Luoyang Wohong Petrochemical Equipment: Introduction to Remote Monitoring and Operation and Maintenance Solutions for Recycling Systems

Solvent recovery and oil and gas recovery systems are often distributed across multiple sites. On-site personnel have limited understanding of the devices, and the difficulties in operation and maintenance lie not in the technology itself, but in the "unseen": parameters drift without being noticed, and minor faults drag on into major downtime. Remote monitoring addresses the issue of visibility - centralized transmission of operational data, automatic alarms for anomalies, remote diagnosis by experts, and a combination of online and offline processing arrangements. For sites with proper configuration, most issues are addressed before users notice, and the frequency and duration of downtime are significantly reduced. The investment in this solution is not large, but what works is connecting scattered points into a network and letting data do the legwork for people.

What does remote monitoring include

The monitoring system consists of three parts: the on-site side - signal acquisition and data gateway for temperature, pressure difference, liquid level, and concentration, with key parameters being transmitted back at the minute level; the platform side - data storage and display, trend analysis, threshold alarm; and the user side - a simple interface for site personnel and an expert interface for operation and maintenance personnel are separated, with site personnel viewing status lights and experts viewing curves and details. Monitoring does not affect the device's local control, and on-site operations always have the highest priority. Remote monitoring only involves surveillance and suggestions, with clear delineation of responsibilities and boundaries outlined in the plan.

How to classify and handle alarms

Alarms are managed at three levels: Alert level - parameters deviate but do not exceed limits, recorded by the platform, and verified during routine inspections; Warning level - parameters approach limits or show abnormal trends, the platform notifies the operation and maintenance team, and a list of on-site actions is provided after remote diagnosis; Alarm level - exceeding limits or interlocking actions, immediate telephone notification, remote guidance for initial handling, and personnel dispatched to the scene according to response time limits. Each alarm record includes five items: time, phenomenon, diagnosis, handling, and reset. The trend of alarm rate is also a barometer of equipment health. If there are more and more alarms, something must be deteriorating. The notification chain should be tested before going online - who can receive it, how long it takes to receive it, and who will take responsibility if it cannot be received. Only after answering these three questions can it be put into operation.

How to combine online and offline

What can be solved through remote diagnosis - parameter setting verification, control logic adjustment, and operational correction, can be completed online; what requires on-site presence - component replacement, leakage treatment, and annual maintenance, should be carried out as planned. The on-site operations are integrated with remote data: the work order is accompanied by alarm records and historical curves, and after processing, the retest data is sent back. All accumulated issues can be resolved in one visit, minimizing travel costs. The interface and process are designed from the user's perspective, making the tools user-friendly. Monthly operation reports are generated, including four sections: recycling volume, energy consumption, alarm statistics, and recommended items. Users can easily understand these reports, making it easier to make decisions regarding insurance renewal.

Steps of operation and maintenance plan

1. Sorting out key parameters, collecting points and deploying gateways;
2. Set threshold and alarm levels, and establish notification links;
3. The dual interface of the site and the operation and maintenance party is launched, with synchronous operation training;
4. Alarm classification and handling, with each closed-loop record;
5. Connect on-site operations with remote data, and close the loop of work orders;
6. Monthly operational report output, rolling assessment of health trends.

Frequently Asked Questions

What should I do if the site network is unstable and the data connection is lost?

The gateway maintains local caching, ensuring data is retained during network disconnection and will be uploaded upon recovery. If the network disconnection exceeds a preset duration, an offline alarm will be triggered, prompting the operation and maintenance team to contact the site for verification. This ensures that monitoring does not encounter blind spots due to network issues.

Can remote monitoring be installed on old devices?

Okay. Most old devices have reserved signal interfaces, and can be connected by adding acquisition devices and gateways. For old meters that indeed have no interfaces, they can be replaced with signal-equipped meters. The amount of modification is assessed on a point-by-point basis, and usually does not affect production operations.

Will remote monitoring affect the business data of the site?

The monitoring scope is limited to device operating parameters and does not involve business data; the ownership and usage scope of data are specified in the agreement, with platform access granted through hierarchical authorization, allowing sites to view their own data records at any time.

This article is compiled by Luoyang Wohong Petrochemical Equipment Co., Ltd., which provides design, manufacturing, and operation and maintenance services for condensation recovery, membrane separation recovery, and complete solvent recovery equipment to chemical and pharmaceutical enterprises. If you need process evaluation or scheme configuration, please feel free to contact us for discussion.