Efficient Plant April 2021 - 14

Sensors connecting
assets to an integrated
condition-monitoring
system greatly bolster
reliability and productivity by detecting abnormal
patterns and predicting
downtime events well
ahead of actual failure.

feature | condition monitoring

Advanced condition
monitoring solutions
reliably track asset
performance and prevent
costly downtime.

Integrate a CMS

Luis Narvaez
Siemens Industry

To Monitor Asset Health
STAYING COMPETITIVE IN today's environment is challenging.
It's made more difficult as customers seek customized products at
the prices of mass-produced goods. Furthermore, growing global
ecological awareness and rising energy prices are motivating many
companies to work toward carbon neutrality, for reasons of cost and
reputation. These, and other factors, require manufacturers to assess
and potentially modify their production processes.
To face these challenges, manufacturers have access to modern
tools that propel them to success in the digital age, but they must be
vigilant to ensure maximum efficiency and subsequent profitability.
Unplanned downtime is a key inhibiting factor to achieving these
objectives. Although it's impossible to completely eliminate downtime, an integrated condition-monitoring system (CMS) can provide
a reliable and cost-effective means of keeping assets operating at
optimum efficiency.

NEW MAINTENANCE STANDARD
A modern integrated CMS greatly bolsters system reliability and productivity without breaking the bank by analyzing real-time condition
and performance data collected by sensors. These systems can detect
abnormal patterns and predict downtime events well ahead of actual
failure. This data is also used to pinpoint root causes. Unlike preventive-maintenance programs, maintenance is only scheduled when
necessary to mitigate equipment issues.

14

| EFFICIENTPLANTMAG.COM

EP2104fsiemens.indd 14

Many issues are caused by excessive machine vibration, resulting in
premature failures. While maintenance personnel and operators can
sense vibration to a point by touch and hearing, vibration sensors are
much more effective. By installing integrated electronic piezo-electric (IEPE) vibration sensors in machines and connecting them to
an integrated CMS, users gain early detection insights in a digitized
format. The sensors' monitoring hub can be configured to generate
operator notifications or modify production, for example by reducing
motor speed.
Modern integrated CMS modules plug into PLC backplanes, with
the option for accessibility over the production network or a separate
subnet, including through secure cloud VPN connectivity. These
modules communicate data directly with a host PLC, enabling control based on equipment data from the condition-monitoring module
and process data from other PLC inputs.
Depending on network configuration, module data can be accessed
through a PLC's integrated automation suite or through onboard
webservers using a browser from any networked device. This means
no special software is required to view equipment health data.
Because these modules perform built-in data logging, users can
review machine performance over time through the web-based
dashboards.
These CMSs come primed for connectivity, including communication using PROFINET, MQTT, OPC-UA, and Modbus TCP

APRIL 2021

3/26/21 8:39 AM


http://www.EFFICIENTPLANTMAG.COM

Efficient Plant April 2021

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