TE’s Low-power Sensors Coupled with Preddio’s Wireless Technology and Cloud-based Analytics to Improve Facility Condition Monitoring Solutions

Condition-monitoring systems have traditionally benefited large industrial facilities, providing valuable information on the real-time performance and status of assets to allow staff to maximize equipment efficiency and output, and even recognize and prevent problems and costly downtime before they occur. Unfortunately, due to their historical cost and complexity, these systems have traditionally only been available to the largest factories and facilities.  Now, thanks to a collaboration between TE, a global leader in connectors and sensors, and Preddio, a maker of fast and easy-to-install remote monitoring solutions for condition-based maintenance and operational productivity gains, industrial and commercial facilities of all sizes can easily and affordably implement and enjoy the benefits of condition monitoring.

“Whether it’s a large refinery, a remote municipal lift station, or a commercial craft brewery, they all have systems and equipment that need to operate within a specific range of parameters,” said Erin Byrne, chief technology officer for TE connectivity’s Sensors business unit. “When that equipment is not performing properly, productivity and sustainability are reduced, and you risk a breakdown that can range from being merely annoying, to in the case of an oil facility or gas facility, a potential environmental catastrophe if it results in a spill or excessive emissions. You can’t manage what you can’t measure, and that’s where industrial and commercial condition monitoring comes in.”

Recent advances in the Internet of Things and in low-power sensors have been a game-changer for condition monitoring. TE and Preddio worked together to find solutions that combine TE’s digital sensors and Preddio’s wireless technology, edge gateway, cloud software, and analytics to provide operators with unprecedented information on the state of their equipment. It includes new low-power sensors that can be installed virtually anywhere, in even the most remote locations, that connect to Preddio’s cloud-based software via a cellular network to provide real-time data on equipment status and performance. From there, Preddio’s software analyzes the data, converts it into insights, and presents it to the operator in an easy-to-understand graphical interface that can be viewed on a PC, tablet, or smartphone. It can even be easily set up to respond to performance deviations by providing trigger notifications or alarms, so that adjustments can be quickly made, and issues avoided.

“Perhaps what’s most exciting about this type of solution is the simplicity, scalability, and ability to deliver immediate results,” said Aaron Ganick, Co-Founder and CEO of Preddio.  “Solutions that unleash captive data can be implemented in minutes, not only for billion-dollar refineries but also for commercial craft breweries; all without modifying existing infrastructure or requiring IT systems access. And regardless of industry or the size of the operation, it enables the facility to be more efficient, more productive, more profitable, and even more sustainable.”

The craft brewery example is a great illustration of the value proposition inherent in these types of solutions. With a front-of-the-house that features comfortable seating, fun music, and a lively crowd, the popular Lord Hobo Brewing Company, with three locations in Massachusetts (USA), will never be confused with a factory or refinery. However, looking through the garage door in the taproom, the similarities begin to emerge. Lord Hobo’s brewery is a state-of-the-art operation, with sophisticated equipment including millions of dollars worth of kettles, kegs, boilers, conveyors, cooling systems, storage tanks, fermentation tanks, piping and tubing, refrigeration equipment, cleaning equipment, waste treatment systems, and more. Successful brewing requires precise pressures and temperatures and, if not properly maintained, thousands of gallons (and dollars) of beer could be wasted – a huge loss for any operation. By implementing Preddio’s solution with TE Sensors, they continuously and remotely monitor their operations 24/7 from anywhere in the world, ensuring the integrity of the brewing process, allowing them to avoid problems, and keeping their customers happy by keeping the taps flowing.