Enhancing safety in energy technology supply chains with digital data loggers Managing transport risks for large-scale industrial plants and key components

It happens quickly and often goes unnoticed: sensitive, high-value industrial goods used in the energy and plant engineering sectors are transported over weeks or months, passing through numerous transshipment points, and sustain damage due to extreme temperature, humidity or mechanical stress. Particularly in the case of large or heavy components, such damage often goes undetected for a long time. Companies frequently only realise the damage has occurred once they reach the project site – and are then faced with the challenge of providing reliable evidence of the damage. In this context, digital data loggers are a useful tool for transparently documenting critical transport events and minimising risks in advance.

Global supply chains are indispensable in the energy sector. Transformers, turbines, generators, switchgears and specialist components for grid infrastructure and power station projects often travel thousands of kilometres before reaching their destination. During this time, they are exposed to extreme weather conditions, long periods of inactivity at interim storage facilities, ports or borders, as well as high mechanical stresses. Particularly in the case of project-related transport, deviations from the planned schedule are almost impossible to avoid – with potentially serious consequences for the functionality, service life and commissioning of the equipment.

The advantages of global procurement – the availability of specialised components and cost-efficiency – are therefore accompanied by significant risks. Every additional handling of heavy energy equipment increases the probability of impacts, vibrations or mishandling of the cargo. Political uncertainties, stricter customs controls and geopolitical tensions further prolong transit times and result in project cargo being held up unexpectedly or packaging being opened.

Energy technology capital goods are particularly susceptible to damage

“The situation is particularly critical in the energy and plant engineering sectors,” explains Josia Fritz, Product Manager at ASPION. The high-tech company from Karlsruhe, specialised in modern sensor technology, develops shock and climate data loggers specifically for the transport of high-value capital goods. Fritz is familiar with the challenges faced by companies whose projects are highly deadline-driven and where transport damage can quickly lead to significant delays.

Transformers, turbines and large motors are sensitive to excessive impact, vibrations or climatic fluctuations, even if these are not immediately apparent from the outside. “In many cases, damage is only discovered during assembly or commissioning,” reports Fritz. “It must then be documented in a traceable manner under which transport conditions the equipment was subjected to stress.”

It is true that complex packaging and securing methods are used for large-scale energy technology components. However, even these reach their limits when heavy industrial goods are set down roughly during handling, containers shift during emergency braking, or equipment is exposed to extreme temperatures for weeks on end. Mechanical shock indicators or simple temperature strips merely provide snapshots of the situation. It is therefore not possible to reconstruct the entire transport journey. For transport insurers, however, objective evidence of damage based on reliable measurement data is crucial.

Data loggers provide transparency for complex energy transports

Modern transport data loggers bridge this information gap. “Our data loggers record temperature, humidity and mechanical stresses, and store relevant events with a timestamp,” explains Fritz. The threshold values are defined on a project-by-project basis and tailored to the specific energy technology component. The devices are attached directly to the piece of equipment or its transport frame and accompany it along the entire route. The measurement data can then be read out via a smartphone app – both at the destination and at transhipment points. Particularly in the case of complex energy technology transports, this enables a condition assessment to be carried out whilst the project is still ongoing, for example before onward transport or installation.

“Data security plays a central role here,” emphasises Fritz. “With our ASPION G-Log data loggers, the measurement data is secured by PIN protection and safeguarded against tampering.” Unauthorised access or alterations are detected and flagged accordingly.

Live tracking: A key advantage for energy projects

Data loggers with a live tracking function offer an additional safety benefit. Josia Fritz: “A 360-degree live tracking system such as the ASPION L-Track transmits status and location data continuously via mobile networks worldwide. An alert is automatically triggered if thresholds are exceeded or in the event of exceptional occurrences.”

This real-time information can be crucial, particularly in time-critical energy projects, such as the expansion of grid infrastructure or power station overhauls. It enables companies to intervene immediately, halt transport operations or implement alternative measures before damage occurs or worsens.

Expert guidance for complex energy products

Data loggers generally record measurement values autonomously. However, interpreting the data meaningfully is a challenging task, particularly in the case of heavy energy technology components. “Which accelerations are critical depends heavily on the size, weight and transport route of the equipment,” explains expert Josia Fritz. “ASPION therefore supports industrial customers in configuring the devices and analysing the measurement data.” This is because transport stresses do not consist solely of individual impacts. Vibrations and shocks during loading operations, dynamic stresses during road transport or brief extreme events can damage sensitive components. “The longer an impact lasts, the greater the likelihood of serious damage, because not all impacts are the same: a controlled settling process can be clearly distinguished from a hard impact,” summarises Fritz.

Learning from real-world transport data for future energy projects

The benefits of digital data loggers go beyond providing evidence of damage in the form of reliable indicators. Companies gain a realistic picture of the stresses their energy-related installations are actually subjected to on specific routes, with specific modes of transport or logistics partners. “Data loggers act like a black box for energy projects,” explains Fritz. The insights gained help to optimise packaging concepts, adapt transport strategies and reduce risks right from the project planning stage. This enables consequential damage, project delays and additional costs to be avoided in the long term.

Conclusion

Digital data loggers are a key tool for the safe transport of high-value capital goods in the energy and plant engineering sectors. They provide objective measurement data on climatic and mechanical stresses, enable early risk detection and serve as compelling evidence in the event of damage. When used correctly, they help companies to implement energy technology projects in a more predictable, safer and more cost-effective manner.

Author: Julia Kowal, Editor at Wordfinder

www.aspion.de