HAZARDOUS AREAS DiGitalisation in hazarDous inDustriEs


Marek lukaszczyk, European and Middle East marketing manager at global motor manufacturer WEG, discusses how digitalisation can reduce risk and improve efficiency in hazardous industries.


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operators, which is costly, slow and labour intensive, with difficult to reach areas. The MTC’s concept robot is tetherless, with the ability to operate autonomously and navigate confined areas, enabling the operator to focus on the inspection. The robot has successfully undergone


simulated trials at the Synthotech test facility in Yorkshire. Simon Langdale, engineering director at Synthotech, says, “It’s been great to put this proof of concept though its paces in a range of simulated environments. Automation of inspections for pipes is a key area that can help build better understanding of the complex infrastructure underground. We have been able to benchmark our current live access robotics against automated robotics and make sure that we can stay at the cutting edge with support from the MTC."” The MTC showcased its robotics


capability and innovative net zero manufacturing technologies at Utility Week Live at the NEC Birmingham in May. As well as displaying its autonomous robotic rat and showcasing real-world applications of Spot the robotic dog, the MTC demonstrated its hydrogen capability where it builds on its manufacturing technology heritage to support and enable the hydrogen industry at every stage of the value chain, from production through to storage and transportation to end use. The MTC aims to provide a competitive


environment to bridge the gap between university-based research and the development of innovative manufacturing solutions, in line with the Government’s manufacturing strategy. The MTC is part of the High Value Manufacturing Catapult, supported by Innovate UK.


Manufacturing technology Centre www.the-mtc.org


hazardous area is any area with an atmosphere containing, or potentially containing, gases, vapours or dust which are flammable or explosive. Industries


such as oil and gas, chemical production, fuel storage and even paper production are all classed as hazardous. These areas are rigorously analysed when installing equipment to minimise the risk to individuals and assets. It is crucial that equipment operating in these


conditions are effectively monitored to pre-empt any issues before they occur. Unlike most industries, these issues not only result in downtime, but present a significant safety risk.


Monitoring Matters


Condition monitoring is integral in industrial operations to avoid downtime, to implement maintenance and to reduce the risk of failure. Remote condition monitoring has previously been limited in hazardous areas due to the lack of cost-effective and easy to install solutions - and the often-challenging environments in which this equipment exists. For example, equipment used in subsea applications or on offshore operations cannot be monitored as frequently or easily.


quickly and minimise unplanned stops. This is especially important in hazardous areas, where failure can result in loss of production. According to Kimberlite Oilfield Research, even a one per cent increase in downtime can cost an oil and gas company up to $5.037 million. With a current average of 27 days of downtime on offshore platforms annually, this adds up to $38 million in financial losses, making it even more important to reduce the potential for error. Planning and carrying out repair operations may be time consuming in hazardous areas and can require specialist resources or procedures which may not be immediately available, making effective monitoring even more advantageous. MFM works in combination with WEG Motor


Scan and WEG Drive Scan - sensors which can be installed in assets to measure their vibration, temperature and running hours and to upload this data to the cloud via the WEG Motor Scan Gateway. All sensors in the plant can be connected and the data can be accessed remotely and in real time, and users can configure tolerances to generate alerts in case of errors. The platform also offers increased fleet


Using digital solutions can offer a viable and


safe way to address the challenges involved with hazardous area monitoring, minimising the need for manual inspection and intervention. WEG Motion Fleet Management (MFM) is a robust digital solution for data collection and condition monitoring of industrial assets. Using cloud computing, operators can easily access the operational status of equipment including motors and drives in any industry or location. MFM collects and processes data regularly both at the edge and in the cloud to generate important information on asset operation. Operators can use these insights to develop predictive maintenance plans and carry out condition-based maintenance. Periodic data collection gives a more


thorough overview of asset condition, removing the need for maintenance teams to carry out observations and collect data manually. Having access to this data more frequently can allow maintenance teams to make informed decisions


visibility remotely, allowing engineers to monitor assets from anywhere in the world. This is key in hazardous areas, for example, in offshore oil and gas operations where assets may not be easily accessible. WEG MotorScan also has Inmetro, ATEX, IECEx and MASC hazardous area certifications Ex ia I Ma, Ex ia IIC T4 Ga and Ex ia IIIC T135°C Da. These codes refer to the level of safety when


installing the product in a hazardous area, and WEG Motor Scan is classed as intrinsically safe for Category 1 environments with a continuous risk of explosion due to the presence of gas or dust. This is due to its low power requirements and thus low temperature and minimal energy of sparks, reducing the chance of an explosion. Digitalisation is increasingly present in


industrial settings and is proving to be an invaluable addition to many operations. Using digital solutions in hazardous industries can not only improve efficiency and reduce downtime and maintenance costs, but can offer significant benefits in safety and risk mitigation.


WEG www.weg.net


inDustrial CoMplianCE | MaY/JunE 2022 11


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