Nidec asi electric power solutions for pipeline applications
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www.nidec-asi.com
ELECTRIC POWERSOLUTIONS FOR PIPELINE
APPLICATIONS
Oil & Gas
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Pipeline Applications ExperiencePipeline Applications Experience
NIDEC ASI provides electric power solutions for pumps and compressors in oil and gaspipelines, guaranteeing the best technology and the best operational conditions along the
entire process: from extraction to distribution.Our engineering team fully realizes your dreams and desires, designing customized solutions
which meet our client’s need in terms of: power quality, network connection, power andfrequency flexibility, low maintenance costs and time, machine durability, optimization of
capital expenditure, best allocation of available space.
With over 40 years of experience we work in close collaboration with End Users, Engineeringand OEM in order to develop the best global solutions for pipeline field operations.
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Electric Power SolutionsMeeting the operational needs
Meeting the operational needs for oil & gas pumps and compressors in terms of operationalspeed range is a primary issue, specific to these applications. The cost, complexity, and
reliability of the drive train will be impacted as more components are added.
To guarantee maximum reliability, uptime and performance in terms of efficiency, electricmotor-drive systems for pump and compressor applications require specific studies
considering all the different operating requirements.
This will affect the motor type, motor size, system configuration, power requirements,network power connection, costs and losses, coupling and operational methodologies.
We meet requirements and desires of our customers, in the selection of the electric motorand drive train configuration, through a customized approach.
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Traditional ApproachApplication up to 5 MW
The traditional approach is usually applied to compressors and centrifugal pumps on oil andgas pipelines where substations are near or else in derivation plants. The motor operates
Direct on Line (DOL) at constant speed and torque.
Today, in order to increase plant longevity and maintain simplicity and costs, the preferredoption for the drive train is to install a softstarter to ramp up the motor to its nominal rated
operating conditions.
Softstarter + Motor Directly Driving Pump or Compressor
Gas
Compressor
N1
N1
Constant 50 or 60 Hz,AC ~ Voltage Electric
Motor Pump orCompressor
Electric Utility orOther Generated
Power
Softstarter
In these types of solutions 2 or 4 poles fixed frequency machines are traditionally used, butthe interest in VFD technologies is steadily growing.
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Softstarter
By starting a motor at a loweffective frequency and thenramping up the speed, motorcurrent and torque can be limitedto near full load values.The Softstarter can provide amotor soft-start while providingfull load torque, also helping toreduce the motor currentrequirements for start-up.
Advantages in using a Softstarter:
• Least severe option for torsionalload and current demand bymotor upon start up means lesswear on equipment
• Guarantees motor can bestarted on virtually any electricalgrid
Medium Voltage Softstarter
3,3 KV up to 15,000 KV
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Incoming line
M
Softstarter
By pass switch
SoftstarterOne Line Diagram
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Plant Phase 1: start up – full efficiency:
The VFD System technologies can beused as Softstarter. With this configurationit is possible to activate a X number ofmotors with a gradual increase of power.This solution permits to optimizefrequency flow, without bearing upon theexternal electrical network and increasinglife span machines.
Plant Phase 2: changes in conditions
In this second phase Flexibility andOptimization of initial investiment are key -needs.
In this phase the drive is used not only tostart the motors but also to adjust thespeed to the required load, thus savingenergy.
VFD SolutionsFlexibility & Life Cycle Management
VFD
M
M
Pumpor
Compressor
Pumpor
Compressor
N° motors
Another option would be to use a VFD as a softstarter. This solution requires a higher intialcapital investment but guarantees maximum flexibility for future operation.
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Silcovert SPrinciple one line diagram for one Softstarter system
11 kV – 50 Hz Line Power
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13,2kV-60Hz Power Supply line
3bBy_passCircuitBreaker
2b OutputCircuitbreaker
Mot.Protect.
1InputlineCircuitBreaker
SILCOVERTSVTN
2a OutputCircuitbreaker
M 2
SynchronizationUnit
M1
3aBy_passCircuitBreaker
Mot.Protect.
Asynchronous Motor 1-2One run. the other isStand-by (reserve)
NIDEC ASI SCOPEOF SUPPLY
Silcovert TNPrinciple one line diagram for one Softstarter system
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Retrofitting can be handled in one of two ways:
• Control - room space management. Thestation can easily be designed from thebeginning to accomodate the futureinstallation of the VFD. In this case NIDECASI can act as consultants, providing theengineering team with the Dimensions andElectrical schemes to size the originalstation.
Or• NIDEC ASI can provide the installation of
the complete solution in container ready tobe connected to the existing plant.
We support the installation of the Variable Frequency Drive System both as a new buildand through retrofitting. This allows our customers a choice in their investment planning.
TN VFD in Container
VFD SolutionsInvestment planning
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Some applications will require the use of a Variable frequency drive (VFD) from the beginningto vary the pump or compressor speed. Typically, these are higher power applications orinstallations where the flow rate is not constant throughout the year. The VFD works to varythe input frequency and voltage supplied to the electric motor.
NIDEC ASI supplies VFD Technologies incomplete Fully Integrated Packagesconsisting of:
• Switchgear
• Drive Transformer
• VFD
• Disconnectors (supplied by a third part)
• Electric Motor or Motor/Generator
VFD PackagesApplication up to 30 MW
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the highest efficiency on the market today (lower energy consumption)
the Lowest Maintenance Costs
the Highest reliability (no down time means higher productivity)
Load VFD VFD+Transf+motor Power Factor% Efficiency % Efficiency % %
100 98.6 – 98.0 97.3 – 96.1 0.96
75 98.5 – 97.5 97.7 – 95.8 0.97
50 98.0 – 97.0 97.5 – 95.0 0.98
VFD SolutionsLife Cycle Cost Evaluation
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Efficiency of the electric motor drive train will be determined by the losses. The gearbox isone of the main significant causes of drive train component losses. Typically, these are onthe order of 5 to 8 %(*).
(*) “Application guideline for electric motor drive equipment for natural gas compressors”, Gas Machinery Research Council Southwest ResearchInstitute, Jan 2008
Electric Utility or OtherGenerated Power
Electric
MotorVFD Gas
Compressor
N1
Variable freq
AC ~
Variable
speed
N1Electric
MotorVFD Gas
Compressor
1Constant 50 or 60 Hz,
AC ~ Voltage
Single motor Directly Driving a Gas Compressor with VFD (without Gearbox)
Electric Motor with VFD (with Gearbox)
Electric
MotorVFD
Variablefreq AC ~
Electric Utility or OtherGenerated Power
Constant 50 or 60 Hz,
AC ~ Voltage GearboxN1
Fixed Speed Ratio,
Variable Speed
N2 Gas
CompressorElectricMotorVFD
Gearbox GasCompressor
To optimize the elecrtic motor’s efficiency the installation of tailor – madesolutions is a primary need
Optimize Electric Motors EfficiencyTo reduce component losses eliminating Gearbox
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Motor Side connection
• Torque distortion
• Motor thermal stresses
• Train dynamics
• Train operability
Subsystems
• Transformers
• Power Converters
• Control system
• Auxiliaries
Grid Side connection
• Current & voltage distortion
• Power factor
• Filters
~
=
~
=
Electric Drive
EM
Integrated Engineering ApproachTypical Electric Drive System
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Torque Input from VSDS
0 20 40 60 80 100 120 140 160 180 2000
100
200
300
400
500
600
700
800
900
1000
frequency in Hz
torq
ue
harm
onic
inN
m
torque spectrum at 3300 rpm and 33 MW
Damping torque response by control algorithms
1st torsional mode
2nd torsional mode
MCL1402FR9E
EM
3MCL1403MCL1402FR9E
EM
3MCL1403MCL1402FR9EFR9EFR9
EMEM
3MCL1403
Steadfast Drive
Drive Control
MCL1402FR9E
EM
3MCL1403MCL1402FR9E
EM
3MCL1403MCL1402FR9EFR9EFR9
EMEM
3MCL1403MCL1402FR9E
EM
3MCL1403MCL1402MCL1402FR9EFR9EFR9E
EMEM
3MCL14033MCL1403MCL1402MCL1402FR9EFR9EFR9E
EMEM
3MCL14033MCL1403MCL1402FR9EFR9EFR9E
FR9
EM
EM3MCL1403
Steadfast DriveDrive
Drive ControlDrive Control
Optimizing Max Ripple at Torsional Modes in Speed Range…
20 25 30 35 40 450
200
400
600
800
1000
Fundamental frequency, Hz
To
rqu
eA
mp
litu
de
,N
m@
Rip
ple
fre
qu
en
cie
s…
|Fsw - 21f0|
|Fsw - 15f0|
20 25 30 35 40 450
200
400
600
800
1000
Fundamental frequency, Hz
To
rqu
eA
mp
litu
de
,N
m@
Rip
ple
fre
qu
en
cie
s…
|Fsw - 21f0|
|Fsw - 15f0|
Speed/fundamental frequency (Hz)
Torsional Mode Analysis
Integrated Engineering ApproachIntegrated Mechanical & Electrical Design
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Operatingperformance
SiteConditions
Shaft Line &Vibration
Cooling &Maintenance
• Reduce Complexity
• Optimize choice of motorTechnology
• Minimize Costs
• Guarantee MaximumReliability & Availability
• Maximize Flexibility
• Optimize choice of MotorTechnology
• Maximize OverallPerformance
• Optimize deviceresponse & Stress
• Improve System Design
• Optimize AuxiliarySystems
• Optimize Maintainability
Our engineering team performs specific studies to develop customize concept based on thecharacteristics of each plant.
Integrated engineering approach regards all aspects related to all technology selectionprocess, taking into consideration thermal and mechanical performance under diverseoperating conditions to minimize harmonics and identify the optimal trade off between
Voltage and Current to guarantee maximum stability of the system:
Integrated Engineering ApproachMechanical Design For Electric Motors
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Motor Power Vs. Speed
compressor load points
speed margin @ const. power
rated speed
cubic power (quadratic torque)
Motor Torque Vs. Speed
compressor load points
quadratic torque
rated speed
speed margin
Motor Voltage & Current Vs. Frequency
V/Hz = const
rated speed
voltage
current
The load features
• Quadratic load Vs. speed are ingeneral required for the VSDSdesign.
• Speed range must be well definedfrom the beginning – critical speedsmust be avoided – maximumoperating speed and the over-speed(120%) shall be mechanically verified– lower speed shall be compatiblewith motor cooling and bearingsdesign.
• In case of an operational speedmargin (example 110% speed),constant power will be consideredaccording to the rated power of theVSDS. Otherwise, with quadratictorque load, the VSDS should beoversized and rated accordingly(example 133% power).
• Compressor load can be highlyinfluenced by the process (gaspressures/temperatures), so propermargins must be considered.
Integrated Engineering ApproachMotor Design – Operating parameters
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Russia - Sakhalin Island LNG Plant
High Power Traditional Solution 4 poles
Sakhalin is a large Russian island in the NorthPacific and is crossed by the one most importantpipeline of Russia.
The strong cold and the other extreme weatherconditions, constantly wear out the electrical andmechanical equipment of the pipeline
Due the site conditions, NIDEC ASI provided thebest solution for the customer, choosing the criticalcomponents to guarantee proper performanceat -50°C.
Integrated Engineering ApproachMotor Design – Site Conditions
Technology: Shell / JGC
Scope Of Supply:n.2 21 MW LCI drives Silcovert Sn.2 motors plus 4 MW fixed speed
motors for Overhead StabilizerCompressors
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Integrated Engineering ApproachMotor Design – Site Conditions
Qatar - Ras Laffan Re-injections Plant
High Power Induction motor + PWM-NPC Solution
Ras Laffan Industrial City is the Qatar's main site forproduction of liquefied natural gas and gas-to-liquid.
In the desert (Ambient temperature +54°C) and in themaritime environment, structural integrity is vulnerableto wind blown sand and to saline of the sea, thereforethe equipment had to be sealed against the elementsand positioned in areas where they were least at risk.
NIDEC ASI supplied the right equipment and the bestsolution, resolving the problems of its customers
Scope Of Supply:n.3 CR 1000 Y 4 – 13.7 MW 11 kV 50 Hz
dual shaft end for gas re-injectionscompressors
n.2 CR 900 X 4 9.6 MW Silcovert GN 2x 3300 V for NGL 4 & NGL 5
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Example of Rotor Dynamics Analysis
Shaft ModelExample of Prediction ofRotordynamic ResponseUnbalance ResponseDeflection ShapeDynamic Couple UnbalanceSpeed = 6060 rpm
z x
y
Integrated Engineering ApproachMotor Design – Shaft Line & Vibrations
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Note to the traditional approach
LCI machines have longer shaft line Complex mechanically Torque pulsations from the electric system Only low pressure restart
Traditional LCI approach - Gas turbine driver - Large compressors:PropaneMixed RefrigerantNitrogen
High speed
G/TLCI
driven motorLP Comp HP Comp
LCI Electric system
Integrated Engineering ApproachMotor Design – Shaft Line & Vibrations
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4 Pole Solution - Gas turbine driver - Large compressors:PropaneMixed RefrigerantNitrogen
Note to the 4 Pole approach
Shorter shaft lines to reduce vibrations Power compensation for high temperature turbine derate No torque pulsations from the electric system Full pressure restart (Higher starting torque) Regenerative to the network independent from the speed Power factor correction and/or filters are not necessary
High speed
G/TParallel drive driven
motor/generator LP Comp HP Comp
4 pole motor w/Parallel Drive Electric System
Integrated Engineering ApproachMotor Design – Shaft Line & Vibrations
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Rotor Winding Head Ventilation
Integrated Engineering ApproachMotor Design – Cooling
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Stator
Rotor
Stator end windings
Rotor retaining rings
Rotor fans
NCVC1: Number ofradial ventilationslots in endchambers
NCVC2: Number ofradial ventilationslots in centralchamber
Internal Ventilation
Integrated Engineering ApproachMotor Design – Cooling
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Bearings supplied by Top manufacturers, designed accordingto our specifications to maximize up time.
Critical Components for Maintenance
Level I components
• bearings and bearing seals• air-to-water heat exchangers• pressurizing system
Level II components
• windings (stator & rotor)• excitation system windings• shaft seals• instrumentation
Level III Components
• gaskets and seal on fixed components• hold-down bolts and alignment shims• painting• terminal box components• soundproof insulation
Integrated Engineering ApproachMotor Design – Maintenance
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• Optimize AuxiliarySystems
• Optimize Maintainability
SwitchingDevice
• Assure device reliability
• MinimizeCosts
DriveTopology
ControlStrategy
Packaging
• Reduce Complexity
• Reduce Parts count
• Maximize Flexibility
• Optimize choice of DriveTechnology
• Maximize OverallPerformances
• Optimize device response &Stress
• Improve System Flexibility
The same care is taken in the choice of Drive Topology and overallsystem design
Integrated Engineering ApproachDrive System
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Thyristor/SCR IGBT/IEGT IGCT
• Current controlled device
• Semi-controlled (turn-on only)
• Highest V-I rating @ lowestcost
• Mature technology
• Voltage controlled device
• Fully controlled
• Faster switching
• Module (mature) orpress-pack (emerging)
• Proven technology
• Current controlled device
• Fully controlled
• Lower conduction loss
• Press-pack packaging
• Proven technology
Integrated Engineering ApproachDrive System – Switching Devices
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• Complexity @ high power
• Complex failure modes
• Use IGBT and IGCT
• Distortion
• More subsystems to get highperformances
• Extensively adopted in Steel industry
• Easy & flexible to control
• Use IGBT, IGCT, IEGT
LCI VSI (3-Level NPC) VSI (Stacked H-bridge)
NIDEC ASI has significant knowledge in drive topologies and can offer customers theright choice for their application
Integrated Engineering ApproachDrive System – VFD Circuit Topology
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Our MV ProductsDrive Topology
Silcovert SThyristor based LCI
for synchronousmotors providesspeed regularity,monitoring andbraking torque
regulation
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Series HAir cooling: up to 8100 KVAWater cooling: up to 18700
KVA (higher power onrequest)
Voltage: up to 7200 V(12000 V on request)
Series NAir cooling: up to 10400
KVAWater cooling: up to24000 KVA (higherpower on request)
Voltage: up to 3300 V
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High Speed Solutions
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High Speed CapabilityMotors Types and Ratings
A
B
C
24000
Exxon / QatarGas – RasGasHS 4-pole turbo motor-generator
PetrocanadaHS 2-pole turbo motor
Transco / TennecoHS 2-pole induction motor
A
B C
20
10
0
30
40
50
60
70
80
2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000
MW
Consolidated
New
Under discussion
Delivered
Recent projects update
rpm
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HS Motors vs gasTurbine
Electrical Solutions
• Best flexibility• Lower noises• Lower maintenance costs(> 10 years continuous field operation
demonstrated)
• Higher efficiency• Lower cost• Smaller size• Lower noise• No air pollution
• Reduction of power lossesin the drive system
• Smaller size• Higher reliability• Lower maintenance (time - cost)• Lower noise
HS motors vs. conventionalmotors with gear boxes
High Speed SolutionsMain Advantages
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Transco 205:Operating andMaintenance CostComparison
Electric Motor Driven Compressor Stations: $10/hp/yr
Gas & Steam Turbine Driven Stations: $35/hp/yr
Gas Reciprocating Engine Driven Stations: $55/hp/yr
Parameter Recip. Turbine Electric
Total Installed Cost 1.00 0.65 0.52
Space Requirement 1.00 0.75 0.65
Maintenance 1.00 0.60 0.15
Spare Parts 1.00 0.60 0.40
Environmental 1.00 0.80 0.10
Availability 96% 98% 99%
Fuel Efficiency 31-40% 21-36% 35-45%
Economic Comparison3700 kW (5000 hp) System
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High Speed ApplicationsOne Line Diagram SVTN 24 Pulses
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References High Speed Motors
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NIDEC ASI works in close collaboration with Project engineering management and Endusers and the OEM supplier to guarantee that equipment is fully tested
before being shipped on site.
Routine tests (according to IEC & IEEE standards);
up to 10 MW @ 9000 r/min: no load tests at motor speed range supplied by amotor-generator set.
Factory facilities, no job equipment needed;
greater than 10 MW @ 9000 r/min: no load tests at motor speed range.
Job transformer, converter, capacitors and other equipment needed;
Main Testing Area for Drives: 2500 kVAExtra power if needed for PCS testing: 1300 kVA
Machines & System Testing CapabilitiesUp to 10 MW
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In order to meet the challenges of de-risking largepowered motors we can provide full load machinetesting in back-to-back full load configuration atour Monfalcone Italian facility if 2 or more machineshave been ordered.We are able to support our customer with completetest in back to back configuration (IEEE 112) forapplications up to 75 MW.
MGSCR1120Z4Motore / motor
MGSCR1120Z4Generatore /Generator
1 2 3 4 5 6 7 8
Convertitorifrequenza / VFD“Perfectharmony”
Ecc / excQ+P Q+P
Quadro interruttori 33 kV / HV Switchgear
Q+P Q+P
S/S Generazione Potenza / Power generation S/S
Unità di commessa / Job Units
Autotrasformatore di prova 10/33 kV /10/33 kV Tool Autoransformer
“Turning-gear” & “pre-charge”10 kV / 415 V
IPT4 IPT3 (T3)
Q+P
G1
GSCR1000Z4
G2
SIG 10 Z4
IG2 (T2) SG1
M
CR 630 Y4
Convertitore frequenza SVGN
/SVGN Frequency Converter
Trasformatore abbassatore 10/3,3 kV /10/3.3 kV Step-down Transformer
IPT1 (T1) SG
IPT2
10 kV /415 V
10 kV /380-220V
Cabina stabilmento 20 kV / 20 kV Plant Cabin
Nuo
voin
terr
utto
re/new
brea
ker
Perdite / losses
Trasformatori VFD /VFD Transformers
Back to back testing is a completetest which gives our customer
additional assurance aboutmachine’s efficiency.
PDS System Testing CapabilitiesBack to Back - Full Load Testing Up to 75 MW
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We work closely with the compressor suppliers to conduct complete string tests at their facilities.This guarantees the final end user that there will be no surprises or risks in the field.
Test stand layout
back-to-back test: electric motor
coupled with a generator and 30
MW resistor banks
Thread 1
Thread 2
Thread 3
Thread 4
M33kV / 3 kV
MV Switchgear
G
Active Partener in String TestsString test at OEM facility
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Stand alone unit capability:
Data log
Basic analysis
Ethernet communication
Re configurable acquisition tasks
Customizable / expansible
Available for Hazardous area
Data signals:
Inputs for vibration probes (mechanical data)
Input for speed sensor (mechanical data)
Inputs for line current / voltage (electrical data)
Excitation current (synchronous machines)
Inputs for Pt100 (thermal data)
Outputs (alarm, trip, status)
Local network USB
Remote connectionEthernet
Remote Diagnostics System
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On this project, for example, diagnostics were managed from Japan via internet from ourfactory in Italy using our drive’s remote diagnostics capabilities.
Our drive control system can be easily integrated and interfaced with existing ControlSystems.
Remote Diagnostics Demostration
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