/> The scope of the project included reducing steam losses on Genentech’s campus and implementing predictive maintenance strategies for the steam traps and research equipment on campus including critical freezers which hold biological samples. It also included an effort to monitor the equipment health of emergency generators. The project implemented wireless monitoring to achieve energy savings and reduce costs through predictive maintenance. The financial goal was to achieve a payback of less than two years.

“We congratulate Genentech on this award,” said Harry Sim, CEO of Cypress Envirosystems. “The focus areas for the project were the steam distribution system on the South San Francisco campus, and freezers and other critical R&D and facilities equipment. Wireless sensing solutions from Cypress Envirosystems were selected due to the lower cost and the non-invasive and non-disruptive nature of these devices. We’re proud to have been an important part of this successful project.”

Wireless, Non-Invasive Technology
The solution uses Cypress Envirosystems’ wireless technology, a 2.4GHz wireless mesh technology to connect remote sensors and a central receiver/hub. Included in the solution was the Wireless Steam Trap Monitor, which non-invasively clamps on to existing steam traps and installs in minutes to detect if the steam trap is operating normally, is blocked, or leaking costly steam. Also employed was Cypress’ Wireless Gauge Reader, which non-invasively clamps on to existing dial gauges to optically read and transmit manual gauge readings. It, too, takes minutes to install and does not require breaking pipes or pressure seals. In addition, the solution included Wireless Freezer Monitors to improve predictive maintenance on custom freezers in the plant.

Cypress’s solution included a built-in database and user interface, which provides alarming, trending and historization. It uses the Microsoft Windows XP/Professional operating system, Microsoft SQL Server database, and Microsoft Internet Information Services Web Server. “The use of standard Microsoft technologies complied with corporate IT guidelines and enabled a smooth integration with the plant LAN,” Sim said.

Results: Lower Steam Losses, R&D Samples Saved
The project successfully reduced steam losses. Fifty-six Wireless Steam Trap Monitors were installed, and installation did not impact operations since the Wireless Steam Trap Monitors were designed to be non-invasive. Over a period of five months, leaks were detected on 20% of the traps, saving more on steam loss than the cost of the entire installation.

The project successfully implemented predictive maintenance for research equipment, reducing the need to perform frequent maintenance activities, and preventing equipment failures from impacting work product. Predictive maintenance for research freezers also reduced risk of lost R&D samples due to unexpected freezer failures. Twenty Wireless Freezer Monitors were installed, and the system predictively detected failures on four freezers. The freezers were able to be repaired, saving enough to pay for the installation costs of this part of the project.

“The use of non-invasive, clamp-on technologies from Cypress Envirosystems enabled much lower installation cost and virtually no disruption to manufacturing operations,” Sim said. “This solution was approximately 75% lower in cost than the next best alternative using traditional sensors, wiring, and I/O.”