Background

Real-time Industrial Internet of Things (IIoT) Vibration Analysis with Diagnostics, powered by the PI system, stands as a transformative solution for safeguarding critical/high-value rotating equipment and averting unplanned shutdowns that can lead to substantial production losses. The conventional approach of manual vibration monitoring by engineers, fraught with challenges such as time consumption, faulty analysis, personnel exposure to equipment, and infrequent data collection, is superseded by the PI system's comprehensive offerings.

Solution

Through the strategic installation of vibration sensors in equipment, the PI system establishes a robust connection, enabling Diagnostic Electronics and Object Configuration via the OPC server for seamless integration.

This configuration simplifies the setup process, ensuring easy data integration through the OPC protocol. The PI suite system, encompassing the PI Data Archive as the centralized industrial data storage infrastructure of the Integrated Asset Intelligence Center, coupled with the PI AF hierarchy, enriches data context from assets. The PI Analysis engine calculates reliability indicators, generates alerts applying Condition-Based Maintenance (CBM) concepts, and conducts trend analysis via Linear Regression. Leveraging PI Notifications as the messaging solution, the system efficiently sends emails based on CBM rules or Linear Regression predictions, initiates maintenance notifications on the ERP system automatically, and periodically dispatches reports to managers with reliability indicators and asset status. The integration with PI Vision allows real-time monitoring through intuitive dashboards.

This comprehensive setup results in a substantial reduction of downtime, heightened asset reliability, diminished maintenance costs, minimized human exposure, increased mill capacity, and a streamlined reduction in manual intervention. The PI system emerges as a pivotal force in revolutionizing industrial asset management, ensuring operational resilience and efficiency.