Tag Archive for: iso50001

Intro Energy transition and climate neutrality

Before we get to the topic of “towards condition-based maintenance”, here is a higher-level digression. Namely, discussions about climate neutrality have reached a new evolutionary stage. This means that nations are actually addressing it extensively politically. Whereby it is also clear that the competence of political intentions is not reflected in the feasibility of time and technology. However, and this encourages me in this discussion, companies are extremely technologically involved in change. Not to show their charity, of course, but to develop growth-oriented and profitable business models from it. Be it decentralised and renewable energies, e-mobility or the complex issues of a smart grid.

The motivation of towards condition-based maintenance

One thing is certain about all climate neutrality projects: we need a lot more electrical energy. This means that in addition to the many known decentralised generators, other types and systems will also be added to a) ensure security of supply and b) protect against a blackout. For both, for example, the VDE ETG ITG technical committee is currently discussing modern and flexible cellular energy systems.

But the focus is not only on the supply of more energy, but also on the reduction of existing consumption. All this in order to improve the CO2 footprint. ISO50001 helps to achieve this, and in Germany, among other countries, it formally calls for energy saving with subsidies. And this is precisely where the topic of “towards condition-based maintenance” comes in. Incidentally, it could also be called “future-oriented maintenance”. You can read why here.

Why maintenance at all?

Here I briefly explain why maintenance makes sense at all. Of course, I make no claim to completeness, as with all the other paragraphs.

  • To guarantee production reliability and avoid breakdowns as far as possible
  • Extend the service life of the equipment
  • Improve cycle times and thus efficiency
  • Ensure the quality of products
  • Not to impair downstream components
  • etc.

Some key basic problems in maintenance

Already with predictive maintenance, the topic begins to struggle with itself. Namely with the aspect of “looking ahead”. It is often the case that you cannot see inside a system or a machine. Unless the hydraulic oil is already dripping onto the floor. As Mr Pirmin Cavelti of Gubser Service put it: “You can’t really see inside. And just from holding your hand on it, like a glass ball, it doesn’t necessarily get better.”

And why the idea of towards condition-based maintenance?

Manufacturing companies in particular can sing a song especially well: Shortage of skilled workers. Finding suitable personnel for demanding technical and manual jobs is becoming more and more of a tragedy. While these types of professions are attractive in principle, they naturally do not correspond to trendy studies or ITC careers. Furthermore, it has been observed for a long time that plants are being pushed to the limit more and more. One exception would be compressors – but we’ll get to that later.

For the sake of simplicity, I will list a few more reasons that may favour the topic of “condition-based maintenance”:

  • Scarcity of resources for wear material due to the current COVID shortage
  • Maintenance is shown as a pure cost factor in the P&L and not seen as a benefit
  • Lack of or inadequate maintenance strategies
  • Rapidly increasing digitalisation in all areas
  • CO2 reduction with national energy strategies
  • Measures versus results (lack of “fitness coach”)
  • Reduced cost budgets to secure and increase margins
  • Demand for more documentation and evidence
  • Trend towards number orientation and balancing in “extra-monetary” areas
  • etc.

Possible solution parameters for condition-based maintenance

If we now look at examples of motors that are used to drive something or to generate something, we can draw on informative parameters. These already indicate the current “state of health” of a drive system. These would be, as always not conclusive, as follows:

  • Temperature
  • Vibration
  • Cavitation
  • Electrical quantities
  • Ultrasonic
  • Humidity
  • Existing historical values
  • etc.

If these parameters are now considered in a permanent context, i.e. as a whole, completely new insights can be gained. Specifically, we already know the individual parameters that make up a “normal” operation. If you now apply various limits and threshold values to all parameters, you can visualise the state of the system in a short time and, if necessary, intervene at an early stage. Or vice versa. Instead of intervening at intervals, you can see the actual state, whether it would be necessary at all.

Temperature and ultrasonic as important indicators

The temperature on motors, bearings, etc. as well as the measured ultrasound in dB on bearings, shafts, gears, etc. provide important information. For example, the ultrasound value changes upwards, i.e. it becomes louder, targeted and dosed lubrication measures can be carried out. If the dB value is reduced, the lubrication has a positive effect. Does the value increases during lubrication, overlubrication could be the cause. If the dB value continues to increase permanently, this could indicate a defect in the near future, which could also be seen as a symptom in the rising temperature.

Electrical values as very useful additional information

Here, you as a maintenance engineer and operator have the opportunity to save energy by intervening at an early stage. This can be seen very quickly by recording the electrical characteristic curves. With their help, increased and reduced KW/h can be expressed immediately in money and CO2. In addition, trends can be derived from the electrical parameters, such as when which power consumption takes place, which efficiency levels the motors have and how they change, etc. Even grid-specific phenomena would become visible, e.g. harmonics, transients during switch-ons or switch-offs, interruptions, etc. Furthermore, you would already be able to find out in which load behaviour your drives usually are. This is particularly interesting for compressors whose (non-)generated compressed air costs the operator enormous amounts of money.

And now imagine that all this would be integrated into an energy monitoring system in your company – i.e. absolutely scalable for all company areas and their infrastructure. Not only for maintenance.

What could such a system look like?

To simplify matters, I’ll let pictures speak for themselves here.

Towards condition-based maintenanceTowards condition-based maintenance with gears

Towards condition-based maintenance at bearings

Barriers to condition-based maintenance?

In the interest of fairness, however, we should also address the elements that are less favourable to the issue of “condition-based maintenance”. These would be as follows:

  • Saving energy means technical as well as HR-intensive initial effort and requires investment
  • Investments have to be approved and are anchored in the annual budget
  • Electricity costs (KW/h) are too cheap in many countries ≠ Energy saving
  • Repairs are usually not investments and easier to approve (forced investment)
  • Predictive maintenance at time intervals is easy and can be planned well
  • etc.

Conclusion of condition-based maintenance?

In summary, we can say that the topic of condition-based maintenance can generate the following benefits:

  • Matching motors to drives (efficiency)
    Damage detection
  • From predictive maintenance to condition-oriented and thus future-oriented maintenance
  • Recognising if and when problems are imminent
  • Maintenance is only carried out when the condition indicates the need for it
  • Logbooks, documents and records are automatically digitised.
  • Automatically contributes to CO2 reduction
  • ISO50001 compliant
  • PEX and OPEX are automatically reduced
  • The whole system is scalable – ROI is fast.
  • There is no need for a maintenance strategy for the objects in question, as this is automated
  • Sustainability and resource conservation are positively influenced
  • The data can be balanced
  • etc.

In this article we will show you possible fields of application for measuring instruments. Certainly, this is only one option and not conclusive.

 

Fields of application of measuring instruments

Especially in the area of data monitoring you rightly demand a highly appealing HMI [Human Machine Interface]. Finally, a multifunctional system overview is to be generated from this. However, you should keep the growing complexity in mind. There is a danger of creating new data graveyards that previously cost money and produce no benefit. It certainly doesn’t help you to seemingly see more and more. And still you lose the overview due to an excess of information.

Multifunctional system overview? What can help you

We suggest the SmartCollect® SC² for this purpose. This is a scalable HMI/SCADA software. This conveniently visualizes your measurement data. Either for your electrical distribution as well as other physical quantities. But the software can also process physically independent information. Unlike the usual less visually appealing SCADA software systems, the SmartCollect® SC² is built on a new ultra-modern web-based platform. In the following you will learn more about the essential core modules.

Interactive single line diagram as multifunctional system overview

Interactive one-line diagram of the SmartCollect SC2

In principle, the structure of the software begins with this module. It continuously monitors all the data included in the
Infrastructure integrated circuits. In doing so, it offers you a compact overview. For the overview display as a single line diagram, you can effortlessly define your individual application design. Tailored to your needs.

Interactive 2D/3D views for your manager perspective

Interactive 2D/3D views of the SmartCollect SC2

Would you like to see energy infrastructure from a manager’s perspective? This is how you want it to be as a business manager or even as a manager with overall responsibility. In fact, this allows you to monitor specific individual performance indicators of a factory, a single plant, an entire complex, etc. Last but not least, to possibly benchmark with other comparable companies or locations.

Multifunctional system overview from the energy monitoring system [EMS]

Energy Monitoring System [EMS] of the SmartCollect SC2The high level of data collection gives you full transparency on energy data. For analytical purposes (e.g. reduction of CO2 emissions, increase of energy efficiency as well as for evaluation of savings potential, etc.) the EMS supports you. Various panel views within the EMS dashboard help you to do this. In addition, various reporting functions support you in your individual business analytics.

Multifunctional system overview with a sophisticated zoom function

Sophisticated zoom function of the SmartCollect SC2The zoom function allows you to perform detailed analysis directly on the dashboard. When zooming, all parameters in the overview are synchronized on the dashboard. Thus, you are able to put all related quantities in relation to each other.

Best in class WebGUI integration

Optimal WebGUI integration of the SmartCollect SC2The software supports your individual integration of device WebGUIs. This allows you to directly access various additional details of the measuring point, depending on the device function. You can also easily perform remote configuration. At Camille Bauer measuring devices, of course, exclusively with the very high cyber security standards according to ENEL GSTQ901.

Functional trend dashboard as multifunctional system overview

Functional trend dashboard of the SmartCollect SC2The state-of-the-art trend dashboard reliably shows you all relevant information. You have a permanent overview of all critical measured values. The data design is built to your individual needs. Again, the nifty zoom function helps you analyze. In addition, you define your individual time ranges that you want to overview as a trend.

Flexible data communication – a must

The software also offers you a wide variance of different data formats. This for your incoming, outgoing and protected data (e.g. Modbus TCP/IP, IEC61850, DNP3, IEC60870-5-104, UPC UA/DA, etc.). You can also export data in csv format by default. And this in actual raw format or also formatted for an MS Excel application. Other formats can be programmed and configured individually.

Learn more at SmartCollect® SC².

“The latest version PQDiffractor is now available for download online.”

But what is actually the current version of the PQDiffractor?

Power Quality software, such as PQView 4 or DranView 7, provides you with a smooth interface for viewing PQDIF and COMTRADE files. In addition, the software solutions offer a wealth of other functions, for example for monitoring and analyzing power quality. But what if you are afraid to invest in software because you only need a view for rough analysis? There are two possible solutions for this. First, the latest version of PQDiffractor and second, a multifunctional web interface.

The current version of PQDiffractor works as a PQDIF and COMTRADE viewer for viewing, searching, diagnosing and converting PQDIF and COMTRADE files. And this free of charge.

Option 1: The viewing and analysis of the data using the current version of PQDiffractor.

PQDIFFRACTOR

If you only need one viewer, PQDiffractor® the free PQDIF and COMTRADE viewer is just what you need.

Main functions of current version PQDiffractor:

  • Reading binary PQDIF files using IEEE Std 1159.3-2003 specifications
  • Reading of ASCII or binary COMTRADE files using the specifications of IEEE Std C37.111-1991 or C37.111-1999
  • View lists of the data source records in each PQDIF file.
  • Displaying lists of analog and digital channels from COMTRADE configuration files
  • Create interactive graphs from PQDIF observations with channels of any size type.
  • Displaying samples from analog COMTRADE waveforms and digital status channels
  • Exporting the displayed observations to Microsoft Excel as CSV files

And you have read correctly. The current version PQDiffractor is free of charge and connects you to the latest MAVOWATT, HDPQ, LINAX PQ3000, LINAX PQ5000, LINAX PQ1000 and LINAX PQ5000-MOBILE devices without any problems.

Option 2: The viewing and analysis of the recorded PQ data via integrated web-browser.

Web Browser

No external software is required for parameterization of the measuring device or evaluation of the measurement results. Das Webinterface stellt alle notwendigen Funktionen zur Verfügung. These functions can be accessed via end devices (e.g. smartphone, tablet, laptop, desktop, server via LAN or WLAN interface) using an IP address. A responsible WebGui guides the user through the menus. The simplicity of operation is to be emphasised. Because the advantage is obvious: There is no need for external software that causes additional headaches for administrators. And this for mobile as well as stationary applications. And it’s Cyber Secure.

Fields of application for the current version of the PQDiffractor as well as the integrated web browser

  • Smaller distribution grid systems
  • Municipal utilities
  • Energy generators (e.g. large PV plants, wind farms, hydropower, coal and gas, nuclear, etc.)
  • Industry (e.g. semiconductor, steel, automotive, pharmaceutical, aviation, etc.)
  • Infrastructure (e.g. rail, metro, airport, etc.)
  • Data centres
  • Clinics
  • Laboratories
  • Institutes
  • Higher education institutions
  • Universities
  • Authorities
  • Military
  • Applications to be reached remotely via VPN
  • etc.

The SmartCollect SC² energy monitoring system, known as EMS for short, gives you full transparency of energy data in accordance with ISO50001. For analytical purposes (e.g. reduction of CO2 emissions, increase of energy efficiency and evaluation of savings potential as well as energy audits), the EMS supports you with relevant panel views within the EMS dashboard. Various manual or automatic reporting functions help you with your individual business analytics.

Read more

In the SmartCollect SC² dashboard, all the information you need is displayed reliably and in a structured way. In doing so, you keep an eye on all critical measured values. The data design is tailored to your individual application and user needs. In addition, the measured values are automatically synchronised with each other by the system and can be used by you for analysis by means of a sophisticated zoom.

Read more

With its hardware and software network components, an IT infrastructure represents a complex and sometimes very complicated system. Especially if you want to map and optimize the energy infrastructure across companies.

SmartCollect®SC², with its web-based architecture, can help overcome a lot of headaches while still providing the highest level of security. In this blog you will find two main types of installation. On the one hand, the so-called “Single Node Installation” (single node connection) and on the other hand, the so-called “Distributed Installation” (distributed connection).

SIngle Node Installation of SmartCollect SC2

Single Node Installation of SmartCollect SC²

 

Distributed Installation of SmartCollect SC²

Distributed Installation of SmartCollect SC²

SmartCollect® SC² is a scalable HMI/SCADA software. Unlike the usual less visually appealing SCADA software systems, SmartCollect®SC² is built on an ultra-modern platform with a web-based 2D/3D graphical user interface. In addition to the high user-friendliness of SmartCollectt®SC², the system offers powerful communication and software interfaces as well as flexible expansion options.

The software is currently available in 4 editions:

  • Starter Edition
  • Standard Edition
  • Professional Edition
  • Enterprise Edition

In addition, the software can be equipped with a modern Energy Monitoring System (EMS) as a plug-in.

Key Features of Software:

  • Interactive single line diagrams
  • Functional dashboards
  • Secure web based design
  • Event and warning messages
  • Flexible data communications
  • Integration of devices from different manufacturers
  • Interactive 2D/3D views
  • EMS: Energy Monitoring System (Dashboard & Reporting)
  • Sophisticated zoom functions
  • Custom WebGUI integrations