Mikko Mäkäräinen

Remote Monitoring

Development and Support

Engineer

North Europe Area

Oy SKF Ab, Service Division

mikko.makarainen@skf.com

Condition Based Maintenance (CBM) is a process by which plant managers scrutinize the ongoing status of operating machinery in order to detect – and hopefully prevent – significant changes or events that could ultimately lead to the deterioration or failure of the equipment.

It is a process that speaks directly to the bottom line. CBM gives managers a systematic approach to maintenance that can help them better control key aspects such as costs, safety, output, downtime and the overall quality of the product.

Identifying and monitoring various factors such as temperature, oil quality, and equipment vibration can help managers establish a clearer appreciation of future expenses. By establishing a better understanding of how technical issues relate to overall business needs, they can also realize an important competitive edge.

At the same time, replacing a company’s existing maintenance process with an effective CBM system can be an expensive, costly endeavour. Fortunately there are cost-effective solutions available.

Remote Monitoring Services

With web-based access to condition monitoring analysis applications and the latest condition monitoring equipment, managers can remotely monitor locally-sited or more widely distributed equipment. For example, vibration measurement equipment today is designed to communicate via the Internet, giving managers the option of monitoring on either a periodic, or continuous basis.

Remote Monitoring Services enable end users to monitor unmanned and even very remote sites, such as hydro or wind turbines. And by centralizing the monitoring process it makes it possible to standardize and synchronize procedures for predictive maintenance. This makes it easier to diagnose the condition of critical equipment regardless of where it is located or who is responsible for on-site maintenance.

Remote Monitoring Services can offer not only increased assurance, but also flexibility. For example, managers can typically select a simple hosted application, or a more expansive approach that utilizes the knowledge base of an experienced provider. At the same time, they enable companies to avoid the costs and other issues involved in setting up an in-house programme. 

With remote solution customer achieved a quick start-up of condition monitoring while at the same time gaining added benefit from supplier’s knowledge and analysis of its equipment.

Cloud Services

– A New Driving Force

The concept of “cloud computing” is a growing force in business that ties directly into the continuing development of Remote Monitoring Services. A growing number of companies today are moving their applications from local application to software application as a service (SaaS). SaaS is defined as software that’s developed and hosted by a SaaS vendor and available to customers through web-based access – requiring only an internet browser to use (hence, the “cloud”). This is different from traditional boxed applications where end-users purchase the software and install it on their computers or servers. With this cloud services framework, the vendor owns the software and runs it on computers in its data centre.

For the end-user, this presents significant advantages in terms of flexibility in application licensing and related costs. Cloud services change the way to get applications and resources without any local installations or start-up costs. Cloud services provide a more dynamic way to purchase the licenses and resources and allow faster start-up for using applications and resources. Software patches, revisions or new versions are all automatically implemented. In addition, the software operates and performs more efficiently because the entire network is running the same version of the application.

Practical Operational Model

SKF Remote Monitoring Services solutions options begin with simple hosted applications, and range all the way up to providing round-the-clock accessibility to our store of knowledge and expertise in machinery diagnosis. Condition monitoring software and the latest data collectors provide the framework that powers a range of available options.

Our Remote Monitoring Services feature SaaS applications that enable users to avoid costly investments by using cloud computing and application virtualization. SKF’s use of SaaS brings together cutting edge technology and cost savings by providing a service that reduces capital investment while at the same time offering users the same ability to collect, store and create databases at an offsite location known as a Remote Diagnostic Centre (RDC). 

Security is paramount. Our RDC servers are deployed behind firewalls and are virtually invisible to the public internet. Only customers and server administrators have the account information necessary to access the server and/or their data. No personal information about customers or users is stored on the RDC server. In addition, daily and weekly backups are stored in multiple locations and optional site-to-site VPN connectivity is available between customer sites and the RDC server. Our Remote Monitoring Services offer the following three basic approaches to managing clients’ needs:

The Comprehensive Solution

This comprehensive solution places the majority of the process in the hands of the supplier who oversees the PdM from start to finish. This solution includes initial setup of the client database, data collector use or purchase options, multiple site functionality, full monitoring of assets and monthly reporting. All data is stored and monitored centrally by specialized experts at the RDC. Any necessary maintenance is reported immediately. This solution is configured primarily for clients with limited staff or resources.

A Business Partnership Solution

This approach focuses on building a partnership between the client and service supplier. Clients take a more interactive role in the types of data collected. A client’s database is set-up by a service provider’s professional in partnership with the client, utilizing best practices for collecting and entering data. Once the database has been created, clients can retrieve information at the RDC from anywhere in the world and can begin to institute a PdM that reflects the client’s specific business goals. Clients still have data collection use or purchase options, as well as multi-site functionality. In addition, clients may have full or limited access to analysis software and other capabilities of the RDC. In the meantime, the supplier stands ready to provide an informed second opinion from experts and can help guide the PdM. This is a solution geared toward a client looking for more of a hands-on approach in terms of maintenance.

Do-it-Yourself Solution

This solution is designed for a client looking for privacy or a non-intrusive role from a provider. Clients have total control over their PdM with full access and use of SKF @ptitude software hosted by the RDC. Data collection reports and developing trends are the client’s responsibility. Again, the supplier is positioned to provide clients with an invaluable second opinion. And clients can have access to all available tools to make informed decisions that best suits their needs.

Remote Monitoring Services

– Case Study

Small and unmanned sites typically are the most common locations for remote monitoring services. For example, small hydro power plants often do not have an established condition-monitoring process, but they do have critical machinery that should be monitored. Such facilities also tend to be distributed across a wide area, which can make it difficult to carry out efficient monitoring with low resources.

This was the case with a small hydro power plant owner that had two hydro power stations that included a total of three turbines. The primary reason the plant owner sought a monitoring solution for its equipment involved a complex problem with turbine gearboxes. Spare parts for the gearboxes incurred an unusually lengthy delivery time. As a result, a solution that would provide continuous monitoring of this critical equipment was crucial. Because the plant owner had insufficient resources to do its own comprehensive monitoring of the equipment, a search was made for another solution to monitor the gearboxes and thus avoid unscheduled breakdowns. 

Click Image to Enlarge

Remote Monitoring Services enable end users to monitor unmanned and even very remote sites, such as hydro or wind turbines.

New solution to an old problem

The plant owner approached us to explore a possible solution to the problem. Our professionals investigated the situation at plant sites and after discussions with the client, suggested a new approach involving Remote Monitoring Service and its hosted interface applications. The plan incorporated two on-site units to measure two turbines on a 24/7 basis. The units were set to measure signals from the accelerometers, displacement probes and process signals to assess the operating condition of the turbines. Simultaneously it was agreed that the supplier performs the follow-up and analysis and report the status of the two turbines regularly. SKF @ptitdue HMI (Human Machine Interface) was selected as the specific interface for the plant operators.

With this solution customer achieved a quick start-up of a new condition monitoring system while at the same time gaining added benefit from supplier’s knowledge and analysis of its equipment. Rather than investing in new personnel and time-consuming training, the plant owner could focus instead on its core business on generating power.

For the plant operator, the decision to use software as a service made the start-up cost lower than what would have been possible with its own local installation.