IIoT - Collecting sensor information using the Industrial Internet of Things

The Industrial Internet of Things (IIoT), or Industry 4.0, is one of the most trending topics in the automation world. Today, there has been a lot of technological progress from automation and instrument manufacturers in collecting numerous data from sensors for process and business analysis. This article outlines a few simple solutions from VEGA that can help businesses easily collect sensor information andhave it on a ready-to-use platform, without the need for much hardware.

Imagine a scenario in which a manufacturer had to plan their production for the expected orders based on daily stock logs and sales intelligence. This would be tedious to handle when managed manually, and explains why such solutions were initially requested. In the world of supply chain management, manufacturers of chemicals, admixtures and other similar products would like to have their suppliers deliver raw materials on time. Likewise, if they are a supplier themselves, they would like to be notified far in advance in order to define their manufacturing. In this way, deliveries happen on time, no one is at a loss with too much or too little stock, business is more efficient, and commitments are honoured. The ideal target would be to achieve a lean management by having a systematic method without sacrificing productivity and minimising wastage.

Rod Jones, managing director of MI Gulf Services (one of the leading suppliers of drilling fluid in the UAE and Oman), decided to deploy VEGA’s tank inventory system in one of their remote liquid mud plant.

Their main concern was to improve safety and remove the need for plant personnel to climb up tanks to check stock.
The key operational advantage was having alarms if the tanks were overfilled.
Additionally, by planning production and logistics based on the empty volumes available, a lean production solution was achieved. Following the approach for continuous improvement, Khemraj Ganesh, supply chain manager at MI Gulf Services, not only wanted to equip their liquid mud plant with a safety system, but also insisted on improving services for customers and suppliers using the systems installed.

 

By providing live inventory stocks to customers, MI Gulf Services was able to establish a transparent relationship. Moreover, with the stock of raw materials now available to suppliers, the company does not expect to run out of products or to be left with unused products. Due to the capabilities of integrating such data to enterprise resource planning, this system provides an electronic trail to verify that all data on the tickets are correct, which was previously done manually. “This system provided live and on the fly data for both MI Gulf Services and our clients, who are mainly operators, so there is absolute transparency with all fluids stored, delivered and received,” says Ganesh. “It also serves as a safety system with the necessary tank alarms.”

 

Level transmitter to gauge volume

With today’s technology, products stored in tanks can be easily measured and accounted for with the right sensors. By equipping them with level transmitters, we could measure the level and hence the volume to calculate the stock. Alexis Alexander from VEGA explains: “VEGA would recommend here the VEGAPULS 64 which has an accuracy of +/-1mm, which measures any product irrespective of the process conditions. From experience, the new 80 Ghz radars were developed as a one-for-all sensor to fit any situations like narrow spaces, build-up and foam.”

Mobile Gateway to transmit values

In combination with a level transmitter, a mobile module should be added with the sensor. This would then transmit information to any web browser almost instantly. VEGA offers the PLICSMOBILE T81 with mobile data and GPRS capability, as well as ATEX certification for hazardous areas.

Once the sensor measures the level in a tank, it transmits this information via the internet to a server. VEGA provides such server facilities to its customers, so that they can avoid the hassle and costs associated with setting up an IT infrastructure. This offers more time to focus on their production, rather than on the IT challenges.