INFOCEL PUERTOS. Product Information

Transcription

1 Product Information SOLUTION FOR REMOTE MANAGEMENT OF MAINTENANCE WITH INFOCEL DEVICES AND SCADA-WEB APPLICATION. PUERTOS

2 INTRODUCTION INFOCEL-Web Puertos is a complete Hardware and Software solution for monitoring the operation of cranes and other devices in port environments. The system is based in the collection and analysis of either digital data (on/off signals) as well as analog data (continuous signals) and finally of data processed from those parameters (hour meter, pulses, alarms orders) through INFOCEL remote management devices. If needed, this devices can interact with machines operation with digital output, analog output and bus ports. INFOCEL devices monitor the cranes' operation state and transmits it in real-time through stand-alone GSM/GPRS connections into a central computer, which stores all the data into a SQL database. INFOCEL devices can send SMS alarm messages to specified telephone numbers by their own, while the system can generate and send s with warnings, alarms and reports. The central computer also acts as a web server, publishing the data in internet, as a standar website that can be opened using any computer, PDA or mobile phone with a web browser. PUERTOS

3 GENERAL OVERVIEW INFOCEL-Web Puertos is a complete and adaptable solution for any particular application. There is a wide range of features that not only helps following any alarm or failure but also adds value to the system with its additional features. Data is continuously collected, analyzed and classified, being stored into the memory system as much as detailed and precised as wished. From the website data can be seen in different presentation formats like: Synoptic charts in real time. Gantt charts of digital signals. Evolution charts of analog signals. Bar charts of pulse counters or activations. Complete historical charts of periods and events, that can be exported into Excel format (csv) from the website. Temperature in engine rooms monitoring pages. Pages with every crane's GPS tracking during all the time. All web access are protected with username and password and logins are saved with a register of date and time for each access. Because all data can be read on the website, no additional software is needed to be installed in the client computers, so the security of your network is not compromised. PUERTOS

4 GENERAL OVERVIEW Figure 1. INFOCEL-Web Puertos system overview. Figure 2. States synoptic PUERTOS

5 HARDWARE USED - INFOCEL DEVICES To achieve detailed monitoring of all the signals of your machinery, we propose our INFOCEL devices, easy to install by following the installation guide and the wiring schemes we provide. These devices work completely independent from the rest of the machinery, so never can interfere with your machine operations. Furthermore their autonomous communications are independent and work in a different channel from the main operations one, which is keeped free of any overload or interference. We propose to monitor all your cranes, including Ship to Shore ones, Yard cranes, toploaders... but also you can include any other mechanic or electric device: transformation centres, refrigerated machines, lighting installations, and at the end, any other element within your production chain. PUERTOS

6 MAIN FUNCTIONS STUDIED SIGNALS INFOCEL-Web Puertos can be fully customized, always offering a set of common functions very useful to ease your preventive maintenance tasks. Among these functions, we can highlight the tracking of these signals: - Tracking of state signals, changing to maintenance and fault modes. - Operations' monitoring of the main lift subsystem variables (Hoist signal, weight signal). - Monitoring of the main translation trolley subsystem variables (Trolley signal, Hoist + Trolley signal). - Monitoring of load subsystem (Spreader, Twistlocks and Twin signals). - Monitoring of lateral translation and boom movement signals (Gantry, Boom). - Monitoring of manoeuvre fault signals (stop by temperature, stop by electric fault). With all those data signals you can do as follow: - Real time tracking and display of status on web: synoptic, evolution graphs, list of records, statistics, etc. - Cumulative study of working time with a precision of 0.1 seconds. Essential for a right preventive maintenance. - Study of numbers of activations of each signal. With all these data you can get reports, listings and events to allow a comprehensive operation of machinery and elements' wearing out. PUERTOS

7 MAIN FUNCTIONS GRAPHICAL DATA PRESENTATION The fundamental task of the system is to track all the parameters needed for accomplishing a good and proper preventive crane maintenance. To perform the analysis of the data in an easy way, there are different website presentations to check the proper perfomance of the machines. Here are some samples: Synoptic view of current state Daily evolution of Twistlock signals Daily evolution of Weight signal Evolution of operations' states Evolution of main signals PUERTOS

8 MAIN FUNCTIONS : CURRENT STATUS SYNOPTIC. The system can contain different synoptic views of the current state, as we will see later, which can be accessed by different users depending of its use: working states, wind pages, operational pages, GPS position, etc. In the synoptic graphs we can see the most recent known states of each element under tracking, being displayed in graphical format and representative of the installation. Besides direct data, you can see graphical or numeric information as a result of processing or combination of multiple signals. An example can be the presentation of the particular state of a machine displayed with a colors scheme: Production (Green). Stand-By (Yellow). Stop (Grey). Fault (Red). Maintenance (Orange). PUERTOS

9 MAIN FUNCTIONS : STATES CHARTS Gantt charts can also display the operating states of single digital signals or the operating states of compounds. Gantt charts show operating states of individual digital signals. Gantt charts show operating states of signal's compounds. PUERTOS

10 MAIN FUNCTIONS : HYSTORIC DATA REGISTERS Historic data records allows us to see in detail all the events for each device's group. The periodic log includes date and time as well as all the values of the parameters tracked. With the logs, we can identify different types of events: Change of states in digital and analog signals. Sending and reception of alarms and control SMS. GPRS connectivity. We can filter by date range or type of event. All the data can be exported to Excel format (csv) from the website. Presentation of historical data. PUERTOS

11 MAIN FUNCTIONS DATA REGISTERS Also a primary part of the data analysis, is the management of operating hour meters and activation's counters listings where you can configure the kind of metering to be collected for each signal. Hour meters data between two dates. Data Twistlocks Computation and signal's activation between two dates Log events listings Step by step hour meter's evolution PUERTOS

12 MAIN FUNCTIONS HOUR METERS MANAGEMENT The hour meters, or cumulative activation's time of a digital signal, and the activation's counter of each one of them, have a big importance in the task of maintaining the machines. As an hour meter, the INFOCEL device works with an accuracy and resolution of 0.1 seconds. Our studies conclude that with some signals like Trolley crane this accuracy has a major importance to measure realistically the time of usage of each element subject to preventive maintenance. In our tests, many of the hour meter devices installed on cranes are not good enough to measure signals as fast as the operators handling can produce. All the hour meter reports can be shown with the own INFOCEL values (Absolute view), with values comparable with the data crane's ones (Relative view) or as a countdown of the remaining time to the next preventive maintenance of each element (Maintenance view). To proceed with the use of the correct time left for the next maintenance stop, it is necessary to reset the counters when the replacement task, greasing or verification requirements has been done: Setting in one hand the value of time after which is needed the preventive maintenance task and in the other hand when you do those tasks, the system always knows the time remaining for the next job on each element. PUERTOS

13 MAIN FUNCTIONS HOUR METERS MANAGEMENT Detailed tracking of the time remaining until the next preventive maintenance job for each element in the crane is a key point in the whole system. Because of the interval definitions of usage time of each element, the reset of counters in every milestone and the 0.1 seconds measuring accuracy, we can warranty that the maintenance stops are made at the right time for each element and never before or after it. In the maintenance website the cranes are shown in order of time remaining until the next intervention of each element, being displayed in order of next milestone: In this page, time remaining for next maintenance jobs are displayed with color codes as well as time left for the next stop. The meanings are: long time until maintenance (green), short time (yellow) or very short time (red). Additionally, reports are automatically generated daily, weekly or monthly and all this information is sent by . The output sheet can be customized by the user (logos, graphs, statistics, etc). In the other hand, events are defined for each of these conditions (customized), and automatically send the warning s regarding the situation changes for each of them. (For example, whenever there is a short time for a maintenance break). PUERTOS

14 MAIN FUNCTIONS COUNTER'S ACCURACY For this main role of tracking hour meter and activiation counters, accuracy is very important, so you can compute all the signals from the different mechanical parts of the crane with effectiveness. Some of them are long term signals and are not very frequent, like the lateral translation motion in a Ship to Shore crane or wheels motion in a Yard crane. These signals are easy to compute accordingly. However, the right measurement of signals in trolley displacement and hoist signals (Trolley, Hoist and Trolley+Hoist) is particularly difficult because their nature (sometimes are long and sometimes very short, specially the trolley signal), so they cannot be properly recorded by some kind of hour meters. Aproximate distribution of types of translation signals: Distribución temporal señal Elevación en segundos 1,5 18 Más de 5 seg De 2 a 5 seg Menos de 2 seg Distribución temporal señal Carro en segundos Más de 5 seg De 2 a 5 seg De 1 a 2 seg Menos de 1 seg 40 PUERTOS

15 MAIN FUNCTIONS COUNTERS CHECKING In our tests with different crane manufactures, we have concluded that the hour meters used can be good for long lasting signals, but cannot measure the short time signals properly, what produce a significant error computing total usage time. This outcome leads to two different cases: the preventive maintenance jobs are done too early (which implies extra cost) or too late (with the security issue it may introduce). The source of this problem can be related to the regular use of this hour meters into industrial environments, where is not often to work with such short time signals like in these cranes (e.g. trolley signals of 0.5 seconds). For the evaluation of the measure accuracy of the hour meters of your cranes, we have devices that generate acurate activation signals repeatedly for different duration times, so connecting your hour meters to them you can test their tracking accuracy with various type of signals. Example of signals of 3, 2, 1.5 y 0.8 seconds generated by the signal generator that must increment 18, 12, 9 y 4.8 minutes of accumulation for each working hour. PUERTOS

16 MAIN FUNCTIONS - EVENTS TRACKING As we have seen before, and we will see later, there are several automatic checks that happen under certain circumstances that can generate events in the INFOCEL WEB PUERTOS monitoring system. All these events are logged onto the system, and can be sent (by or SMS) automatically and checked at any time. We show a list of events not yet solved in each moment in the main system webpage, as well as a powerful log events manager for checkup. This management includes temperature event alarms, monitoring signal faulty alarms, machinery faults, electrical supply fault alarms, etc. From another set of webpages protected with a harder security access level, you can program the action to be taken for each event: if it must trigger an alarm or not, just send an or SMS and to whom. Also it can be generated and send an with a daily report with a summary of all the events happened, if they were solved or not, and compiled in a convenient Excel table. PUERTOS

17 EXTRA FUNCTIONS TEMPERATURE MONITORING The monitoring device INFOCEL-L3 has 8 inputs for analog probes, although we have only described the weight probe. The other analog inputs can be connected to any other type of probes (from 0-10V or 4-20mA) to expand the system's capabilities. An example are temperature probes for monitoring the temperature in the electricity rooms, usually with air conditioning and requiring to be kept in working order to maintain the room under certain temperature. Also in some cases the cranes have its own temperature probes and stop the machine operation when reaching certain threshold, carrying out logistic problems. Pages that displays the temperature in a table format can be created, easily displayed in a mobile phone screen, and incluide these synoptic values, manage temperature alarms to avoid problems in the machinery room, and show graphics by crane type, etc. A system of a continous warning every 15 minutes until the problem is solved, makes the times of reaction fast enough to avoid the machinery to be topped. In the left image we can see some consecutive days where the alarms sent when the temperature reached 35ºC in the room avoided the crane to stop. PUERTOS

18 EXTRA FUNCTIONS - WIND SPEED Another possible use for any free analog input is the measurement of the wind speed with an anemometer, usually available on the top of the cranes. It is a good idea to measure each anemometer of the cranes at least in the Ship to Shore type, all along the port, so you can have a map of winds in the port perimeter. A webpage with all the wind speed data can be done in a table format, with different access permission as the whole aplication. Also you can include these data in the synoptic presentation of general state for maintenance personnel. Also special reduced webpages are generated with wind data registers, evolution graphs, etc. to be used by the aforementinoned users. At the same time, wind events are studied and notified to proper lists when triggered. Also event logs registers are managed for review, reporting, etc. PUERTOS

19 EXTRA FUNCTIONS FUEL CONSUMPTION Another aplication for free inputs and outputs of the INFOCEL devices could be fuel consumption tracking, remaining fuel in the tank and the change to low comsumption state in those machines supplied from diesel generators. With proper probes you can measure fuel current consumption, remaining fuel, as well as other generator working variables, main generator status,engine speed, operating temperature, etc. that help to anticipate any working breakdown. If the generator has low consumption mode, thanks to the information collected and processed, INFOCEL can automatically switch the generator to this low consumption mode. This can lead to intelligent strategies that can also be remotely changed at any time, optimizing the switching time to low consumption mode. Monitoring tank fuel level allows us to optimize the management tasks and the overhaul stops, as well as detecting possible fuel leaks (breaks, etc.). PUERTOS

20 EXTRA FUNCTIONS ELECTRICAL CONSUMPTION TRACKING INFOCEL-L3 devices can be connected to external equipments with a RS485 bus connection. Among the possibilities of this feature are to follow machinary electric consumption, measuring the main parameters: power supply, current per phase, reactive power, phase voltages, etc. To that end, we use a net analyzer with RS485 capability. This device gives INFOCEL up-to-date data of the intended variables, saving, processing and sending them to the webpage. Based on this data, the system can generate alarms on overvoltage, undervoltage, overcurrent, over-reactive, neutral unbalance, etc. Information includes synoptic states, graphs, etc. PUERTOS

21 EXTRA FUNCTIONS GPS LOCATION Another feature of the bus extension is to connect a GPS device on each crane, for streaming in real time the crane's position together with the others variables. This gives us the right position in real time of the Ship to Shore cranes regarding norays, and the Yard cranes over the containers area, so you can see their actual positions mapped onto you port's map. The icon of each crane on the map also shows us if some of them have some problem, if it is under maintenance, standby or it is in production. We provide a GPS box fully sealed and connected by bus so it can be mounted far away from the INFOCEL device, that allows to fix it in a safe place with best visibility of GPS satellites. PUERTOS

22 EXTRA FUNCTIONS LIGHTING SAVINGS Thanks to INFOCEL comprehensive monitoring of operational status of the cranes, relying on suitable ballasts, electric lighting consumption can be managed to suite the needs anytime. The information collected and processed by the INFOCEL device allows to switch the ballast to a low consumption mode. To achieve this saving you have to use headlamps with integrated power regulation, or only change current ballards. Depending on the type of lighting used, reduction could be up to 50% consumption, and thanks to the different outputs of the INFOCEL, several rules of scheme behavior can be configured. For example, switching to low consumption after 3 minutes of inactivity a subset of the lighting, if continue, switch to low comsumption another set of lightings after 5 minutes and so on. Also can be programmed the switch to maximum lighting depending on several signals (presence in cabin, movements, etc.) and logic functions between them. This intelligent management of the lighting in the crane area, can highly reduce the consumption of fuel or electricity. PUERTOS

23 EXTRA FUNCTIONS - FUNCTIONALITY AUTO CHECKING Thanks to INFOCEL comprehensive monitoring of the crane's operational status, and due to the large amount of interrelated signals supervised, we can check automatically the correct working of signals. Even though cranes from different manufacturers are physically different, and even with different operators, final performance is very similar. Crossing all related data we can detect signal malfunction studying basic rules, for example: - If a crane is operating, and has Trolley movement, it must have also Hoist (and viceversa). - If a machine is operating, and has Trolley movement, it must have also Twistlock activations. In case of failing of any of the rules, a warning is generated automatically saying what kind of incident is most likely (wiring problem or malfunction of any intermediate relay). PUERTOS

24 EXTRA FUNCTIONS - DAILY PERFORMANCE REPORTS The remote monitoring INFOCEL device collects all kind of diversity and different data, and depending on the user's needs, this application can generate several types of daily reports showing the operation's performance and maintenance information, etc. The system can be configured to create the following type of reports: - Report of container's movements. Fully with number of each kind of operation, weighting of each of them, movement duration, and the statistics sort by machine, working shift or crane type. - Alarm events duration, reaction and repairing time of maintenance services. - Electric consumption or diesel consumption reports, sorted by operations, type of machine, etc. - Relative percentages of use of each type of translation's signal and comparison of them machine by machine, group by type of machine or shift work. PUERTOS

25 EXTRA FUNCTIONS- MIRROR SERVER As seen before, the client can access the information from any web-enabled mobile device such a PDA, tablet, computer or any other device with a web browser. If the servers are located outside of the client private network, it is needed for the device trying to access the service to have internet access or access to the intranet where the servers are located. We recommend to have a mirror server in another safe place, and with a different data connection, to increase the system's availability and working also as a permanent backup. This way you can always work with any of the servers, being both updated at any time with the same information. This feature also makes the service to be up and online when a (single) server or connection problem occurs. PESYR I+D can host your second server, if you wish. PUERTOS

26 PESYR I+D - CONTACT INFORMATION We are specialized in designing and manufacturing remote monitoring devices, having a standard functions range of products devoted to remote supervision of electrical installations. Some of these standard products are INFOCEL L3, L6 and CODI that offers a similar functionality but with different number of inputs, outputs and expansion buses. We also make some special application products for monitoring photovoltaic plants and remote monitoring and control of street lighting. Finally we do also make tailor-made devices and projects under request. PESYR I+D Electrónica y Sistemas Calle César Vallejo, 34 Pol. Industrial Guadalhorce 29004, Málaga SPAIN Tlf: Mobile: info@pesyr.es big