Jun 4 2010
The Managing Automation magazine’s 2010 Progressive Manufacturing Award was bagged by Genentech for its novel energy saving system that utilized technology of Cypress Semiconductor’s subsidiary Cypress Envirosystems.
The 2.4 GHz based wireless mesh technology of Cypress Envirosystems was used by the solution for connecting a central hub/receiver and remote sensors. A wireless steam trap monitor that clamps on current steam installs and traps non-invasively in minutes TO senses whether the steam trap is blocked or costly steam is leaking out. It can be installed in minutes and does not need pressure seals or breaking pipes. This solution also includes wireless freezer monitors for enhancing predictive maintenance of the plant’s custom freezers.
The energy saving system project involved reducing steam losses at the campus of Genentech as well as implement predictive strategies for maintenance of research equipment and stream traps including vital freezers that contain biological samples. The project also included an initiative for monitoring the emergency generators’ health. For achieving reduced costs and energy savings through predictive maintenance, wireless monitoring was implemented during the project. The project’s financial aim was to get a payback under two years.
The project could reduce steam losses successfully. The number of wireless steam trap monitors was 56 and their installation did not affect operations due to their non-invasive capability. It was possible to detect leaks in 20% of the traps during five months, which resulted in more steam loss savings than the entire installation cost.
The project was able to implement the research equipment’s predictive maintenance successfully. There was a significant reduction in the need to perform maintenance actives frequently to prevent failures in equipment that affect the work product. The research freezers’ predictive maintenance also helped to lower risks due to lost R&D samples caused by unexpected failures of the freezer. Among the 20 wireless freeze monitors installed, the system detected predictively failures on four freezers that were repaired. This resulted in sufficient savings that helped towards component installation cost payments.
Cypress Envirosystems’ CEO Harry Sim revealed that this solution cost 75 % lesser when compared to next best options using customary sensors, I/O, and wiring. He added that clamp-on/non invasive technologies could be integrated with low installation cost with minimum disruption in production operations.
Source: http://www.cypressEnvirosystems.com