Over the last few years a shift has been happening in the manufacturing industry. Instead of running to failure, companies have begun leveraging IIoT to monitor their assets to identify problems before a breakdown occurs. Not only can reactive maintenance result in expensive downtime, 70% of workplace injuries happen while conducting reactive maintenance. Staying ahead of potential failures creates a safer plant and creates higher productivity. Implementing a predictive maintenance strategy is now easier than ever with Grace Engineered Products’ newly launched Predictive Maintenance System.
I recently had the opportunity to travel to Grace Engineered Products headquarters in Davenport, Iowa to learn first-hand from the people who developed the Grace product lines. The Predictive Maintenance System features products from both their Graceport and GraceSense lines. The use of GracePort products alleviates hazards for personnel, while the GraceSense lines provide continual machine health. Together, these products protect your high dollar assets and the potentially dangerous areas of your plant floor.
The GraceSense Hot Spot Monitor (HSM) uses non-conductive fiber optics to get the information you need from inaccessible locations or areas where the IR window can’t get a clear picture. HSM reports on potential hot spots to help predict failures in your electrical equipment. Install this solution on lugs of a drive, MCC or switchgear bus bars, power supplies, etc – and continuously monitor the temperature of those devices back to your control system. This solution allows fiber optic cables to be routed through a cabinet where IR windows are simply not practical, and in turn provides that information on Modbus RTU485, Modbus TCP/IP, or EtherNet I/P. The HSM reduces hazards associated with personnel trying to access your highest risk assets.
For your machinery components, GraceSense offers Temperature and Vibration Field Mount Nodes. These nodes monitor important pumps, turbines, and generators for anomalies. Bearing/gearing failures, pump cavitation, ect – can all be seen. They install easily with field replaceable batteries that deliver 3-5 years of life. Additionally, Panel Mount Nodes can be added to GracePort housings with customizable transducer options for accelerometers, flow, pressure, humidity and fluid levels
The Maintenance Hub ties all of these assets together in a user-friendly web-based app. Multiple Field Mount Nodes can be networked via a proprietary IEEE 802.15.4 Zigbee compatible protocol to a Cloudgate (LTE or WiFi) where it pushes the encrypted data up to the cloud-based Maintenance Hub (Amazon AWS) for viewing. The Maintenance Hub provides real-time asset status using dashboards, plot trends, and analytics. It can generate reports and issue alerts with step-by-step action plans to correct issues as they arise. The system is available with an open API that allows in-hub data calculation or data sharing with existing control systems you may have (i.e. CMMS, SCADA, DCS). This enables a cost-effective, wireless end-to-end encrypted communication to enhance safety and productivity while decreasing downtime.
The GraceSense Predictive Maintenance System has the versatility to scale to the needs of your specific application. These products can be installed independently to monitor assets without any inclusion to the control system, or with the use of EDS/AOPs, they can provide Logix full tag reference for more advanced machines and integration. Add as many field mount nodes as needed to get the correct picture of the assets on your plant floor.
Rumsey has a demo unit of the GraceSense Predictive Maintenance System available to show the products in action and how the system works together. If your company would like to schedule a site visit to see how GraceSense can work for your particular application, please contact me.
Grace Engineered Products will also be at our upcoming predictive maintenance seminars – Optimize Your Predictive Maintenance Process with IIoT being held in Claymont and Allentown this October. These seminars will focus on ways you can leverage technology to increase uptime, improve safety and move towards a proactive maintenance approach. Grace will be leading the session “Using Technology to enhance electrical safety and maintenance operations” that will discuss specific use cases where technology can really complement facility maintenance. For more information and to register click here.