OpreX Asset Health Insights

IIoT Sensor Pump Monitoring & Predictive Maintenance

Yokogawa’s OpreX Asset Health Insights connected all pump sensors and presented all data on pump activity via a user-friendly dashboard for our mining customer to oversee and execute predictive maintenance once anomalies are detected.

Feautures included: IoT water quality sensors connected to Yokogawa Cloud collect real-time data (pH, DO, ORP, salinity & temperature). • Video Analytics with Machine Learning. • Cloud-based dashboard.

Optimizing Wellhead Pressure Monitoring

Yokogawa’s OpreX Asset Health Insights was deployed to tackle the challenge of monitoring wellhead pressure in different locations of a large Oil & Gas company and identifying abnormal pressure trends for early intervention. The deployment of IoT sensors and Anomaly Detection provided early warnings and organized alerts, enabling early anomaly detection and improving response time.

Optimizing Chiller Performance 

For food & beverage producer in Singapore who faced issue with rising energy utilities bill, Asset Health Insight helped to improve their chiller efficiency and performance. As one of the most energy consuming equipment in the plant, Yokogawa helped customer to optimize the chiller performance by leverage AI/ML method to suggest optimum set point for the chiller. As a result, customer can show significant reduction of their energy consumption compared before implementing the chiller optimization.

Enabling Smart Aqua-Farming

A client in the aquaculture industry leverages Asset Health Insights to optimize maintenance procedures and monitor  water tank conditions, shrimp health, and process productivity in real-time via the cloud. Through data from probe sensors, AHI enhances automation in maintaining water quality parameters such as dissolved oxygen, pH levels, salinity, and temperature. 

Enhancing Pump Performance and Efficiency

As part of their digital transformation, a South American refiner improved maintenance and operational parameters to reduce downtime and costs. Asset Health Insights enhances pump efficiency by collecting data on various parameters, identifying performance gaps and potential energy savings. AI alerts on-site engineers of abnormal processes. With Asset Health, the client achieved improved product quality, reliability, pump efficiency, and warranty programs. 

Monitoring Solar Power Plant Performance

For a solar plant in Singapore, AHI was implemented to seamlessly integrate solar inverter data for comprehensive analysis. It allowed the client to accurately forecast energy production based on various factors and identify key factors impacting solar power generation for optimization.

AHI proactively detects deviations in inverter behavior to prevent downtime analyzing variables' impact on performance for optimization. Hence, AHI allowed the company to gain insights into parameter relationships for data-driven decision-making.
 

Data Management Module: Optimal Data Integration & Calculation

• Streamline data integration for assets, processes, and energy.
• Aggregate and implement First-Principle models to create asset models.
• Set up alarms/alerts for timely notifications.
• Calculate KPIs and EnPls for performance evaluation.
• Establish plant hierarchy according to ISA95 standard.

Data Insight Module: Performance Visualization & Reporting

• Develop dashboards based on integrated data for easy monitoring.
• Analyze correlations, KPIs, and EnPls for performance overview.
• Identify potential failure modes with actionable recommendations.
• Discover opportunities for efficiency improvements and energy savings.
• Schedule and distribute customized reports.

Data Analytics Module: Data Analysis & Performance Optimization

• Utilize clustering, regression, and machine learning techniques.
• Pre-process data for optimization and anomaly detection.
• Predict targets and forecast energy usage.
• Identify variable importance and recognize patterns for insights.

STEP 2: Data and process configuration

Data collected is cleaned and optimized within the Yokogawa Cloud. We configure Asset Health Insights to monitor KPIs, failure criteria and other benchmarks you care about–with alerts and notifications for better situational awareness.