Remote Monitoring & IoT
Remote monitoring allows supervising the compressed air system from any location, detecting problems early, and optimizing performance. Modern IoT solutions integrate cloud connectivity with advanced analytics.
System Architecture
Components
┌─────────────────────────────────────────────────────────────────┐
│ CLOUD │
│ ┌──────────────┐ ┌──────────────┐ ┌──────────────┐ │
│ │ Web │ │ Data │ │ Alerts │ │
│ │ Dashboard │ │ Analytics │ │ Email/SMS │ │
│ └──────────────┘ └──────────────┘ └──────────────┘ │
└────────────────────────────┬────────────────────────────────────┘
│ Internet
│
┌────────────────────────────┴────────────────────────────────────┐
│ IoT GATEWAY │
│ ┌──────────────────────────────────────────────────────────┐ │
│ │ Data aggregation │ Buffering │ Encryption │ MQTT │ │
│ └──────────────────────────────────────────────────────────┘ │
└────────────────────────────┬────────────────────────────────────┘
│ Local network (Ethernet/WiFi)
┌───────────────────┼───────────────────┐
│ │ │
┌────┴────┐ ┌────┴────┐ ┌────┴────┐
│ Compr.1 │ │ Compr.2 │ │ Dryer │
│ + PLC │ │ + PLC │ │ + PLC │
└─────────┘ └─────────┘ └─────────┘
Connectivity Levels
| Level | Description | Latency | Cost |
|---|---|---|---|
| Local | Plant network | ms | Low |
| SCADA | Control center | sec | Medium |
| Cloud | Internet | sec-min | Variable |
| Edge | Local processing | ms | Medium-High |
Data to Monitor
Operational Variables
| Variable | Unit | Frequency | Use |
|---|---|---|---|
| Discharge pressure | bar, psi | 1 sec | Control |
| Discharge temperature | °C | 10 sec | Protection |
| Electrical power | kW | 1 sec | Efficiency |
| Air flow | CFM, m³/min | 1 sec | Demand |
| Oil temperature | °C | 10 sec | Lubrication |
| Oil pressure | bar | 10 sec | Lubrication |
| Operating hours | h | 1 min | Maintenance |
| Status (ON/OFF/Alarm) | - | 1 sec | Supervision |
Efficiency Variables
| KPI | Calculation | Target |
|---|---|---|
| Specific power | kW / 100 CFM | less than 20 |
| Load factor | Load hours / Total hours | greater than 85% |
| Availability | Time ON / Scheduled time | greater than 98% |
| Cost per CFM | $/CFM-h | Minimize |
IoT Platforms
Manufacturer Solutions
| Manufacturer | Platform | Features |
|---|---|---|
| Atlas Copco | SMARTLINK | 24/7 monitoring, benchmarking |
| Ingersoll Rand | Helix | AI, predictive maintenance |
| Kaeser | Sigma Smart Air | Efficiency analysis |
| Gardner Denver | iConn | Universal connectivity |
| Sullair | SullairConnect | Alerts, diagnostics |
Generic Platforms
| Platform | Type | Application |
|---|---|---|
| AWS IoT | Cloud | Scalable, analytics |
| Azure IoT | Cloud | Microsoft integration |
| Google Cloud IoT | Cloud | Machine learning |
| ThingsBoard | Open source | Customizable |
| Ignition | SCADA/IoT | Industrial |
Communication
IoT Protocols
| Protocol | Use | Characteristics |
|---|---|---|
| MQTT | IoT Cloud | Lightweight, pub/sub |
| HTTP/REST | APIs | Universal, simple |
| OPC UA | Industrial | Standard, secure |
| Modbus TCP | Equipment | Legacy, common |
| CoAP | Constrained IoT | Low power |
Security
| Layer | Measure | Description |
|---|---|---|
| Transport | TLS/SSL | Data encryption |
| Authentication | Certificates | Verified identity |
| Authorization | Tokens/OAuth | Controlled permissions |
| Network | VPN/Firewall | Isolation |
| Data | AES encryption | Data at rest |
Alerts and Notifications
Alert Types
┌─────────────────────────────────────────────────────────┐
│ ALERT SYSTEM │
│ │
│ ┌─────────┐ ┌─────────┐ ┌─────────┐ │
│ │CRITICAL │ │ WARNING │ │ INFO │ │
│ │ 🔴 │ │ 🟡 │ │ 🔵 │ │
│ └────┬────┘ └────┬────┘ └────┬────┘ │
│ │ │ │ │
│ ▼ ▼ ▼ │
│ • Phone call • Email • Log │
│ • SMS • Dashboard • Dashboard │
│ • Email • App push • Report │
│ │
└─────────────────────────────────────────────────────────┘
Alert Configuration
| Condition | Type | Action |
|---|---|---|
| Pressure less than 6.0 bar | Critical | Call + SMS |
| Temperature greater than 100°C | Critical | SMS + Email |
| Efficiency less than 80% | Warning | |
| Overdue maintenance | Warning | |
| Compressor stopped | Info | Dashboard |
| Scheduled hours | Info | Report |
Dashboards
Typical Elements
┌─────────────────────────────────────────────────────────────────┐
│ COMPRESSED AIR SYSTEM - MAIN PLANT │
├─────────────────────────────────────────────────────────────────┤
│ │
│ ┌──────────────────┐ ┌──────────────────┐ ┌────────────────┐│
│ │ PRESSURE │ │ FLOW │ │ POWER ││
│ │ ┌────┐ │ │ 2,450 │ │ 185 kW ││
│ │ │7.2 │ bar │ │ CFM │ │ ││
│ │ └────┘ │ │ ▄▄▄▄▄▄ │ │ ████████ ││
│ └──────────────────┘ └──────────────────┘ └────────────────┘│
│ │
│ ┌─────────────────────────────────────────────────────────────┐│
│ │ COMPRESSOR STATUS ││
│ │ ││
│ │ Comp 1 [████ ON 100%] Comp 2 [████ ON 100%] ││
│ │ Comp 3 [░░░░ OFF ] Comp 4 [░░░░ STANDBY] ││
│ │ ││
│ └─────────────────────────────────────────────────────────────┘│
│ │
│ ┌─────────────────────────────────────────────────────────────┐│
│ │ 24-HOUR TREND ││
│ │ ╭─╮ ╭────╮ ││
│ │ ────╱ ╲──╱ ╲──────────────── ││
│ │ ││
│ └─────────────────────────────────────────────────────────────┘│
└─────────────────────────────────────────────────────────────────┘
Predictive Maintenance
Predictive Indicators
| Indicator | Measurement | Prediction |
|---|---|---|
| Increasing vibration | mm/s | Bearing failure |
| Rising temperature | °C | Lubrication problem |
| Efficiency drop | kW/CFM | Internal wear |
| Increased starts | #/hour | Leak or demand |
| Pressure differential | bar | Saturated filter |
Algorithms
┌─────────────────────────────────────────────────────────┐
│ PREDICTIVE ANALYSIS │
│ │
│ Historical data ───→ ┌─────────────┐ │
│ │ ML Model │──→ Failure │
│ Real-time data ────→ │ (Machine │ prediction │
│ │ Learning) │ │
│ └─────────────┘ │
│ │ │
│ ▼ │
│ ┌─────────────────┐ │
│ │ Estimated │ │
│ │ remaining life: │ │
│ │ 847 hours │ │
│ └─────────────────┘ │
└─────────────────────────────────────────────────────────┘
Reports
Report Types
| Report | Frequency | Content |
|---|---|---|
| Daily operational | Daily | Status, alarms, hours |
| Weekly efficiency | Weekly | kW/CFM, trends |
| Maintenance | Monthly | Upcoming services, history |
| Energy cost | Monthly | kWh, $, comparisons |
| Executive | Quarterly | KPIs, investments, ROI |
Report Example
═══════════════════════════════════════════════════════════
MONTHLY REPORT - COMPRESSED AIR SYSTEM
JANUARY 2024
═══════════════════════════════════════════════════════════
OPERATIONAL SUMMARY
─────────────────────────────────────────────────────────
Total operating hours: 2,160 h
System availability: 98.5%
Air volume produced: 5,184,000 CF
Electrical consumption: 432,000 kWh
EFFICIENCY
─────────────────────────────────────────────────────────
Average specific power: 18.2 kW/100 CFM
Best day: 17.1 kW/100 CFM
Worst day: 21.3 kW/100 CFM
Target: less than 20 kW/100 CFM ✓
COSTS
─────────────────────────────────────────────────────────
Energy cost: $43,200
Cost per 1000 CF: $8.33
Comparison previous month: -5.2%
MAINTENANCE
─────────────────────────────────────────────────────────
Services performed: 3
Next service: Compressor 2 - Filters
Active alerts: 0
═══════════════════════════════════════════════════════════
Remote Monitoring ROI
| Benefit | Typical Savings |
|---|---|
| Early fault detection | 30-50% repair costs |
| Energy optimization | 5-15% consumption |
| Reduced technician visits | 20-40% service costs |
| Less downtime | 50-70% downtime |
| Predictive maintenance | 25-35% maintenance costs |
Investment
The cost of a remote monitoring system is typically recovered in 6-18 months through savings in energy, maintenance, and reduced unplanned shutdowns.