Project Description
BTESA has carried out an innovative IoT project for monitoring industrial conditions in critical environments. This development, carried out at the CEPSA’s San Roque refinery (Algeciras), represents a significant advance in the digital transformation of predictive maintenance and efficient asset management.
CEPSA’s objective was to have a system capable of managing sensors, monitoring their health status, and reporting metrics to its existing data mining systems.
BTESA, with extensive experience in monitoring and communications solutions, designed and implemented a scalable, secure, and adaptable solution with LoRaWAN technology for multiple use cases.
The project comprised several strategic phases:
Technical and conceptual study of the environment:
A comprehensive study of the refinery’s environment was carried out, characterized by particularly demanding conditions, especially in relation to radio propagation, due to the tremendous amount of pipes and metal structures in the plant. Different IoT technologies were evaluated, and LoRa technology was chosen as the most suitable for the environment and the sensors’ use case.
The main needs were identified regarding the types of sensors required (vibration, temperature, pressure, among others), and criteria such as low power consumption, ease of installation, durability, and resistance to adverse conditions were assessed. A selection of the most suitable sensors available on the market was made, with the condition of having to comply with ATEX regulations.
Design of the LoRa-based IoT architecture:
A modular and secure system was built that leverages the advantages of LoRa technology: long range, low power consumption, and the ability to operate in areas without direct internet access. The solution enables the efficient collection and management of large volumes of data generated by hundreds of distributed sensors.
Implementation of an advanced onboarding system:
One of the pillars of the project has been the development of an agile, flexible, and centralized sensor onboarding system. With a friendly user interface, it allows for quick and easy registration, configuration, updating, or removal of sensors, regardless of the manufacturer, facilitating large-scale management and significantly reducing deployment times.
Plant testing and simulations:
Simulations and tests were conducted in real environments to verify coverage, communications reliability, and metrics accuracy. These tests validated the communication model and adjusted key parameters to ensure optimal performance under real-world operating conditions.
Training and Technology Transfer:
The CEPSA team received comprehensive training in the use and administration of the system, ensuring its future autonomy. The project was delivered with complete transparency, including technical documentation and all the necessary elements for its evolution, adaptability, and replicability.
Project Validation and Expansion:
The success of the initial implementation has led CEPSA to consider expanding it to other facilities, confirming the system’s robustness and versatility. The scalable model is prepared to support new sensor additions and diverse use cases in different industrial environments.
This project has allowed CEPSA to significantly improve its analytics and predictive maintenance capabilities, reducing operating costs and increasing safety in critical environments. BTESA thus reinforces its commitment to innovation in telecommunications and industrial IoT, providing technological solutions that allow companies like CEPSA to optimize resources, reduce operating costs, and strengthen security and control in critical infrastructures.