How does the Industrial Internet of Things save a factory millions of dollars a year?

  • The Importance of Industrial Internet of Things

As the country continues to promote new infrastructure and digital economy, the Industrial Internet of Things is emerging more and more in people’s eyes. According to statistics, the market size of China’s industrial Internet of Things industry will exceed 800 billion yuan and reach 806 billion yuan in 2021. According to the national planning objectives and the current development trend of China’s Industrial Internet of Things, the industrial scale of China’s industrial Internet of Things will further increase in the future, and the growth rate of the industrial market will gradually increase. It is expected that the market size of China’s industrial Internet of Things industry will break through one trillion yuan in 2023, and it is predicted that the market size of China’s industrial Internet industry will grow to 1,250 billion yuan in 2024. China’s industrial Internet industry has a very optimistic prospect.

Chinese companies have carried out many industrial iot applications. For example, Huawei’s “Digital Oil and Gas Pipeline” can effectively help managers understand pipeline operation dynamics in real time and reduce operation and management costs. Shanghai Electric Power Company introduced the Internet of things technology into warehouse management and built the first unattended warehouse in the system to improve the level of material management…

It’s worth noting that while nearly 60 percent of Chinese executives surveyed said they have a strategy for iot development, only 40 percent said they have made relevant investments. This may be related to the large initial investment in the industrial Internet of Things and the unknown actual effect. Therefore, today, the author will talk about how the industrial Internet of things helps factories reduce costs and increase efficiency with the actual case of intelligent transformation of air compressor room.

  • Traditional air compressor station:

    High labor cost, high energy cost, low equipment efficiency, data management is not timely

Air compressor is an air compressor, which can produce high-pressure air for some equipment in the industry that needs to use 0.4-1.0mpa high-pressure air, such as cleaning machines, various air momentum meters and so on. The power consumption of air compressor system accounts for about 8-10% of the industrial energy consumption. The power consumption of air compressor in China is about 226 billion kW•h/a, of which the effective energy consumption only accounts for 66%, and the remaining 34% of the energy (about 76.84 billion kW•h/a) is wasted. The disadvantages of traditional air compressor room can be summarized as the following aspects:

1. High labor costs

The traditional air compressor station is composed of N compressors. The opening, stopping and state monitoring of air compressor in air compressor station depend on the management of air compressor station personnel on duty, and the cost of human resources is large.

I2

And in the maintenance management, such as the use of manual regular maintenance, on-site detection method for air compressor fault troubleshooting, time-consuming and laborious, and there is a lag after the removal of barriers, hinder the use of production, resulting in economic losses. Once equipment failure occurs, over-reliance on equipment service providers to solve door-to-door, delay production, resulting in a waste of time and money.

2. High energy consumption costs

When the artificial guard is on, the actual gas demand at the end is unknown. In order to ensure the use of gas, the air compressor is usually more open. However, the demand for terminal gas fluctuates. When the gas consumption is small, the equipment idles or is forced to relieve pressure, resulting in energy consumption waste.

In addition, manual meter reading is timeliness, poor accuracy, and no data analysis, pipeline leakage, dryer pressure loss is too large waste of time can not be judged.

I3

 

3. Low device efficiency

Stand-alone operation case, on-demand boot to gas constant can meet the production requirements, but under the condition of many sets of parallel, exist different production workshop power equipment size is differ, gas or gas time inconsistent situation, for the whole QiZhan scientific dispatching switch machine, meter reading put forward higher requirements, energy saving, electricity consumption.

Without reasonable and scientific collocation and planning, the expected energy saving effect cannot be achieved: such as the use of first-level energy efficient air compressor, cold and dry machine and other post-processing equipment, but the energy saving effect after operation cannot reach the expectation.

4. Data management is not timely

It is time-consuming and laborious to rely on equipment management personnel to make manual statistics of gas and electricity consumption reports, and there is a certain lag, so enterprise operators cannot make management decisions according to electricity consumption and gas production reports in time. For example, there is data lag in the daily, weekly and monthly data statements, and each workshop needs independent accounting, so the data is not unified, and it is not convenient to read the meter.

  • Digital air compressor station system:

        Avoid waste of personnel, intelligent equipment management, real-time data analysis

After the transformation of the station room by professional companies, the air compressor station will become data-oriented and intelligent. Its advantages can be summarized as follows:

1. Avoid wasting people

Station room visualization: 100% restore the overall situation of air compressor station through configuration, including but not limited to real-time data monitoring and real-time abnormal alarm of air compressor, dryer, filter, valve, dew point meter, electricity meter, flow meter and other equipment, so as to achieve unmanned management of equipment.

I4

Scheduled configuration: the equipment can be automatically started and stopped by setting the scheduled time, so as to ensure the gas use according to the plan, and personnel are not required to start the equipment on site.

2. Intelligent device management

Timely maintenance: self-defined maintenance reminding time, the system will calculate and remind maintenance items according to the last maintenance time and equipment running time. Timely maintenance, reasonable choice of maintenance items, to avoid over maintenance.

I5

Intelligent control: through precise strategy, reasonable control of equipment, to avoid energy waste. It can also protect the life of the equipment.

I6

3. Real-time data analysis

Data perception: The home page can directly see the gas-electricity ratio and unit energy consumption of the station.

Data overview: View the detailed parameters of any device in one click.

Historical tracing: You can view historical parameters of all parameters according to the granularity of year, month, day, hour, minute, second, and corresponding graph. You can export a table with one click.
Energy management: excavate the abnormal points of equipment energy consumption, and improve equipment efficiency to the optimal level.

Analysis report: combined with operation and maintenance, control and operation effectiveness to get the same analysis report and analysis of optimization plan.

In addition, the system also has an alarm center, which can record the history of the fault, analyze the cause of the fault, locate the problem, eliminate hidden trouble.

All in all, this system will make the air compressor station work more safely and efficiently, and most importantly, it can reduce costs and increase efficiency. Through the detected real-time data, it will automatically trigger the execution of different actions, such as controlling the number of air compressors, ensuring the low-pressure operation of air compressors, to avoid energy waste. It is understood that a large factory used this system, although the initial investment of millions for transformation, but a year to save the cost of “back”, after each year will continue to save millions, such investment Buffett saw a little heart.

Through this practical example, I believe you will understand why the country has been advocating digital and intelligent transformation of enterprises. In the context of carbon neutrality, the digital-intelligence transformation of enterprises can not only help environmental protection, but also make the production management of their own factories more safe and efficient, and bring solid economic benefits for themselves.


Post time: Mar-14-2022

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