Leveraging IoT for Condition Monitoring in

WATER TREATMENT PLANTS

Client Profile

A prominent company specializing in providing power and water services.

Category

IoT

Project Overview

Water treatment plants heavily rely on centrifugal and high-pressure pumps as vital assets. To ensure these pumps operate efficiently, our client previously employed a method of monitoring based on scheduled vibration and temperature checks, recorded on a calendar. This data was then manually input into spreadsheets to establish a performance baseline and detect any deviations. However, this process was labor-intensive, prone to errors, and failed to promptly identify reasons behind abnormal readings, resulting in costly breakdowns. To address these challenges, we introduced a solution called SeeMyMachinesTM, an Industrial Internet of Things (IIoT) platform designed for condition monitoring and predictive maintenance of pumps.

Click Above to View Pdf

Business Requirement

  • Monitor asset health from a distance, tracking factors like vibration, temperature, water quality, and flow in real-time.
  • Forecast potential breakdowns and detect declining performance.
  • Prolong the lifespan of pumps by addressing issues at their onset.
  • Reduce losses due to unexpected pump failures and unscheduled maintenance.

THE MAVA PARTNERS SOLUTION

Our implementation of SeeMyMachinesTM, an Industrial Internet of Things (IIoT) solution, involved capturing data from equipment by connecting to controllers and sensors. The deployment followed a staged approach. Initially, six pumps at a single unit were covered in a pilot phase, which included setting up, fine-tuning, gathering data, configuring the portal, ensuring cloud accessibility, and enabling online monitoring. Over the following eight months, additional phases expanded connectivity to 174 pumps. SeeMyMachinesTM offered a comprehensive overview of pump conditions, providing continuous, real-time performance data accessible 24/7. Access to equipment information was available through both web and mobile interfaces, accessible securely and with authorized permissions from any location.

Technologies

  • Hardware
  • WirelessHART
  • Wi-Fi Repeaters
  • Edge Devic
  • Software
  • Spark
  • Amazon DynamoDB
  • Amazon S3
  • Amazon EMR
  • AWS Lambda
  • Parquet
  • Amazon Glacier
  • Amazon ElastiCache
  • Amazon Kinesis
  • Android

Positive Outcomes for Business

  • Streamlining condition monitoring procedures led to savings equivalent to 4800 hours of manpower within the initial year of implementation.
  • Heightened data collection frequency led to precise anticipation and measurement of failures.
  • The workforce efficiency saw a substantial boost as the capability to predict failures allowed for maintenance as required, rather than on a fixed timetable.
  • Downtime was minimized, and both equipment and plant availability were notably enhanced.
  • Timely intervention through predictive maintenance prolonged equipment lifespan, ensuring interventions occurred at the right moments.

Key Features

  • Utilizing interactive data displays and dashboards for insights.
  • Managing the entire lifespan of assets effectively.
  • Monitoring conditions remotely to ensure optimal performance.
  • Anticipating maintenance needs through predictive analysis.
  • Streamlining tasks digitally for improved efficiency.
  • Maintaining detailed records of maintenance activities.
  • Tracking key performance indicators (KPIs) and statistical metrics.
Scroll to Top