Data acquisition
historical data analysis is the basis of the real advantage for diagnostics; identifying trends over time gives the capability to make effective preventative maintenance.
By continuously monitoring data over a long- term period, maintenance teams can detect drift or inconsistencies to identify, and resolve, issues that could develop into significant challenges if left unchecked. This could range from corrosion caused by elevated pH levels over a long period, through to malfunction resulting from extended exposure to excess heat.
As well as monitoring parameter levels that could cause maintenance problems, data analysis can also directly inform on component or system health. Setting up an alert according to the number of cycles completed by a pilot valve, for example, can action a maintenance check, and any remedial action required, before an unexpected breakdown due to end of life can occur.
IMPLEMENTING DATA DIAGNOSTICS If the process system already involves sensors for purposes of production quality and safety, data could be drawn from these sources. However, if new data capture devices are required, a
Instrumentation Monthly September 2024
common challenge to implementing data diagnostics for maintenance needs is the requirement for PLC integration and the demand on programming expertise. Today though, a range of sensors and meters are available with integrated PC tools to enable fast commissioning and straightforward operation, without requiring programming expertise. These devices are usually available with Ethernet-based communications, such as Profinet, so they can also integrate with PLC systems when required. Valves are vital to virtually all process control systems, and to manage a valve array and enhance preventative maintenance, a valve island like the Bürkert Type 8652 can send data to any configured device, ranging from a smartphone to a PLC. This enables remote monitoring with automated, configurable alerts. It can also achieve trend monitoring and historical reports, with data relating to parameters such as switching time function or manifold pressure, through to total number of cycles. To monitor the parameters of the media involved in the process, a variety of sensors for maintenance diagnostics can also be integrated without the direct requirement for a PLC. For example, to monitor drinking water or fresh water
in industrial processes, the Bürkert Type 8906 Online Analysis System enables the modular integration of sensors such as pH, free-chlorine, and turbidity, that can also be monitored remotely via available GSM modules. These sensors can also be combined with volumetric flow meters that can also provide diagnostic data in addition to their typical process control roles.
LOW COST OF OWNERSHIP
Although the integration of data for diagnostics requires planning, the initial time investment can pay dividends to achieve more efficient maintenance engineering long-term. The data- driven approach means a more proactive response to maintenance, without the need to increase available engineers.
While maintenance teams may be able to draw on the data available from already installed hardware, even if investment is required for equipment such as additional probes or valve islands, the resulting productivity gains from enhanced diagnostics can generate a low total cost of ownership for the long-term.
Bürkert Fluid Control Systems
www.burkert.co.uk
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