Track & trace of mobile assets under Ex conditions

The challenge

The oil, gas and chemical industries produce and transport huge quantities of valuable but also dangerous goods worldwide. Today, companies lack the transparency in the supply chain to determine where the goods are or where their capital is, and whether there are transport disruptions or dangerous situations can arise. To create this transparency, SAVVY has developed a standard solution for the following applications:

The user monitors the process parameters of the product, the plant and the supply chain in real time - in stationary and especially decentralized plants as well as in globally mobile containers (rail freight cars, tank containers and containers) - under the harshest and potentially explosive conditions. This is to ensure the safety and availability of product and plant at all times.

The user is automatically informed of any deviation of the process parameters from the expected state. Current and historical values can be viewed worldwide via an online portal or can be integrated into the user’s ERP system or shared with external parties.

The solution:

IIoT Guidance defines the requirements for transport monitoring in close cooperation with the customer.

The monitoring solution combines sensors that measure vibration, temperature, humidity and location.

For the transmission of the data to the gateway a 4-20 mA connection was chosen because it is available on the market and has been tested for years and no battery change is necessary. Extension possibilities were included in advance and are possible without problems. An own sensor technology was also developed to reliably detect wear and tear on the wheels of the transport trains.

In clearly defined time intervals only the necessary data is sent with focus on low data consumption, the longest possible battery life and of course transparency about changes.

Transmission with worldwide approved, standardized IEEE 802.15.4 radio technology and LTE Cat M1 with NB-IoT and 2G backup mobile networks. This means that the solution is no longer limited by wired installations and at the same time allows increased reliability at low life cycle costs. 

Data is sent encrypted to a secure cloud platform and critical data is protected by 128-bit AES security keys.

An intelligent algorithm developed together with the customer gives an alarm when errors occur. This lays the foundation for predictive maintenance thanks to on-board vibration analysis.

Convenient monitoring directly in the SAVVY Synergy Enterprise web portal via various end devices selected by the customer. This information is prepared for specific target groups.

Simple and fast installation / retrofit even during operation. Thanks to highly efficient battery supply, the monitoring solution is completely self-sufficient and maintenance-free with the exception of battery replacement after approx. 10 to 15 years.

The advantages:

The SAVVY® CargoTrac-ExR-M1 telematics device is allowed to travel in danger zones with potentially explosive atmospheres, because the telematics device is approved in accordance with Directive 2014/34/EU for potentially explosive areas in zones 1 (gas group IIC) and 21 (dust group IIIC) and is also IECEx-certified.

  • Transparency in the supply chain for the consignor and the consignee as well as for all service providers involved in transportation
  • Estimated time of arrival (ETA) determination
  • Hazard detection thanks to sensor technology
  • Predictive maintenance thanks to on-board vibration analysis
  • Localisation of damage to product or container
  • Increased plant and container availability
  • Reduction of failures thanks to immediate intervention options
  • Convenient monitoring directly in the customer’s control system (integrated via standardised interfaces)
  • Convenient monitoring directly in the SAVVY Synergy Enterprise web portal
  • Reliable and secure global data transmission
  • Simple and fast installation / retrofit even during operation