Your Industry Needs
Here we’ve collated the typical assets, sensors and tech used, industry by industry, to increase production and revenue through Asset Health Monitoring, with user examples below of how clients have harnessed the value and benefits that you could potentially be missing out on
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AHM by Industry
Below are some examples of how clients from your industry have increased their performance through asset health monitoring…
Oil & Gas
Business problem
-Valve monitoring
–Speed at which a valve opens and closes – around 30 seconds
–If the valve takes longer to close it can start to cause issues elsewhere
Solution
–Currently most companies collect data on almost all of their assets and store them in spreadsheets
–Most of the time a lot of this data goes unused
–We propose using this old SCADA data
–With this data and our tools we can set thresholds and monitor for unusual signs from the data that could indicate a fault
Business Value Delivered
–Change in time between opening and closing
–Cheaper to fix something before it breaks
Water Utilities
Business problem
–Boilers generating and providing power to plant
–These boilers are frequently shut off due to a number of issues, and need regular inspection and maintenance
–Increasing the life of a boiler
–Lowering failure rates of boilers
–Long term history of the conditions of a boiler
Solution
–We propose a boiler monitoring solution using IoT sensor data, weather data and historical data and tracking to monitor the health of a boiler and to reduce the amount of time lost due to downtime and failures caused by common issues on a boiler.
–A lot of common issues are around loss of pressure, ineffective heating or monitoring of heat due to faulty equipment and using electrical current sensing to notice changes that could result in issues.
Business Value Delivered
–Cost of electricity due to running through the boiler not on the grid.
–Reducing the amount of working hours lost due to injuries in the workplace.
–Obtaining a greater understanding of the various factors contributing to Boiler failure.
–Understanding the effects changes in the environment have on a boiler e.g. cold weather means more current drawn?
–Reducing the amount of maintenance performed on the boiler due to previously unforeseen effects.
Power Generation
Business problem
–Transformers lose efficiency over time
–This causes the amount of current going through it to increase to achieve the same results on the other side
–One of the largest issues is the transformer oil degrading
–This causes a build up of gas inside the transformer
Solution
–Depending on the size of the transformer there are different options
-Some large transformers could be fitted with IoT enabled gas sensors to see this build-up over time
–For the smaller transformers we can look at the overall asset health by monitoring other attributes like temperature, current in and out, oil temperature and ambient temperature
Business Value Delivered
–Longer life transformer
–Better power transfer
–Less loss from using more electricity
Manufacturing
Business problem
–Car manufacturing company produces vehicles with a ‘tact time’ of around 1 minute per vehicle.
–Profit per vehicle is around £5000
–If the plant has unplanned breakdowns the cost is around £5000 per minute.
–There are many ways to stop the production line
•Machines may breakdown without warning
•Parts may not be available for vehicle assembly
•Team members may leave their workstation (this is very rare)
•Team members may identify a production quality problem – in which case they use an Andon system to stop the plant and notify management.
Solution
–This line uses automated guided vehicles to move parts around the plant
–These vehicles are all charged the same, but some carry different loads
–This causes some to stop due to low charge before the others and causes a stoppage in the plant
–Using IoT sensors we are able to monitor the current of each of the vehicles and know when they will discharge and can prepare for this
Business Value Delivered
–A number of AGVs were modified to allow battery voltage monitoring – this was a very inexpensive
–The software costs to the customer were also minimum
–The customer got immediate value from the solution and have started to roll this out to other parts of the business.
Ports
Business problem
–Container tracking
–Large amount of containers stored and lost inside of shipping ports
–Lack of space for new containers
–Time spent finding missing containers slows down the port
Solution
–By using GPS Tracca sensors by Entopy
–These sensors have a 10-year battery life and GPS chip
–They can either be pinged or setup to send an alert with location out at set intervals
–Small and easy to attach to containers without effecting the container
Business Value Delivered
–Containers can be located through an app which can be send by either the port or the customer to ensure their containers location
–Allows staff to more easily find the containers and move them to the required location without wasting time on locating them
–(struggling to find a statistic about the amount lost in ports only find lost at sea)
Airports
Business problem
–Baggage handling discrepancies
–Failure in the handling system can have an effect around the whole of the airport and guidelines are set by governments for time taken in baggage handling with fines for failure to meet this.
–Something like downtime in the handling system can set back flight times and space on the runway
–Lighting issues (IAC BECKOFF)
–Airbridges and comfort levels – too warm inside has caused passengers to faint
Solution
–Sensors on the baggage handling, vibration/temperature sensors on motors
–Lighting issues can be sorted using a Modbus gateway to control all lights in an airport – at any one point in time 20 bulbs could be broken or flicking around an airport (exact number could be found from IAC)
–Sensors monitoring the temperature inside of airbridges
Business Value Delivered
–Baggage handling – late baggage causes delays at the airport and company's like Swissport would have to cover this cost – faults from other sources could also be found but changing situations on the belts.
–Lighting issues – cost of bulbs due to wear and tear – reduce the number of lights switch on with no one around.
–Less time spent in terrible conditions on airbridges
FM (Facilities Management)
Business problem
–Large office spaces and meeting rooms with bad ventilation can cause a build up of co2, once co2 starts to cross a few different thresholds it can start to effect people and cause drowsiness and headaches – 800 is average – 1500 loss of productivity
–Empty rooms booked on a system can cause a shortage of meeting room space (ask anyone who works in Southbank!). These empty meeting rooms are also used by people who see them empty and sit in there alone wasting space in an office.
–Cleaning is currently done on a regular cycle, however sometimes people are cleaning areas that don’t need it and sometimes other areas have been left in a poor state for a large amount of time
Solution
–Enocean climate sensors which measure co2 and also temp/humidity can be placed around an office and in meeting rooms to help to understand problem areas in offices
–Room monitoring can also be done with Enocean under desk sensors which will send a signal for change of state from empty or occupied, and will send reminders every 15 minutes for the state of the room – MODCAM sensors can also be used, these can help be put into the main office area and help with hotdesking space and demographics
–Using motion sensors again here we can put them in areas and set alerts to understand how the areas are frequented to change around the priority of the cleaning cycle
Business Value Delivered
-Better working conditions in the office can cause staffs productivity to increase with them working until finishing time with around 5-7% increase
–Room booking and space inside an office can help with auditing and could be tracked easily by employees to know if these space to come in (example of this from Sweden)
–Staff waiting to clean areas on a set time could change to cleaning as a service
Civil Infrastructure
Business problem
–Water levels in rivers, lakes, reservoirs
–Cracks or leaks in damns
–Displacement/Vibration of bridges and structures
Solution
–‘Senceive’ sensors
•Long range low power sensors
•Crack sensing/Displacement sensing/Vibration
–Flow meter sensors – either by laser or materials that absorb water at different rates – Enocean sensors
Business Value Delivered
-Using high accuracy sensors to measure the change by mm structures move, this can aid in detecting potential issues such as cracks before they form
–More accurately measuring water levels from a central area to help mitigate the chance of flooring, either by early warning or by using the information to direct the flow to fewer problematic areas.
