by Gary Mintchell | Jun 23, 2016 | Automation, Internet of Things, News, Process Control
This week Honeywell Process Solutions held its 41st annual Honeywell Users Group (HUG) for the Americas in San Antonio. Speakers were all over the Industrial Internet of Things (IIoT) trend.
I did not make it. There are too many places to go, and I no longer work for a larger company with a financial base for lots of travel. So, I stayed in Sidney. News came via HPS’s PR agency and Control Global. Walt Boyes posted some cryptic notes on his blog one or two days.
Vimal Kapur, president of HPS, told attendees, “The Industrial Internet of Things will allow manufacturers to more efficiently gather and analyze a broader range of data across multiple operations and plants to use data to transform entire enterprises.”
Showing how IIoT is working in real-world scenarios is especially critical this year. A recent survey of North American manufacturing executives suggests that investments in data analytics are rising. However, companies are still grappling to better understand its benefits.
The Honeywell-commissioned survey, conducted by KRC Research, found the majority of respondents (between 60 and 70 percent) believe data analytics can help reduce equipment breakdowns and unplanned downtime. It can also help reduce supply chain management issues. This is noteworthy because around 40 percent of the executives see unscheduled downtime and supply chain management issues as the top two threats to maximizing revenue.
At the same time, though, nearly half of the respondents said they don’t fully understand the benefits of data analytics. More than a quarter say more proof is needed to show that data analytics work.
IIoT to Analytics
I find it fascinating how quickly the news from HUG transitioned from IIoT to data analytics. Some people look at the IIoT phenomenon as connected edge devices often through a network using the IP protocol. Increasingly analysts are broadening the scope to include the entire system of connected sensors, data collection, analytics, visualization.
That automation companies, such as HPS, are now emphasizing data science over control and instrumentation is an intriguing proposition to ponder over the future.
Digital Transformation
Just as I witnessed in Hannover, the real technology and term people are concerned with is digitalization.
“We are seeing a lot of interest from our customers attending this conference on how best to manage this digital transformation within their companies. They are looking to get more production out of existing assets and determine the best areas for investment for the long-term success of their operations – to improve process safety, reliability, security and sustainability,” said Kapur.
“HPS has been providing solutions and technologies to help manufacturers leverage critical operational data on a site by site basis for years,” said Andrew Hird, vice president and general manager of HPS’ Digital Transformation business. “Today, with the increased connectivity and the IIoT by Honeywell, they are able to gather and analyze data across multiple sites to find and implement best practices. The results of the IIoT survey of manufacturers reflect very closely the areas where Honeywell has been investing in solutions.”
Product Introductions
Honeywell’s newest industrial automation technologies unveiled at HUG included:
- Data acquisition and analytics: The expanded Uniformance Suite software provides real-time digital intelligence through advanced process and event data collection, asset-centric analytics and powerful visualization technology, turning plant data into actionable information to enable smart operations. This solution is a backbone for the IIoT by Honeywell. New this year is Uniformance Insight, which allows customers to visualize process conditions and investigate events from any web browser.
- Control: ControlEdge PLC, one of Honeywell’s first IIoT-ready controller, is part of Honeywell’s next generation of controllers providing unprecedented connectivity through all levels of process and business operations. When combined with Experion, ControlEdge PLC provides secure connectivity and tight integration to devices from multiple vendors and works with any SCADA system. Also showcased is the newest version of Experion Orion that will help industrial plants further optimize automation project execution, reduce loop commissioning time, minimize operational risk and protect intellectual investments while keeping current with today’s technology.
- Natural gas measurement: Honeywell’s new IIoT-ready gas measurement and data management solutions for North American gas transmission and distribution from the wellhead to the burner tip. The portfolio includes the EC 350 PTZ Gas Volume Corrector, Honeywell Elster Rotary Gas Meter, the Cloud Link 4G Modem, MasterLink and PowerSpring.
- Connectivity: MatrikonOPC Unified Architecture (OPC UA) extends the highly successful OPC communication protocol, enabling data acquisition and information modeling and communication between the plant floor and the enterprise reliably and securely, accelerating the IIoT.
- Mobility: Honeywell Pulse is a new mobile app used to remotely connect plant managers, supervisors and engineering staff to customized real-time plant performance notifications sent from HPS’ industrial automation software. It brings relevant metrics and the tools to resolve issues directly to their mobile device.
by Gary Mintchell | Jun 13, 2016 | Automation, Manufacturing IT, News
I’m in Orlando at the annual summer gathering of Rockwell Automation distributor and customer tech specialists. This is where they go for training in current products and introduction to new ones. And to get a little fired up about the company.
Rockwell Automation currently bills itself as the largest company solely devoted to industrial automation. True to the billing, current Senior Vice President and incoming President and CEO Blake Moret told the 2,100 gathered attendees, “All we do is industrial productivity.”
Moret’s other significant quote revealed a huge cultural shift that Rockwell Automation has undergone under current CEO Keith Nosbusch—We describe the value of the Connected Enterprise to customers in language specific to each. That means that the company has learned to speak other terminology than discrete manufacturing and machine control. Historically it lost credibility by going into batch and continuous processing companies and describing offerings using the terminology of discrete. Now they can talk pharma, or oil & gas, or whatever.
Sujeet Chand, SVP and CTO, gave the technology keynote. Chand talked about connecting silos of information—something we’ve discussed for years but seems closer to reality than ever before.
He did not spend much time on trends (collaborative robots, wearables, mobility), but pointed out that many countries are starting advanced manufacturing initiatives. The danger of so many independent initiatives is that this could lead to multiple standards, which would be a mess. He urged us to work for common standards.
Chand reinforced the value propositions for the Connected Enterprise, Rockwell’s focus for several years:
- Faster time to market
- Lower total cost of ownership
- Improve asset utilization
- Enterprise Risk Management
Why do we care about IT/OT convergence—something else we’ve discussed for years. This convergence is a key factor for Connected Enterprise, however, another benefit is it leads to improved workflow.
Since I follow all things IoT, I found Chand’s “IoT Stack” interesting. It’s fairly typical, but he differentiates data abstraction from data accumulation in the mix and does not specifically use the term analytics.
- Collaboration & processes
- Data Abstraction
- Data Accumulation
- Edge Computing
- Connectivity
- Physical devices
Frank Kulaszewicz, SVP Control and Architecture, delved into High Performance Architecture. Fundamental to high performance architecture are devices that are self-aware. A photoelectric, for example, can send a notification that it needs to be aligned or cleaned. Or a motion control servo drive can be self-tuning. Stepping up from self-aware devices are systems that are “system-aware.”
Dean Kamen, prolific inventor and entrepreneur, was the “star” keynote.
He began with a bit of discouragement, “As society get older, adoption of technology slows.” But then he showed development of some of his notable inventions that have made the world better for many. There is the insulin pump, portable dialysis machine, prosthetic arms with such great control that people can pick up a grape and eat it without crushing the grape designed for people who have lost their entire arms. Lack of clean drinking water is the #1 killer of children globally. He invented “slingshot” a machine that distills and condenses water such that just about anything wet even from manure piles can be converted to safe drinking water. He partnered with Coca-Cola to get them distributed to areas of great need.
His greatest achievement is the invention of the FIRST Robotics competition. Begun in 1989 to inspire high school kids to develop a passion for science and engineering, the movement has spread to 86 countries.
Technology development, especially through the middle ages and even by technologists like Da Vinci, was for development of tools of war for their princely benefactors. Kamen’s vision is to challenge kids (and the rest of us) to develop technology to solve human problems. No Terminators, here.
by Gary Mintchell | May 31, 2016 | Automation, News, Process Control, Safety, Security
Schneider Electric automation President Gary Freburger talked about living in a time of immense change in the industry. Sandy Vasser of ExxonMobil (my last report) discussed some of the disruptions his team is working on. One of the disruptions relates to configurable I/O.
At the conference, Schneider Electric announced an update to its Intelligent Marshalling solution. It now contains redundancy capabilities. Likewise the Tricon CX compact safety system has been enhanced with the addition of the 3902X TMR universal I/O module.
The Foxboro Evo FBM 248 and Tricon CX 3902X remove the dependency among control and safety system design and the installation of I/O systems. Universal I/O offerings for Foxboro Evo and Triconex enable process automation professionals to seamlessly adapt to last-minute I/O design changes and provide backup to eliminate the impact of any process downtime.
“Upgrading our award-winning Intelligent Marshalling solution to include redundancy and safety capabilities demonstrates our commitment to providing the connected solutions our customers need to improve the safety, reliability and efficiency of their plants and business operations,” said Chris Lyden, senior vice president of strategy, Process Automation, Schneider Electric. “Configuring control and safety systems I/O can be costly, labor-intensive and subject to change. With their additional flexibility, the Foxboro FBM 248 and Tricon CX 3902X I/O offerings allow our customers to adjust to unforeseen module changes and errors with little impact to installation time. That can drive huge savings when it comes to project execution and operations.”
With its universal I/O and software-configurable modules, Intelligent Marshalling allows users to configure I/O points from anywhere in the plant or in the world. It also enables flexible options for future expansions and upgrades, as well as significant cost savings by reducing marshalling infrastructure, increasing I/O density per cabinet, reducing field and maintenance labor costs and drastically reducing the need for onsite replacement inventory.
Modicon Finds a Home
Modicon, and factory automation in general, has been a bit like an orphan step child for years at Schneider. The group now reports into the automation group under Freburger. It’s a learning experience for the process automation people—new language, new distribution, new service options. But things seem to coalescing well.
The PlantStruxure PES hybrid control system, build on a Modicon PLC platform, received its moment in the sun at the conference. Schneider Electric has added redundant controllers to the PlantStruxure PES system. Today, 50 percent of PlantStruxure PES projects require at least one pair of redundant controllers within the configuration. PES V4.2 meets the next generation of requirements with the M580 ePAC and the ability to lock down ports within a single configuration environment. With the highest levels of cybersecurity available on the market, PES V4.2 ensures nearly 100 percent uptime for customer systems.
“As IT and OT converge, we need solutions that boost plant connectivity and security,” said Lyden. “PlantStruxure PES enhances the ability of plant operators, engineers and managers to take better advantage of process and energy management data, which better enables them to improve maintenance, increase asset reliability and uncover additional operational efficiencies, all in a more secure environment. By making our PlantStruxure PES automation system secure and future proof by design, we are meeting the needs of tomorrow’s production facilities, today.”
A core feature of the Modicon M580 ePAC is its Ethernet-based architecture. Integration into the PES solution improves system management and provides customers with a level of standard communication, guaranteeing a future-proof system. Additionally, new services will be available for engineering and commissioning, which will make navigating a control program easier, as well as improve performance when making project changes. PlantStruxure PES V4.2 is also equipped with ready-to-use application and industry libraries, allowing systems to be built more quickly and with lower engineering costs. And by integrating energy-management features from other Schneider Electric automation and power devices, such as Altivar drives, the system will help users realize higher energy cost savings.
by Gary Mintchell | May 30, 2016 | Automation, Internet of Things
by Gary Mintchell | May 27, 2016 | Automation, News
The 2016 edition of Schneider Electric’s Foxboro/Triconex/Modicon user group meeting attracted a fair number of people. This is amazing given that advanced notice wasn’t very advanced.
It’s always great catching up with some of the industry’s thought leaders, as well as getting a glimpse of new and coming products. Among the themes that came across strongly included “security by design” and focus on customer’s assets not just control and automation.
The acquisition has turned out pretty much as I thought it would. Schneider Electric has brought financial stability and investment in research and development. Organization stability is getting there, but people are still moving around a little. The only surprise I had was Schneider’s view of software. I figured that since Schneider Electric had very little history with software that it might shop the division. In fact, the Aveva reverse acquisition (or whatever) seemed to prove the point. Yet, hallway conversations universally pointed to a different reality. Schneider senior management sees great possibility for its new software assets. Since one of its competitors just renamed its upcoming event by removing the word “software”, I find this a significant competitive move.
Different Project Ideas
In an interesting twist, the opening keynote was given by a customer—Sandy Vasser of ExxonMobil. Vasser had presented his vision at the ARC Forum in Orlando in February, so I had an idea what was coming—a challenge to Schneider Electric, and indeed all suppliers. The oil & gas industry faces many challenges and it is time to think differently about traditional automation practices and technologies. The key is lowering the cost of projects and time to first oil.
A new approach is required:
Reduce customization
- push customization to the software, use standard hardware
- eliminate the need for project specifications
- eliminate the need for the infrstructure to support customized solutions
Reduce complexity simplify designs
- reduce the component count and the number of divergent systems
- take full advantage of the capability of the installed systems
- reduce the number and simplify interfaces
Eliminate simplify or automate processes
Mitigate the effects of dependencies
Reduce the amount of automatically generate documentation
Take managed risks accept some compromises
Develop and enable trust with our suppliers and our contractors
Key enablers:
- Smart configurable I/O in standard field junction boxes
- Virtualization (runtime and engineering) completely separate hardware so can test software without hardware
- Customization pushed from hardware to software
- Autodetect/Autointerrogate/Autoconfigure/Autoenable/Autodocument I/O
New challenges for our key suppliers
- control systems age in place
- system architectures made simple
- systems consist of building blocks that can be easily upgraded to current technologies
- upgrades or repairs will not be intrusive, disruptive, or unnecessarily costly
- rip and replace will never be necessary
- control system selection for a facility will be for life; fully supported and sustained
We have heard Vasser’s challenge before. But this reinforcement shows how serious ExxonMobil is about moving project planning and implementation to a new level. Faster time to start up and greatly reduced cost. The challenge for suppliers such as Schneider Electric is to bring what the customer wants and still make money. If the customer drives the supplier to a point where profits are just not there, then innovation will cease. But a good challenge from a supplier can spur innovation. We’ll see.
