Advancing Industrial Reliability with Commtest's vbOnline® Integration: A Comprehensive Case Study at Eners-Suez Energy Peru

April 01,2025

Introduction to the Integration Project

In the rapidly evolving landscape of industrial automation, the integration of advanced monitoring systems with existing infrastructure is essential for enhancing operational efficiency and safety. A recent project by Commtest exemplifies this trend by successfully integrating its vbOnline® permanent condition monitoring system with Bently Nevada products at Eners-Suez Energy Peru, a 130-megawatt hydroelectric power plant. This collaboration aimed to add vibration analysis to the plant's protection system, ensuring regular monitoring and analysis of planned readings for improved predictive maintenance.

The Eners-Suez Energy Peru Challenge

Eners-Suez Energy Peru, the largest energy supplier in Peru, also supplies a significant amount of energy to neighboring Brazil. Situated high in the Andes mountains near the edge of the jungle, the plant's remote location posed unique challenges. The need for a reliable seismic reading system was paramount, given the plant's critical role in the region's energy supply. The decision to install a remote monitoring system was driven by the facility's inaccessibility and the necessity to transmit data to a remote location for analysis.

The Journey to Implementation

The journey to implement the vbOnline system involved a 300-kilometer drive along steep and winding roads from Lima by Commtest's customer success engineer, Shane Smith, and local channel partner, Marco Ortiz. Despite the altitude challenges, the team was struck by the breathtaking views from the mountain. The inherent inaccessibility of the facility underscored the importance of a system capable of remote monitoring and data transmission.

The vbOnline System in Action

Two sets of 32-channel vbOnline systems were deployed, reading 39 readings from the buffered outputs of Bently Nevada 3500 racks. These signals corresponded to a variety of sensors, including 18 radial proximity probes, 6 axial probes, 3 keyphasor® sensors, and 12 gap sensors, all pre-installed on three 4.5-megawatt hydroelectric generators. The system's ability to provide reliable seismic readings was crucial, with 18 dual-output (measuring vibration and temperature) low-frequency sensors aligned with the probes.

The first vbOnline system was dedicated to measuring seismic sensors, ensuring comprehensive data collection on shaft vibrations and structural measurements of the shaft neck bearings. The second system focused on measuring the vibration of 12 key oil pumps and 2 air compressors, connected to 32 universal tachometers distributed across the equipment. These readings were collected twice daily, providing a wealth of data for analysis.

Commtest's Ascent® Software Integration

Both vbOnline systems were integrated with Commtest's award-winning Ascent® software, offering remote diagnostics and analysis capabilities. This integration allowed for the provision of remote diagnostics and analysis where needed the most, enhancing the plant's operational efficiency and safety.

Conclusion: The Impact of Advanced Monitoring Systems

The successful integration of Commtest's vbOnline permanent condition monitoring system with Bently Nevada products at Eners-Suez Energy Peru underscores the importance of advanced monitoring solutions in modern industrial settings. By leveraging such technology, companies can not only improve operational efficiency but also ensure the reliability and safety of their critical infrastructure. As industries continue to evolve, the demand for sophisticated monitoring solutions like vbOnline will grow, making them indispensable tools for maintaining machinery health and operational integrity in critical sectors. This detailed exploration of the EPRO PR6423/002-010 CON021 Eddy Current Sensor underscores its importance and functionality in ensuring the safety and efficiency of industrial operations. Its integration into safety systems is a testament to its capabilities and the trust placed in its performance by industries worldwide. As technology continues to advance, the role of such sensors will likely expand, making them even more critical in shaping the future of industrial automation and safety.

In conclusion, the case study at Eners-Suez Energy Peru demonstrates the significant benefits of integrating advanced monitoring systems like Commtest's vbOnline with existing infrastructure. This integration not only enhances the plant's ability to predict and prevent equipment failures but also contributes to the overall reliability and safety of the energy supply chain. As more industries recognize the value of such systems, we can expect to see a growing trend towards the adoption of advanced monitoring solutions in various sectors. This shift towards more proactive and data-driven approaches to industrial operations will undoubtedly contribute to more sustainable and efficient industrial practices in the future.

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Advancing Industrial Reliability with Commtest's vbOnline® Integration: A Comprehensive Case Study at Eners-Suez Energy Peru

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