Mouser - White Papers

Mouser Electronics White Paper Challenges of Brownfield Facilities Brownfield facilities are legacy installations with control systems that predate modern Internet of Things (IoT) connectivity. Retrofitting such facilities is difficult because these operations typically run 24/7 with minimal downtime. Implementing PdM in a brownfield setting comes with several technical challenges. Limited Sensorization of Equipment Many older industrial machines lack built-in sensors for condition monitoring. To obtain the necessary real-time machine data, such as vibrations and temperatures, operators must install new sensors on the equipment. Physically mounting these sensors onto industrial machines can also be challenging due to space constraints. Legacy Control Systems Existing facilities often rely on programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and industrial networks that are at least one generation old. These systems face issues interfacing with modern IoT devices. For example, an old PLC might have no spare I/O points or no support for protocols to process high-frequency vibration data. Therefore, integrating new PdM data streams without requiring a complete overhaul of the existing control architecture presents a significant challenge. Downtime Constraints Since legacy sites run around the clock, taking equipment out of service to install sensors or new hardware can be extremely costly. Even scheduling a brief outage to retrofit equipment can require long planning lead times, creating a paradox where the need to implement PdM to reduce downtime will cause downtime if not done correctly. Data Management and Analysis Managing the high volume of industrial machine data and converting it into actionable insights is a technical challenge. Active sites may lack the necessary back-end infrastructure, including data servers, analytics software, and high-bandwidth networks, to handle continuous high-speed data. Shifting to an algorithm-driven PdM approach can also strain the workforce's skills. The scale of the problem with maintaining such facilities is massive. Industry reports consistently identify aging equipment as one of the primary causes of unplanned downtime, accounting for approximately 34 percent of cases. 4 These statistics reinforce that many facilities are struggling with old machinery that fails unexpectedly. A growing number of industrial companies are implementing PdM data analysis for their assets on a broad scale. Companies must focus on improving aging infrastructure and reducing downtime as key goals, as well as recognizing the potential of PdM. Banner Engineering's Scalable PdM Solutions Banner Engineering has developed an integrated suite of hardware and software solutions specifically designed to address the challenges of brownfield PdM. These solutions comprise three key components: sensors, a central controller, and an analytics software platform, which work together to provide comprehensive, end-to-end condition monitoring. QM30VT3 High-performance 3-Axis Vibration Sensor Banner's QM30VT3 (Figure 2) is a multi-axis vibration and temperature sensor for industrial condition monitoring of industrial assets. The device is intended to be deployed at the front line of sensing, integrating onto motors, pumps, fans, gearboxes, and other rotating equipment to detect slight tremors and temperature changes that precede mechanical failures. Figure 2: Banner Engineering's QM30VT3 high-performance 3-axis vibration sensor identifies asset failures and reduces downtime on a range of industrial equipment. (Source: Banner Engineering)

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