Mining & Minerals Product Review March/April 2018

1 ISSN 2219-0880 R133.00 NEW PRODUCTS • DEVELOPMENTS • TECHNOLOGY • INNOVATIONS VOL 11 NO 1 BRINGING BUYER AND SUPPLIER TOGETHER March | April 2018 4IR enables remote monitoring and analysis of data Contributed by Kegan Smith We are now in the Fourth Industrial Revolution (4IR) where real time technology service and solutions enable companies to translate acquired data into actionable results. databases; the industry is being left behind in comparison to the tools available today. Industry 4.0 talks about a connected world; data streams coming from all corners of your environment with intelligence built into the technologies to make our life easier. We are seeing a growth in the smart sensor and the interfacing networks that connect the ground layer instrumentation. Sensors and the interfacing systems with built in ‘intelligence’ give rise to localised and self- diagnostics. This functionality is great for maintaining the health of the instrumentation and ideally suited for smaller repeatable balance of plant infrastructure. However, for large integrated machinery and process trains there is no context given to the diagnosis. Process instability can set off alarm bells pertaining to asset health indicators and vice versa, giving a false sense of diagnosis and leading you in the wrong direction. The next concern in a developing industry is convention; parties talking about the same observations Mines and industrial processes in remote areas have been updating to the latest software and digital sensors to move them into the Fourth Industrial Revolution, enabling them to monitor and control these facilities, remotely via internet communications and cloud data storage, this can even allow their venders to have access to this information, allowing them to supply spares, equipment and services ‘just in time’. Most companies and software developers have focused on the equipment maintenance spares and expendables as well as the manufactured process product data. Prei Instrumentation, industry 4 turbomachinery and setpoint (B&K Vibro) use high speed data collection and the power of OSI Pi to collect data from process machinery, and critical control loops to monitor and analyse critical process machinery. The level of expertise required to analyse this rich data is not always available on isolated sites and plants; by leveraging cloud services and connected partnerships Industry 4 turbomachinery can offer remote support and expertise in times of need or merely for routine reporting. Rotating machinery is still at the heart of all major processes; whether it is compressors or turbines. However, currently, knowledgeable and experienced personnel for this critical skill is scarce and reaching retirement age. The control, maintenance and monitoring equipment and staff for rotating machinery is aged, and while the knowledge base is strong, much of the expertise remains in isolated departments with little unified migration to centralised intelligent Rotating machinery is considered the heart of all major processes. www.miningandminerals.co.za | Interact with your industry but from different perspectives, or worse, people talking about different observations but using common terminology. The concept of which is not our own, but is fast becoming a means of levelling the playing field. The importance of good clean data The errors in data and its respective information content get compounded as one steps through the algorithms required to display, analyse and predict asset health. Let us consider the flow of information. We start at the source… the measurement of the correct information, the reliability of the measurement and the trust in that information once it is converted into recorded data. The quality of the instrumentation is crucial to the trust placed in the protection, control loops and analytics alike. The same is to be said for the sampling of the information. Resolution in measured magnitude often surpasses the requirements, however poor time scales often lead to mistrust in the information. Firstly, any engineer who has performed a root cause analysis on data depicted as quantified step trends knows the frustration of allocating a cause and effect. Next, remembering that we are discussing industry 4 and the analysis of data across systems; time synchronisation of the various data streams needs to be maintained at a similar resolution to the sampled data. Having a one second drift on data that is time stamped compared to a millisecond resolution is also problematic in assigning cause and effect (a problem that many are unaware of and think that the equipment is safe). After measuring and sampling information comes the collection and storage. The high-resolution data and high sampling frequencies required for in depth analysis will saturate your data storage in short time if not managed correctly. There is always a level of filtering and compression involved in industrial historians. It is an old question that has plagued anyone with data and limited storage, what can I ignore without losing sight of the picture? Legacy systems rely on the crossing of finite thresholds and alarm points to trigger data collection with a Continued on page 8 PAGE 1 FEATURE Cover story feature 4IR enables remote monitoring and analysis of data 4 Health & Safety feature Playing with fire 14 Events and Exhibitions The man with the plan PAGE 2 7 10 16 18 PRODUCTS  Health and Safety Managament Mining and Engineering Sustainability Transport / Mobility March | April 2018 • Mining & Minerals Product Review