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Posts from the ‘IoT’ Category

The Path From IIoT to Predictive Maintenance for Commercial Refrigeration

JohnWallace_Blog_Image John Wallace | Director of Innovation, Retail Solutions

Emerson Commercial & Residential Solutions

Emerson is writing a series of articles about the implications of new and transformative technologies for the commercial refrigeration industry. In our first article, I described the challenges and methodologies related to transforming a newfound wealth of data into true predictive maintenance capabilities. You can read the full article here.

 

One trend driving the commercial refrigeration industry’s rapid adoption of Industrial Internet of Things (IIoT) technologies is the promise of predictive maintenance. Collecting massive amounts of real-time data comes with the potential to develop data-driven algorithms that can accurately predict looming problems and failures in refrigeration systems and equipment.

In the commercial refrigeration space, operators’ goals related to predictive maintenance are to reduce energy savings, lower maintenance and service costs, improve food quality and safety (and indirectly, customer experiences), increase comfort, and reduce downtime. So as IIoT technologies become more affordable, widely deployed and interconnected, a question naturally arises: “When will we see the results of these predictive maintenance capabilities?”

It’s a fair question. After all, some industries, such as industrial automation, are seeing rapid advances in their predictive maintenance capabilities. But many of these industries also have an inherent advantage: they’re often monitoring identical devices with well-defined historical performance models, making early problem detection relatively easy.

However, commercial refrigeration is a different ballgame. Commercial refrigeration applications are diverse and complex, making the development of their predictive maintenance capabilities far more challenging. Commercial refrigeration systems consist of many diverse and interdependent components, which often originate from multiple vendors. They encompass a wide range from traditional centralized direct expansion systems to an ever-expanding array of emerging architectures designed to achieve very specific operational (and more often, sustainability) objectives. Industry trends further complicate the issue, such as the adoption of new refrigerants and the migration from centralized to distributed, self-contained and integrated systems.

These complex systems differ in the amount, type and quality of the data they can provide — making data modeling and writing algorithms for different equipment even more difficult. Add more variables into the mix, such as weather, humidity and climate — not to mention widely varying operator goals, processes and workflows — and you can start to comprehend the depth of the challenge.

Developing predictive maintenance capabilities for commercial refrigeration is not a matter of simply pouring more data into the cloud via the IIoT. That data is as diverse as the equipment and systems which produce it. Determining the predictive potential of all that data requires fundamentally changing how we understand and approach the needs of the commercial refrigeration industry.

At Emerson, we’re tackling this challenge head on, taking a methodical, deliberate approach to predictive maintenance. Our goal is not to simply throw more IIoT technologies at the challenge. We’re working to help deliver on the promise of predictive maintenance by applying our deep knowledge of the commercial refrigeration space to help operators uncover the predictive value of data gathered from many different applications. By doing so, we’re simplifying the complexities and uncovering insights into the industry’s most common refrigeration scenarios.

We’re deriving predictive maintenance solutions from IIoT data via a three-pronged methodology: 1) understand the complexity of the domain and its individual systems; 2) define what data is relevant to which situations; and 3) determine how application sensors should be used to generate the necessary data. Then we can take the crucial step of developing tools to extrapolate true predictive maintenance answers from real-time and historical data.

In upcoming articles, Emerson will expand on these learnings and provide examples of how new technology is already being used for successful predictive maintenance programs in commercial refrigeration.

HVACR Contractors Discuss the Potential of New Technologies

BobLabbett_Blog Bob Labbett | V.P. – Aftermarket Distribution, Cold Chain

Emerson Commercial & Residential Solutions

At a recent E360 Breakfast, Emerson hosted a panel discussion among HVACR contractors to glean their insights and opinions on the biggest challenges and emerging trends impacting their businesses. It was a valuable opportunity to get a working perspective on issues more often discussed by industry analysts. A recent article covers a wide range of topics, including talks of new, high-end technologies at a practical level. You can read the whole article here.

The new technologies, IoT and analytics in the field

In recent years, the HVACR industry has experienced an influx of new electronic controls, connected technologies and data analytics enabled by the internet of things (IoT). As these technologies have come online, each of the three contractors on the E360 panel, with companies and customer bases of different sizes, has had different degrees of experience and interaction with these technologies in the field — from working with component-level information to gathering insights on facility management.

Making better use of data and analytics in the enterprise

Jim Wharton, area vice president of Link Network, ABM in Atlanta, works with an enterprise-level customer base. He explained that while data collection capabilities have been available for decades in different forms of energy management systems (EMS), many operators don’t use them to their full potential. Many may glance at their facility dashboards, see multiple areas running in the red (out-of-tolerance conditions), and may simply ignore the potential problems. “Most operators know the way their building behaves, and if they see an alarm in a certain area, they also know whether it will go away or if they need to act on it,” he said. He added that advanced data analytics now offer more insights and the potential to add tangible operational value by helping to drive informed decision making, detecting performance trends and providing equipment diagnostics and troubleshooting.

Embracing new technologies at home

Residential consumers are also embracing whole-home automation, said Martin Hoover, owner of Empire Heating & Air Conditioning in Atlanta. He said that his customers love getting notified of routine maintenance items, such as when to change filters or fix a water clog or leak. But most importantly, homeowners are using these systems to diagnose problems. “They like the fact that their home automation systems can let us know if something’s broken, so we can fix it before it affects their comfort levels,” said Hoover. But from a contractor’s perspective, he stressed that a home system also helps properly trained and educated technicians perform their own diagnostics. “This doesn’t allow us to take someone straight out of high school and put them in the field, but it certainly makes it easier,” he added.

On-board compressor controls are also helping service contractors gain deeper insights into overall refrigeration system performance. Michael Duffee, owner of Restaurant Equipment Services, Inc. of Tucker, Ga., cautions that these advanced controls require trained technicians. “If they’re not familiar with the technology, then you have to train them to avoid misdiagnosis, as there’s still the potential for things to go wrong,” he said.

Developing new technology for the real world of refrigeration

Designing new sensor technologies to be resistant to the impacts of weather, water and humid conditions are also very important considerations for Duffee. For example, he said, “In walk-in cooler environments, where it’s wet and sometimes caustic with the food and so forth, we’ve seen issues with consistency and where sensors and microprocessors can cause problems.”

With our broad knowledge of the full range of commercial refrigeration applications, Emerson keeps these environmental considerations upfront as we develop and introduce next-generation sensors and controls. For applications as simple as automated residential controls or as the source of real-time data for enterprise and IoT analytics, Emerson continuously consults with end users on the real-world issues raised by new technology.

Six Steps to a Successful Refrigeration Retrofit

AndrePatenaude_Blog_Image Andre Patenaude | Director, Food Retail Marketing & Growth Strategy, Cold Chain

Emerson Commercial & Residential Solutions

This blog summarizes an article from ACHR NEWS, entitled “Refrigeration Retrofits Offer ‘Cool’ Savings for Supermarkets.” Click here to read the article in its entirety.

The commercial refrigeration system is the biggest energy user in supermarkets, accounting for about 40 to 60 percent of electricity consumption, according to the Environmental Protection Agency (EPA). For food retailers, getting energy consumption under control is a top priority, and the refrigeration industry has stepped in with new, higher-efficiency equipment and technologies, such as advanced monitoring and control via the internet of things (IoT). However, for many retailers, virtually all their equipment is aging, and buying new equipment and systems across the board would be prohibitively expensive. But there is another path to saving a considerable amount of energy: targeted retrofits or upgrades to their existing systems.

Some energy-saving modifications can be simple and obvious, such as adding doors to cases. But at a recent Emerson E360 Forum, I explained how a systematic approach to retrofits and upgrades can identify savings throughout a store’s entire refrigeration infrastructure, particularly older, energy-demanding direct expansion (DX) centralized systems. It is a six-step process that reveals the primary causes of energy loss and, step by step, proposes energy-saving retrofits and upgrades to your system that can systematically reduce energy costs without breaking the bank.

  1. Conduct a baseline energy audit throughout the store by installing energy-monitoring equipment. These sensors help you analyze the existing energy signature of the entire store before you make any adjustments or retrofits, and will also be invaluable for future temperature monitoring and control to ensure food safety and quality.
  2. Recommission your existing equipment to factory specifications. This may include adjusting setpoints, superheat, suction pressure and other settings. In the process, any broken components can be repaired. This one step alone can result in energy savings of 18 percent or more.
  3. Upgrade your refrigeration technologies. One effective upgrade is changing discus compressors to digital compressors. This single retrofit can reduce compressor cycling, increase system reliability, and improve energy efficiency by 16 percent or more. Installing variable-frequency drives on condenser fan motors can save even more.
  4. Upgrade your HVAC system. Ambient store temperatures are major stressors on refrigeration systems. Consider upgrading rooftop units and adding demand-controlled ventilation and humidity controls. Integrating the rooftop units with the refrigeration system in the store is another option, creating a self-contained ecosystem that balances ambient and refrigeration temperatures for significant energy savings.
  5. Upgrade lighting and other renewables. Adding modern lighting technology lowers temperatures. Installing doors onto units lowers energy losses. Electronic case controls and expansion valves (EEVs) fine-tune equipment temperatures, while upgrading to electronically commutated (EC) motors lowers electricity consumption while improving equipment efficiency.
  6. Perform condition-based maintenance. Once you’ve migrated to these capital upgrades, it’s important to step up your regular maintenance intervals to continue your gains in efficiency and cost savings.

With these targeted retrofits and upgrades, you can systematically make your centralized DX system more effective in maintaining food quality and safety while simultaneously uncovering efficiencies that can result in significant savings.

The Risks and Rewards of Connecting Commercial Kitchens

Paul_Hepperla Paul Hepperla | Vice President, Solutions Integration – Foodservice

Emerson Commercial & Residential Solutions

 

Join us our next E360 Webinar, “The Risks and Rewards of Connecting Commercial Kitchens” on Tuesday, December 11 at 2 p.m. EST / 11 a.m. PST.

The Risks and Rewards of Connecting Commercial Kitchens

It seems everywhere you turn and across multiple industries, companies are touting the promise that the internet of Things (IoT) will digitally transform their operations. The restaurant sector is no exception. In recent years, original equipment manufacturers (OEMs) and restaurant retailers have spent considerable time and effort figuring out how to leverage the power of connectivity in commercial kitchens.

While it’s relatively easy to conceptualize how the internet of things (IoT) could improve operational efficiencies and provide business value, bringing these ideas to fruition has proved more difficult. Too often, we see retailers make the jump to connecting assets without first having a clear idea of what problem they’re trying to solve, or how connectivity will fundamentally change the way their business operates. Then, once everything is connected, they’re left wondering: “What’s next?”

Our next E360 Webinar will examine why this is the case, and focus on how foodservice OEMs and retailers can work together to tap the seemingly limitless potential of IoT. My presentation, “The Risks and Rewards of Connecting Commercial Kitchens” will focus on these key points:

  • The importance of defining the scope and purpose of your connected project
  • An examination of the far-reaching and dramatic impacts to your business
  • Real-world examples of successful and failed connectivity projects
  • Evaluating business models that involve service contracts, recurring revenue or monetization

Another common problem with connected kitchen projects is underestimating the complexities inherent with these new business models. For example, a connected maintenance offering might require somewhat sophisticated coordination of not only OEM and end user roles, but also the inclusion of an authorized service provider. Frankly, these are the types of business relationships and interactions that are often overlooked when companies rush to exploit the power of IoT before thinking through the implications.

The webinar will look at these challenges from both OEM and retail perspectives. For an OEM, it’s critically important to understand their customers’ business needs before launching a connected initiative. Similarly, retailers need to realize that without involving and engaging their OEM partners in their connected kitchen strategy, they’re not likely to achieve the maximum potential of their IoT solution.

So, if you’re thinking about entering into a connected kitchen project or IoT business model in the restaurant sector, register now to gain a better understanding of the risks and rewards of connectivity.

Supermarkets Embrace IoT Revolution

ronchapek_2 Ron Chapek | Director of Product Management/Enterprise Software

Emerson Commercial & Residential Solutions

Grocery store chain owners and managers are embracing Internet of Things (IoT) technologies to monitor the performance of their refrigeration equipment. I was recently interviewed by ACHRNews (the News) to discuss how IoT is transforming supermarket operations; this blog is a summary of that article.

Supermarkets Embrace IoT Revolution

When it comes to refrigeration equipment, supermarket operators are primarily concerned about reliable performance. With an aging generation of qualified contractors retiring and a growing shortage of trained technicians to replace them, ensuring reliable performance is becoming more difficult. It’s not surprising that as a result, grocery store owners and managers are embracing the potential of IoT to proactively monitor the performance of refrigeration equipment.

IoT is helping to fill the technician void by allowing store managers to take immediate action when refrigeration problems arise. Unplanned downtime can be extremely costly, and IoT gives operators the ability to head off issues before they become potential emergencies.

With IoT, supermarket managers are equipped with the knowledge to make quick repairs and prevent future errors, both of which deliver critical benefits that directly impact a store’s profitability and brand reputation:

  • Increased refrigeration system uptime
  • Reduction in revenue and inventory losses
  • Assurance of food safety and quality

Emerson’s ProAct™ Enterprise Software and Services is a leading example of robust IoT technology at work. Utilizing our Site Supervisor facility management controller and connected refrigeration equipment via sensors to cloud-enabled data analytics, ProAct provides alert and setpoint management while allowing grocers to take a more reliable, cost-effective, condition-based maintenance approach to refrigeration — and seamlessly transition to complete facility management of critical systems in individual stores and across the enterprise.

In this way, IoT uncovers deeper insights into how a facility is running, giving store managers the tools to take proactive measures to ensure reliability, maximize energy efficiencies, and consistently deliver optimum food quality and safety.

From an enterprise perspective, IoT allows store operators to compare trending and historic performance data at multiple sites to better optimize a grocery chain’s complete store network. Operators can also evaluate equipment upgrades and retrofits to determine which systems deliver the best performance and determine if there are any opportunities for cost savings.

Having access to preventive maintenance and predictive failure alerts is beneficial to store owners and contractors alike. Instead of performing preventive maintenance at pre-determined time intervals, IoT triggers maintenance activities based on actual system performance — giving contractors critical information to help them decide when to perform service before failures occur.

Connected refrigeration equipment also helps operators and contractors identify other indicators of asset health, including: spikes in energy use, increased compressor vibration and excessive noise — all signs that equipment could soon be at risk for failure. Not only can IoT prevent costly refrigeration downtime, it can also reduce the need for expensive emergency service calls.

For the newer generation of service contractors, IoT provides a plug-and-play capability that helps overcome their knowledge gap. With the abilities to collect and store all system-related information, IoT helps replace contractor reliance on the intelligence passed down from older contractors who are approaching retirement.

Learn how IoT and ProAct Enterprise Software and Services can help transform the efficiencies of your supermarket operations

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