us on twitter at http://twitter.com/hclers and our blog, athttp://ers.hclblogs.com/Visit our website: http://www.hcltech.com/engineering-services/About HCLAbout HCL TechnologiesHCL Technologies is a leading global IT services company, workingwith clients in the areas that impact and redefine the core of theirbusinesses. Since its inception into the global landscape after its IPO in1999, HCL focuses on “transformational outsourcing,” underlined byinnovation and value creation, and offers an integrated portfolio ofservices, including software-led IT solutions, remote infrastructuremanagement, engineering and R&D services and BPO. HCL leveragesits extensive global offshore infrastructure and network of offices in 31countries to provide holistic, multi-service delivery in key industryverticals including Financial Services, Manufacturing, ConsumerServices, Public Services and Healthcare. HCL takes pride in itsphilosophy of “Employees First, Customer Second,” which empowersour 77,046 transformers to create a real value for the customers. HCLTechnologies, along with its subsidiaries, had consolidated revenues ofUS$ 3.5 billion (Rs. 16,034 crores), as on 30 June 2011 (on LTMbasis). For more information, please visit www.hcltech.comAbout HCL EnterpriseHCL is a $6.2 billion leading global technology and IT enterprisecomprising two companies listed in India - HCL Technologies and HCLInfosystems. Founded in 1976, HCL is one of Indias original IT garagestart-ups. A pioneer of modern computing and a transformationalenterprise, HCL’s diverse range of hardware and software offeringsspan a wide array of focused industry verticals. The HCL team consistsof 88,000 professionals of diverse nationalities, who operate from 31countries including over 500 points of presence in India. For more onHCL, please visit www.hcl.com

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