Engineers are always under pressure to reduce costs, improve quality and optimise plant utilisation, but as the saying goes, if you can’t monitor it, you can’t control it.  So how is cloud computing helping plant managers monitor and control both local and remote assets?

A growing trend

The trend for remote monitoring systems is towards the use of cloud computing.  Cloud computing is simply the term used when services such as infrastructure, applications and business processes are delivered on demand using remote servers accessed via the Internet.  The big advantage of providing software as a service (SaaS) in this way is that it is scalable (both up and down), reliable and easily accessible.  Importantly, new applications can be trialled, deployed and shared quickly and easily.  Decision making and implementation can also be faster as there is no capital expenditure needed, and the resources can be used to complement or replace the user’s own ICT infrastructure.

Many companies already do this for example by using SCADA (supervisory control and data acquisition) software, although this can become both complex and expensive for multiple locations. Now however, the simplification of remote monitoring technology makes it viable to monitor anything from a single device to multiple installations spread across the globe safely and securely.  Security of the data and access to it are also important features of any system.

Benefits

The main benefit of using cloud is improved access to information leading to the saving of time, improving performance and saving resources.  From any computer or mobile device with an Internet connection you can see what’s happening 24/7.  Further, if there are any problems you can instantly receive alarm emails or text messages: if equipment starts to function out of parameters you can be notified and react before failure occurs.  You can log historical data and produce graphical trends; automatically backup or restore remote configurations, and even can track/monitor vehicle locations and record their loading or status in real-time.

How does cloud work?

 Three main elements

 There are three main elements to a cloud based remote monitoring solution: the first is the physical layer that comprises of communication gateway devices that link to your equipment; acquire the data, and communicate it to the remote server.  The second is the remote server that collects and stores the data, and the third is secure access to the data through a customised online dashboard.

The communication gateway devices take several forms for ease of connection to the device or equipment being monitored.  The connection is generally through serial communications or by using a popular open protocol such as Modbus RTU.  Additional functionalities such as global positioning systems (GPS) are available to meet the demands for location based services (LBS) like tracking and geofencing (providing notification when a tracked device enters or leaves a predetermined geographical location).

The acquired data is sent to the remote server by the gateway devices at selected logging intervals ranging from real-time to 300 seconds as demanded by the application.  To communicate with the server, gateways generally use either GSM/GPRS wireless technologies or Ethernet TCP/IP connections.

Where the communication gateways use Ethernet based connectivity it is via wide/local area networks (WAN/LAN) with direct connection to the server via the Internet.  The use of special firewall friendly communications between the remote gateways and the data centre makes it possible to retain the existing broadband security infrastructure at the customer’s site.  This procedure is accepted by most IT departments and gives confidence that the installation is controlled from a security perspective.

Data is communicated to and stored on a remote server.  Typically, the server is located at one of two or more data centres and the data backed up at the other two.  Information held there can be displayed graphically in the form of customised dashboards, or downloaded into the customer’s businesses management system for analysis and reporting.  All server activity is logged at a password holder level.

Information on the server is viewed using a standard web browser.  To simplify configuration of the graphical display, standard tools are incorporated into the server.  These will include: downloadable device templates for establishing communications between the remote plant and the communicating device; auto-commissioning to auto-detect a new device or machine attached to the communication gateway, and auto web pages (dashboards).  Some systems containing libraries of ready-made web page dashboards for applications such as power generators, water/waste management, base stations, building and HVAC management and many more.

Security

User access is controlled by multi-level passwords, which is linked to a user profile to define the level of information or control available.  Access is available from any location via the Internet using any suitable PC or mobile device such as a Smartphone, tablet or similar, and because the dashboard is displayed on a standard web browser no special software is required by the user.  This makes it convenient for field service staff or business managers away from base.

Access to the server information means you can log historical data and produce graphical trends or diagnostics, manage alarms, or automatically backup or restore remote configurations.  Although not originally conceived as a SCADA package, the functionality exists to easily configure one.  The servers data can also be accessed by the users own ERP system for further analysis and reporting.

Industrial cloud applications

Anywhere information from remote locations needs to be collected and analysed has the potential to use remote monitoring.  It can reduce costs and improve equipment performance by flagging problems at an early stage and optimise maintenance programmes.

Popular applications include:

– the monitoring of fuel, oil, battery condition of standby generators;
– tank management to monitor levels and temperatures, schedule refills and optimise logistics;
– remote pumping station monitoring to notify if service interruptions, unauthorised entry, and reduce routine service visits
– in building automation to optimise energy consumption, monitor HVAC and security

Remote management can be integrated into new equipment to provide customers with enhanced functionality and services, or added to existing fixed or moving assets.  It helps avoid unnecessary travelling of service personnel to remote locations as emergency visits can often be avoided. It saves time, money and offers businesses the opportunity to provide new services.

For information on Netbiter gateways and cloud computing contact 999 Automation