Industrial IoT boiler heating remote monitoring integrated equipment

The EG20 full network gateway used in the integrated device for remote monitoring of industrial IoT boiler heating adopts a high-performance industrial grade ARM processor and 4G communication module. It improves device stability through software multi-level detection and hardware multiple protection mechanisms. It can be connected to the EMCP IoT cloud platform through 4G/2G network or wired network, with multiple protection designs such as protective isolation and EMC protection, suitable for harsh industrial sites.

1Solution Overview

1.1 Project Background

Industrial IoT boiler heating remote monitoring integrated equipmentIt is an essential power equipment in industrial production such as chemical, refining, and power generation. With the continuous expansion of industrial production scale and innovation of production equipment, boilers, as the power and heat source of the entire plant, are also developing towards large capacity, high parameters, and high efficiency. Due to the low level of boiler automation control in our country,At present, boilers are mainly operated manuallyinspectionmainly.However, the location of boiler equipment is scattered, and if maintenance personnel are required to be present for inspection and repair, it not only takes time and effort, but also incurs huge operation and maintenance costs. The on duty personnel only knew about the malfunction after it occurred and reported it over the phone, resulting in delayed handling of the problem. It is particularly important to establish 24-hour monitoring for boilers in order to ensure safe and stable production through high-tech means.

1.2 Requirement analysis

1. The devices are relatively independent, scattered, and inconvenient to manage

With the large-scale expansion of industrialization, the number of boiler installations is also increasing. However, the equipment is relatively independent, geographically dispersed, and even has a large spatial span, which makes it difficult for management personnel to quickly and effectively monitor and manage each site.

2. The cost of operation and maintenance services is high, and the labor cost is also high

High offline operation and maintenance services, travel costs, and time costs; The reuse rate of equipment service technology is low, and there is no record or maintenance of work order operation and maintenance knowledge. It is not possible to view and summarize repair, maintenance, inspection records, etc. Unable to objectively assess operation and maintenance personnel,

3. The operating status of boiler equipment cannot be known at any time

The status of boiler equipment has a certain degree of uncontrollability, and it is impossible to obtain the internal operating status of the equipment and the thermal efficiency of the boiler at any time solely through manual inspection.

4. Without remote video surveillance, on-site faults cannot be promptly reported and handled

When the equipment malfunctions, on-site maintenance personnel need to actively detect the equipment failure. However, the low degree of boiler automation results in alarms not being received in a timely manner, and problems cannot be promptly investigated, which is time-consuming and laborious.

5. Without complete system monitoring data support, lacking scientific analysis and statistical methods

It is impossible to record large amounts of data in real time solely through manual labor, and workers lack relevant technical knowledge and skills in scientific statistical analysis.

1.3 Significance of the Plan

The remote monitoring of boilers adopts industrial grade network transmission and storage technology to collect real-time online operating parameters of boilersedgecalculateNot only can it ensure the safe and stable operation of the boiler, reduce the labor intensity of operators, but it can also improve thermal efficiency, reduce coal and electricity consumption, achieve economic operation, and achieve the goal of easy operation and production management.

2、 Overall design of the plan

2.1 Design Principles

The system design considers the following principles:

applicabilityFully research and analyze customer needs, and combine the current equipment situation with the customer's long-term planning to achieve system functionality under the concept of long-term, reliable, advanced, and energy-saving.

progressivenessApply mature and advanced control hardware and network technology in China, combined with our company's successful experience in boiler control in the past, to optimize and improve the design of the remote control system.

economyAdopting reasonable software and hardware configurations to achieve a high cost performance ratio.

Reliable and secureFully consider hardware and software redundancy in system design, isolate and weaken the impact range of faults, and follow standards during installation and debugging.

opennessThe system design, software and hardware configuration, network and communication protocols, database, etc. all meet relevant international and domestic standards. During system design, interfaces are reserved to make hardware and software functional modules easy to maintain, expand, and upgrade in a short period of time.

2.2 Architecture Design

The boiler remote control system consists of two parts, one is the industrial gateway, and the other is the IoT cloud platform.

The industrial gateway collects the data of boiler equipment at the lower end, uploads the data to the EMCP cloud platform, and provides equipment networking, edge computing and other functions; The cloud platform is the operating platform for this solution, where relevant device data, report information, operating parameters, etc. are summarized and displayed to provide users with analysis and decision-making basis. At the same time, users also manage and control their devices on the cloud platform.

3、 Detailed design of the plan

3.1 Hardware Design

Industrial IoT boiler heating remote monitoring integrated equipmentIt consists of three parts: boiler equipment, gateway collection equipment, and cloud platform monitoring center. The gateway collection device is connected to the boiler equipment, and the gateway transmits the real-time data collected to the monitoring center through wireless/wired networks. Since Internet transmission is not limited by distance, multiple terminal devices are connected to a monitoring center at the same time, so a monitoring center can monitor multiple boiler equipment. The monitoring center is mainly responsible for processing the data sent by each terminal and displaying it in real-time on the computer to save historical data. At the same time, the monitoring center can also provide real-time alerts for any hazardous data that may occur.

3.2 Platform Monitoring

1Remote monitoring of equipment:Real time monitoring of all parameters of the boiler, including its operating status, can be achieved through web pages or mobile apps. Support remote debugging and downloading of equipment PLC, making message communication faster and more convenient. It is possible to quickly set up monitoring screens that are the same as those on site. Remote monitoring of boiler status as if in person. This can solve the problems of difficult equipment maintenance, high travel costs, and delayed message acquisition.

2. Fault alarm and remote diagnosis:Set different thresholds for parameters such as steam pressure, temperature, flow rate, furnace temperature, exhaust gas temperature, and water level of the boiler. In the event of a malfunction, the management personnel will be notified immediately through WeChat messages, APP messages, telephone voice, SMS, and other means. Equivalent to having "electronic safety production"Eye ", management personnel now have a pair of" thousand mile eyes - smart eyes "that can quickly locate and solve problems without having to go to the scene.

3. Historical report statistical analysis:flatThe platform can achieve data aggregation and calculation for multiple boiler equipment, and can store and analyze intermediate summary variables such as boiler pressure, primary return water pressure, outlet water pressure, and total steam flow rate, ensuring that historical data is traceable. High quality reports can make the basic situation of the boiler more transparent and help managers make decisions that are beneficial for improving production efficiency.

4. Rich user permissions:

For convenience, system functions need to be customized according to different users, adding roles with different permissions. Set up different roles to view different menus, add different accounts to view user operation log information, and facilitate fine-grained management of personnel.

5. Work order operation and maintenance management:Users can create equipment inspection plans and perform operations such as device repair reporting and maintenance inspection records on their mobile devices. It can manage the consumable and core components of the burner throughout its entire lifecycle, effectively improving the efficiency of after-sales work. Realize the traceability and traceability of maintenance issues to strengthen the responsibility of operation and maintenance.

6. BI Data Summary Screen:Display the operating status and work data of boiler equipment scattered in different locations in the form of charts, which can be monitored uniformly through computers, mobile phones, and large screens. The data presented in graphical form is more three-dimensional and visually appealing, making it easy for people to understand at a glance. And the display in graphical form can show dynamic changes in a clear and immediate manner.

4、 Advantages of the plan

1Wide compatibility:Any serial device with Moubus protocol can be easily configured to connect to the EMCP IoT cloud platform, plug and play. The gateway adopts an independent interface module, which does not require further modification of equipment such as boilers and water pumps.

2Efficient operationThe data center adopts modular and matrix design, with each functional module processing large amounts of data in a timely manner, and can run smoothly even with multiple connections.

3Diversified DisplayUsers can remotely view the device's operating status through mobile apps and computer web pages.

4Reliable and stable performance:Blue Bee has provided wireless monitoring solutions for multiple customers, specializing in device management, data display, disaster backup, and other functions to ensure the long-term reliable and stable operation of the system.

5low costNo need to build a network, install servers, or hire professional engineers. Simply connect the gateway to the device to be monitored and enter the platform for simple configuration.

67x24 hour security operation and maintenanceAs a device manager, the gateway monitors the operation of devices 24 hours a day and implements unified monitoring access and intelligent alarms for all servers under the platform.

7Data transmission securityAdopting Alibaba Cloud Shield and cloud monitoring technology, the gateway and platform data transmission adopt bidirectional encryption to ensure that it cannot be stolen.