Protecting critical infrastructures in the Industrial IoT is challenging, especially when it comes to combined heat and power (CHP) plants. These plants are crucial for decentralized energy supply, for example in agriculture. But they must be protected against cyber attacks and technical faults. Innovative IoT solutions and predictive maintenance increase the operational reliability and efficiency of combined heat and power plants.
The challenge: Protecting critical infrastructure in the Industrial IoT
Combined heat and power plants (CHP) are used for the simultaneous, decentralized generation of heat and electricity. There are various application scenarios for them, including in agriculture. There they are used to dry grain and hay, especially in remote locations without their own electricity connection.
A failure of such plants leads to short-term damage to the harvest and thus to negative economic consequences for the farms. For this reason, it makes sense to closely monitor the condition of the CHP units with the help of the Industrial IoT. Without networking, the machine conditions cannot be viewed live. This results in a delayed analysis of the processes.
However, CHPs belong to critical infrastructures (KRITIS) and are therefore subject to strict legal requirements for IT security. The risk of hacker attacks on these plants is high. The plants must therefore be constantly updated and protected against new threats. This is made more difficult by the rapid technological development in IT, which makes today’s plants quickly outdated.
In addition, CHP plants, like all industrial plants, have a long life cycle and may be in use for several decades. Here, too, there is a risk that older plants no longer meet current standards. For this reason, CHP manufacturers need a customized IoT solution.
The solution: Robust connectivity and predictive maintenance for optimal performance
The manufacturer relies on the services of two experienced service providers to monitor the condition of its combined heat and power plants: secunet Security Networks AG ensures secure connectivity, while doubleSlash Net-Business GmbH offers IoT services and cloud strategy expertise.
Robust connectivity with high security
The solution they have developed enables the secure collection and transfer of data to Microsoft Azure, enabling predictive (remote) maintenance and efficiency gains. The robust connectivity edge solutions from secunet guarantee reliable and secure data processing and storage. They securely integrate the data into the Azure cloud platform.
This means that firmware updates can also be carried out easily and securely. Modern technologies such as Docker make it possible to update plants on the installations and implement future protocol changes. This ensures a sustainable and future-proof architecture that is equipped for the rapid succession of technology generations in IT.
Targeted planning of maintenance work with predictive maintenance
A central component of the solution is predictive maintenance based on multi-client capable software from doubleSlash. This allows potential problems to be identified at an early stage and allows for targeted planning of maintenance work. This is made possible by recording and evaluating operating data such as temperature, energy consumption and energy generated.
The data collected is crucial for monitoring the efficiency of the plants and identifying potential weak points. Thanks to the comprehensive data analysis, problems can be identified in advance of a fault so that repairs can be carried out immediately and in most cases the system does not have to be taken out of operation, or only for a short time.
The result: Reduced downtimes and longer service life thanks to predictive maintenance
The comprehensive IoT solution with condition monitoring and predictive maintenance has significantly increased operational reliability. Maintenance work can now be planned in a more targeted manner, which extends the service life of the plants. This helps to avoid unplanned downtimes, which saves costs and increases the efficiency of the energy supply.
The energy supply at locations that are difficult to access becomes more reliable, as the plants experience less downtime thanks to improved monitoring and maintenance. The solutions support operators not only in meeting current requirements, but also in overcoming future challenges. By continuously updating and adapting the systems, the technology remains at the cutting edge, which ensures the long-term operational reliability and efficiency of the combined heat and power plants.
