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IoT for Condition Monitoring and Predictive Maintenance in Water Treatment Plants

Client

A leading power and water utilities company.

Industry

Utilities

Overview

Centrifugal and high-pressure pumps are the most important assets at water treatment plants. To monitor performance and efficiency of these pumps, our client followed a calendar-based vibration and temperature monitoring process that captures data based on a predetermined schedule. This data is manually entered into a spreadsheet, and forms the baseline to analyze threshold variations. Apart from the time and effort involved, this process was highly error-prone. Inability to identify and determine cause of deviation from normal values often led to time- and cost-intensive breakdowns.

To overcome the problems associated with manual monitoring of pumps, we proposed SeeMyMachinesTM, an Industrial Internet of Things (IIoT) solution for condition monitoring and predictive maintenance.

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Business Requirement

  • Remotely monitor condition of assets in real-time with insights into operational aspects such as vibration, temperature, water quality, and flow
  • Predict failures and identify performance deterioration
  • Extend pump life by attending to problems early
  • Minimize losses caused by pump failures and unplanned maintenance activities

QBurst Solution

We deployed SeeMyMachines, an Industrial Internet of Things (IIoT) solution that captures data from equipment by interfacing with controllers and/or sensors.

Deployment was done in a phased manner with the pilot implementation covering six pumps at one unit. This involved commissioning, calibration, data collection, portal setup, configuration, cloud access, and online monitoring. Subsequent phases were completed in eight months with connectivity established across 174 pumps.

SeeMyMachines provided a bird’s-eye view into the condition of pumps, with performance data available 24X7 in real-time. The platform supports web as well as mobile interfaces to access equipment data from anywhere through secured and authorized connections.

Key Features

  • Dashboards and interactive visualizations
  • Asset Lifecycle Management
  • Remote Condition Monitoring
  • Predictive Maintenance
  • Digital Task Management
  • Maintenance Records
  • KPIs and Statistics

Business Benefits

  • Automation of condition monitoring process resulted in savings of 4800 man hours in the first year following implementation
  • Increased frequency of data capture resulted in accurate failure prediction and measurement
  • The ability to foresee failures and perform maintenance on an as-needed basis rather than on a set schedule significantly enhanced workforce efficiency
  • Reduced downtime and improved equipment and plant availability
  • Predictive maintenance ensured timely intervention and an increase in functional life of equipment

Technologies

Hardware
  • WirelessHART
  • WiFi Repeaters
  • Edge Device
Software
  • Spark
  • Amazon DynamoDB
  • Amazon S3
  • Amazon EMR
  • AWS Lambda
  • Parquet
  • Amazon Glacier
  • Amazon ElasticCache
  • Amazon Kinesis
  • Android

Business Requirement

  • Remotely monitor condition of assets in real-time with insights into operational aspects such as vibration, temperature, water quality, and flow
  • Predict failures and identify performance deterioration
  • Extend pump life by attending to problems early
  • Minimize losses caused by pump failures and unplanned maintenance activities

QBurst Solution

We deployed SeeMyMachines, an Industrial Internet of Things (IIoT) solution that captures data from equipment by interfacing with controllers and/or sensors.

Deployment was done in a phased manner with the pilot implementation covering six pumps at one unit. This involved commissioning, calibration, data collection, portal setup, configuration, cloud access, and online monitoring. Subsequent phases were completed in eight months with connectivity established across 174 pumps.

SeeMyMachines provided a bird’s-eye view into the condition of pumps, with performance data available 24X7 in real-time. The platform supports web as well as mobile interfaces to access equipment data from anywhere through secured and authorized connections.

Key Features

  • Dashboards and interactive visualizations
  • Asset Lifecycle Management
  • Remote Condition Monitoring
  • Predictive Maintenance
  • Digital Task Management
  • Maintenance Records
  • KPIs and Statistics

Business Benefits

  • Automation of condition monitoring process resulted in savings of 4800 man hours in the first year following implementation
  • Increased frequency of data capture resulted in accurate failure prediction and measurement
  • The ability to foresee failures and perform maintenance on an as-needed basis rather than on a set schedule significantly enhanced workforce efficiency
  • Reduced downtime and improved equipment and plant availability
  • Predictive maintenance ensured timely intervention and an increase in functional life of equipment

Technologies

Hardware
  • WirelessHART
  • WiFi Repeaters
  • Edge Device
Software
  • Spark
  • Amazon DynamoDB
  • Amazon S3
  • Amazon EMR
  • AWS Lambda
  • Parquet
  • Amazon Glacier
  • Amazon ElasticCache
  • Amazon Kinesis
  • Android

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