by Gary Mintchell | Aug 14, 2019 | Asset Performance Management, Manufacturing IT, Software
The concept of digital twins was born from the marriage known as cyber-physical systems. The cyber representation of a product or process was often held digitally within CAD/CAM or PLM systems. These became linked to the physical object through a feedback loop that kept the two in sync.
Digital Twin has moved from the esoteric to mainstream within industrial culture. And digital no longer is consigned to drawing databases, as my recent conversation with Michael Kanellos and Perry Zalvesey of OSIsoft reveals.
They described the process this way, “From devices all the way to buildings and factories, we’re now living in a world where everything is connected. And as these operations become more connected, it’s increasingly important to identify the strongest solution to monitor them. With the introduction of IoT, sensor and even AI technology to industrial operators, there’s been a surge of unfamiliar digital strategies – the latest being digital twins.”
OSIsoft prefers to consider digital twin as a loose term, as it can be either a complete network doppelganger or just a copy of key data streams to narrow in on specific issues. Everyone has their own preference and iteration.
OSIsoft named its digital twin technology the Asset Framework, which allows companies to take a project-by-project approach, creating solutions for each need on a rolling basis.
When one of its customers, DCP Midstream, began deploying OSIsoft’s AF tool it rolled out 12 AF based applications in two months, experiencing a $20-$25 million one-year return.
Application of OSIsoft’s Asset Framework has been strong in the water industry. Zalvesey says that his first work in the area was with modeling processes that were only static models. Today’s digital twins are dynamic. Designers can model the facility and objects within it. Each object has attributes that data are then associated with. Where originally there was a pump object—say we define “Pump 12” and associate data such as temperature and pressure and more. Now with Asset Framework, designers can create a template class “pump” and be able to replicate for as many pumps as a facility contains.
1. Asset Framework is the core digital twin offering. It’s as a relational layer on top of PI that combines all the data streams (temp, pressure, vibration) of an asset into one screen. A lot of people get fancy with the digital twin term but to us it’s a simulation combined with live data.
2. A simple AF template for a pump probably takes a half an hour to build. It can then be replicated ad inifinitum. It’s a drag and drop process. AF is part of PI Server (it was a separate product years ago but combined into it.) Complex ones can take months. Element, a company that OSIsoft helped incubate (and has since culled investment from Kleiner Perkins, GE and others) has built a service called AF accelerator. Basically, they parachute a team of data scientists to study your large assets and then develop automated ways to build AF templates for complete mines or offshore oil platforms. It still takes two months or so but they can streamline a lot of the coding tasks. BP used them.
3. Examples:
- DCP. In 2017, the company launched an effort to digitize operations. One of the first steps was using PI to collect the data and use AF to create simple and complex digital twins. DCP has 61 gas plants for instance. Each one has been modeled with AF. Plant managers are show a live feed of current production, idealized production, and the differential in terms of gas produced and revenue. DCP discovered that it could increase production per plant on average $2000-$5000 per day, or millions a year, by giving the plant managers better visibility into current production and market pricing. In year one, it saved $20=$25 million, paying off the entire project (including the cost of building a centralized control center in Colorado and staffing it.) The next year (2018) it saved another $20 million.
- MOL. One of the largest uses of AF. MOL tracks 400,000 data streams and has 21,000+ AF instances based on 300 templates (a single template can be replicated several times.) MOL says that it has added $1 billion EBITDA since 2010 by using its data better. With AF, for instance, they figured out why hydrogen corrosion was exceeding the norm. In some instances, they’ve used advanced analytics—an experiment to see if it could use high sulfur crudes required deep analytics—but most of the time MOL has made its improvements by creating AF templates, studying the phenomena and taking action.
- Colorado Springs. Complete opposite end of big. It’s a small, regional utility.
- Heineken uses AF to model its plants to reduce energy. Aurelian Metals used it to boost gold extraction from ore from 75% to 89%. Michelin saved $4 million because AF let them recover more quickly from a previous outage. Deschutes Brewery meanwhile boosted production by $450K and delayed a plant (per our 2018 meeting.
by Gary Mintchell | Jul 26, 2019 | News, Organizations, Software
Short take: OSIsoft appoints Michael Siemer President and Wolfgang Kuchen Senior Vice President of Sales and Marketing revamping the senior management ranks.
OSIsoft, a leader in data technology for critical operations, recently announced these new appointments. I had thought that the transition from founder Pat Kennedy to his daughter running the operations was well under way. But Kennedy took on some VC investments a couple of years ago [https://themanufacturingconnection.com/2017/06/osisoft-announces-softbank-investment-fund-internet-things-infrastructure-growth/]and I’m betting that the investors were looking for experienced leadership to grow their investment.
Siemer, an energy industry veteran with extensive experience in leveraging software technologies to transform complex industrial operations, comes to OSIsoft from Devon Energy Corporation, a North American oil exploration and production company, where he served as Vice President of Engineering, Exploration and Production, Data and Analytics. Siemer led many enterprise-wide digital transformation efforts at Devon, including initiatives around field automation, data management, advanced analytics, decision support and strategic innovation. Prior to Devon, Siemer worked at SandRidge Energy, a startup E&P energy company, and prior to SandRidge he was employed for 18 years with 3M/Imation.
Kuchen, meanwhile, brings more than 20 years of experience providing financial, strategic and operational leadership in challenging business environments. Most recently, he served as President of Allergy Research Group (ARG), a Kikkoman portfolio company in the healthcare professional market. Prior to ARG, he was responsible for the growth and acquisition strategy at Soho Flordis International, a global healthcare company based in Australia.
Both Siemer and Kuchen will also serve on OSIsoft’s newly formed Executive Committee. Siemer will officially begin on September 1, 2019 while Kuchen will begin on August 1, 2019.
“Customer satisfaction has always been one of our most important principles at OSIsoft so we are very excited to bring in executives like Michael and Wolfgang who have experience in the type of digital transformation initiatives that many of our customers are starting to implement,” said Dr. J. Patrick Kennedy, CEO and founder of OSIsoft. “They will play a pivotal role in our growth as we enter a new decade.”
39 Years of Digital Transformation
Founded in 1980, OSIsoft has consistently been focused on software that lets people collect, understand and use data from critical operations, i.e. data generated by the production lines, safety equipment, power grids, and other systems that are at the foundation of their success. OSIsoft’s PI Systems acts as a data infrastructure, enabling individuals from across an organization to quickly obtain real-time insights into operations to save costs, increase productivity, develop new products or extend their capital investments.
OSIsoft customers have used PI System technology to predict wind turbine failures, increase output at a mine site by $120 million, reduce the power consumption of a supercomputer center at a national laboratory, deliver water services to millions of new customers in a major metropolitan city, boost the fuel efficiency of cruise ships and improve the quality and consistency of beer, among other accomplishments.
Over 1,000 leading utilities, 80% of the world’s largest oil and gas companies and 65% of the industrial companies in the Fortune 500 rely the PI System in their operations. Worldwide, over 2 billion sensor-based data streams are managed by the PI System.
“It is an honor to join OSIsoft. The company has long been recognized as a leader in industrial innovation and a critical partner for improving the performance of real-time operations,” Siemer said. “OSIsoft has earned an admirable level of trust with its customer base through technology-leading software and a genuine and consistent emphasis on service and support. My own experiences as a customer of OSIsoft are a big part of why I’m here. I look forward to working with the team and expanding upon the success they’ve achieved.”
“Data is the foundation of digital transformation and OSIsoft’s PI System is the gold standard for turning system data into an asset that people can use to make better decisions, improve their competitiveness and get the most out of their operations,” said Kuchen. “The impact of the PI System is set to expand rapidly.”
by Gary Mintchell | Jun 17, 2019 | Manufacturing IT, Software
Digitalization requires digital data, which in turn requires a place to robustly store that data. This place is most often the cloud these days. OSIsoft PI System must be the most widely used industrial database. The company has released OSIsoft Cloud Services—a cloud-native, real-time data management system for unifying and augmenting critical operations data from across an organization to accelerate industrial analytics, data science projects, data sharing, and other digital transformation initiatives.
OCS highlights and capabilities:
- Data sharing – partner companies can access a shared data stream to remotely monitor technology
- Functionality – seamless crossover between the PI System and OCS to compare facilities, perform root cause analysis and run hypotheticals
- Scalability – tests proved OCS can simultaneously manage over two billion data streams, and safely share information with partners
- Petuum uses OCS to stream historical data and live data on production, temperature and variability to its AI platform to assist Cemex, a global cement manufacturer, improve yield and energy to 7% from 2%.
- DERNetSoft uses OCS to aggregate data in one place, allowing users to access useful analytics for ways to reduce power and save money.
- Pharma companies will use OCS to give a regulator access to anonymized drug testing or production, without risk of unauthorized users in the manufacturing networks.
With OCS, an engineer at a chemical producer, for example, could combine maintenance and energy data from multiple facilities into a live superset of information to boost production in real-time while planning analysts could merge several years’ worth of output and yield data to create a ‘perfect plant’ model for capital forecasts.
OCS can also be leveraged by software developers and system integrators to build new applications and services or to link remote assets.
“OSIsoft Cloud Services is a fundamental part of our mission to help people get the most out of the data that is at the foundation of their business. We want their cost of curiosity to be as close to zero as possible,” said Gregg Le Blanc, Vice President of Product at OSIsoft. “OCS is designed to complement the PI System by giving customers a way to uncover new operational insights and use their data to solve new problems that would have been impractical or impossible before.”
The Data Dilemma
Critical operations data—i.e. data generated by production lines, safety equipment, grids, and other systems essential to a company’s survival—is part of one of the fastest growing segments in the data universe. IDC and Seagate estimate in “Data Age 2025: The Evolution of Data to Life Critical” that “hypercritical” data for applications such as distributed control systems is growing by 54% a year and will constitute 10% of all data by 2025 while real-time data will nearly double to more than 25% of all data.
Critical operations data, however, can be extremely difficult to manage or use.
Data scientists spend 50 percent or more of their time curating large data sets instead of conducting analytics. IT teams get bogged down in managing VPNs for third parties or writing code for basic administrative tasks. Data becomes inaccessible and locked in silos. Over 1,000 utilities, 80% of the largest oil and gas companies, and 65% of the Fortune 500 industrial companies already use the PI System to harness critical operations data, turning it into an asset for improving productivity, saving money, and developing new services.
Natively compatible with the PI System, OCS extends the range of possible applications and use cases of OSIsoft’s data infrastructure while eliminating the challenges of capturing, managing, enhancing, and delivering operations data across an organization. Within a few hours, thousands of data streams containing years of historical data can be transferred to OCS, allowing customers to explore, experiment, and share large data sets the same day.
Two Billion Data Streams
The core of OCS is a highly scalable sequential data store optimized for time series data, depth measurements, temperature readings, and similar data. OSIsoft has also embedded numerous usability features for connecting devices, managing users, searching, transferring data from the PI System to OCS, and other functions. OCS can also accept data from devices outside of traditional control networks or other sources.
“The scale and scope of data that will be generated over the coming decades is unprecedented, but our mission remains the same,” said Dr. J. Patrick Kennedy, CEO and Founder of OSIsoft. “OSIsoft Cloud Services represent the latest step in a nearly 40 year journey and there’s more to come.”
To test the scalability and stability of OCS, OSIsoft created a deployment that contained the equivalent of the data generated by all of the smart meters in the U.S. over the last two years, or two billion data streams (100 million meters with 20 data streams each). OCS successfully stored up to 1.2 billion data points per hour and was managing all two billion streams simultaneously within 48 hours.
PaaS for OSIsoft Marketplace Partners
Software developers are already creating services based around OCS. DERNetSoft is creating a secure marketplace for sharing utility and electric power data to improve energy forecasts and peak shaving strategies. Meanwhile, others are collaborating with customers on efforts to bolster well integrity at oil drilling sites, pinpoint tank leakage, predict maintenance problems, and reduce energy consumption with OCS. OSIsoft partners developing OCS services include Petuum, Seeq, Toumetis, Transpara, Aperio, and TrendMiner. These services will be available from OSIsoft marketplace as they are released.
“Digital transformation requires the ability to compare data and outcomes across multiple plants and data sources,” says Michael Risse, VP/CMO at Seeq. “OCS is a unified solution for process manufacturing customers to enable this type of analysis, generating predictive insights on thousands of assets across company operations to improve production outcomes.”
Pricing and Availability
OCS is a subscription service currently available to customers and partners for use in facilities in North America. OCS will be extended to Europe and to other regions in the near future.
Pricing is based on the average number of data streams accessed, rather than the unique data streams stored, giving customers the freedom to experiment more freely with their data without incurring added costs..
by Gary Mintchell | Nov 27, 2018 | Manufacturing IT, Operations Management, Software
I’m still deep in cyber security meetings in Germany. A pause here for software and cloud news from the west coast of America—OSIsoft and Amazon Web services. Since PI is used by many industrial companies, these announcements reveal the deep acceptance of cloud technologies.
In short, here are three bullets:
- AWS Quick Starts for PI System: enables industrial customers to quickly deploy and manage the PI System on AWS.
- PI Integrator for Business Analytics: optimized for AWS to reduce time and cost of bringing operational and IoT data to AWS for sharing or advanced analytics.
- Enhanced connectivity and data sharing to accelerate digital transformation and shrink the OT-IT gap.
OSIsoft launched a suite of products today designed to enable manufacturers, utilities, and other industrial customers to run the OSIsoft PI System on Amazon Web Services.
AWS Quick Starts for the PI System consists of AWS CloudFormation templates, scripts, and reference architectures for quickly spinning up and managing a fully functioning PI System on AWS. Customers will use the PI System Quick Starts for moving PI System workloads to the AWS cloud or for providing an aggregate PI System across an enterprise, monitoring remote or isolated assets and enabling data science efforts.
The PI Integrator for Business Analytics, meanwhile, has been optimized to extract, clean and transmit data from PI Systems and reduce data preparation tasks that bog down big data and data science initiatives. Some customers have successfully used PI Integrator technology to reduce the time consumed by data preparation in advanced analytics projects by over 90%.
AWS Quick Starts will be available in 2019. PI Integrator for Business Analytics, previewed at Hannover Messe earlier this year, is available this month.
Under the Hood
Quick Starts are built by AWS solutions architects and partners to help deploy solutions on AWS, based on AWS best practices for security and high availability. These reference deployments implement key technologies automatically on the AWS Cloud, often with a single click and in less than an hour. You can build your test or production environment in a few steps, and start using it immediately.
The PI Integrator for Business Analytics can integrate to Amazon S3, Amazon Redshift, and Amazon Kinesis Data Streams, enabling industrial customers to speed up their data science experiments, combine disparate data sets for business intelligence, and operationalize the outcomes of advanced analytics that augment decision making.
The Life of the PI System
OSIsoft’s PI System transforms the vast number of operational data streams from sensors, devices and industrial processes into rich, real-time insights to help people save money, increase productivity or create connected products and services.
The PI System can be found inside thousands of companies and complex industrial sites around the globe. OSIsoft customers have used PI System technology to predict wind turbine failures, increase output at an iron mine by $120 million in a single year by fine-tuning logistics, reduce the power consumed by a supercomputer center at a national laboratory, deliver water services to millions of new customers in a major metropolitan city, transform how medicines are produced and reduce the time and expense and improve the quality and consistency of beer. Over 1,000 leading utilities, 90% of the world’s largest oil and gas companies and 65% of the Fortune 500 industrial companies rely the PI System in their operations.
“Worldwide, over 2 billion sensor-based data streams are managed by the PI System with some customers monitoring over 25 million data streams.
“Data from operations—the information being generated by chemical reactors, transformers and other industrial devices—is incredibly valuable. Operations data will be the most valuable asset companies have for moving ahead of the competition in the future. Until recently, this data has been mostly confined to the factory floor or production line in part because of the size, scope and complexity of the data generated by operations,” said John Baier, Director of Integration Technologies, Cloud Analytics Practice at OSIsoft. “Working with Amazon Web Services, we want to unlock the value of operations data by eliminating barriers and bringing it to as many people as possible.”
www.osisoft.com
by Gary Mintchell | Mar 23, 2017 | Data Management, Internet of Things, Operations Management
Digital Transformation and Internet of Things were prominent at this week’s user conference. I could be in San Francisco at the OSIsoft user conference. But, no, I’m in Detroit at a different one. However, we have two news items from the conference.
The first one is Marketplace, an online collection of software and hardware solutions for accelerating digital transformation for the industrial world. It links utilities, energy companies, manufacturers, food and beverage producers, and other industrial customers with the 300+ hardware, software, and integration partners in the OSIsoft Partner EcoSphere as well as the 2600 third-party developers in the PI Developers Club.
On Marketplace, customers can discover and compare leading solutions for the Internet of Things, predictive analytics and machine learning, reducing asset downtime, data visualization and cloud-based analytics. Customers can also engage specialists for remote asset and process monitoring, condition-based maintenance, and performance benchmarking.
“Industrial transformation is one of the largest, and most challenging, economic opportunities of our time. Marketplace will help our customers extend the value of their existing investments while laying the groundwork for new digital services,” said Martin Otterson, Senior Vice President of Customer Success at OSIsoft. “With Marketplace, customers will be able to connect with companies and service providers with deep experience in their fields and accelerate their journey for digital transformation.”
OSIsoft Marketplace participants and solutions include:
- National Instruments (NI) provides LabVIEW system design software and NI InsightCM Enterprise software for condition monitoring, which can bidirectionally communicate with the PI System
- Rockwell Automation, which integrates the PI System into its FactoryTalk platform, making it easy to aggregate plant automation data across the enterprise for real-time insights
- Power Factors, providing high-quality, independent performance data for renewable energy, which allows owners and operators to standardize across their diverse portfolios and drive improvements in the physical and financial performance of their assets.
- Element Analytics, an advanced industrial analytics software company that rapidly builds Asset Frameworks through software and empowers organizations to achieve new levels of operational performance, by rapidly turning data into actionable reliability, productivity, and sustainability insights.
- eVision Industry Software creates best-in-class Control of Work software. Innovative solutions that improve the way oil, gas, chemical and other hazardous industries operate on a global and local scale. eVision’s integration with the PI System provides users with real-time situational awareness, from permit draft to control room.
The OSIsoft partner EcoSphere helps customers maximize the value of their PI System infrastructure. Over 300 companies are official members of the OSIsoft Partner Ecosphere. In addition to the Marketplace, the Partner EcoSphere provides accreditation and specialization programs to recognize individuals from partner companies who have completed comprehensive technical training requirements. Globally, 250 people from more than 40 partner companies are accredited PI System specialists.
Industrial Internet of Things
The second announcement concerns collaboration with partners such as Advantech/B+B SmartWorx, ADLink, Arrow and RtTech to encourage the development of new products and offerings that will deploy PI-based gateways, for example, to link facilities data to production data or enable pipeline companies to harvest data in remote locations.
“Our customers face a digital dilemma. They want to invest in new IIoT technology and begin to capture and analyze new sources of data. At the same time, they worry about incompatibilities or integration challenges that can outweigh the benefits,” said Otterson. “Through these partnerships we can eliminate these problems by ensuring that these new sources of data can be added to existing data infrastructures easily. Ultimately we want to make it easier for any authorized person to get insight into any device or process at any time.”
OSIsoft has prepared a software portfolio for edge gateway hardware providers and others that contain the necessary PI System technology to accelerate connectivity with remote and mobile assets, IIoT sensors and the PI System. With this combination of OSIsoft software and partner hardware technology, OSIsoft enables a host of partners including equipment suppliers, application providers and system integrators to quickly and easily create solutions at the edge. This will allow customers to run the PI System closer to remote assets – transformers, gas compressor stations, distributed gas, electric and water meters, industrial vehicles, wind turbines – where the data can be stored, viewed, and analyzed, enabling robust data collection, faster decision making, and optimized network bandwidth utilization.
IIoT in Action
In addition, where existing control and monitoring systems cannot accommodate new sensors, or are too costly to upgrade, new streams of IIoT sensor-based data can be added in parallel to existing process data and viewed in a common interface.
As an early advocate of using the PI System for IIoT, RtTech is blazing the trail on what’s possible when combining these technologies. RtTech, for instance, is working with tissue manufacturers to instrument and monitor remote ‘log saws’ that cut lengthy tubes of paper into rolls of toilet paper or other consumables. Because of their isolation and age, the only option for monitoring their health was to rely on manual inspections with pencils and clipboards, or complex retrofits that are often cost prohibitive.
Using new edge gateway technology with integrated PI system technology, RtTech’s energy and reliability apps can now help with efficiency and energy savings on remote equipment. As a result, customers now have operational insight into isolated equipment and can take corrective actions in real time.
“We’ve seen manufacturers reduce power consumption by 7%, increase asset availability by as much as 10% and improve event capture rates to 99% accuracy,” said Keith Flynn, President of RtTech. “By working with OSIsoft and using IIoT technology, we are pushing these same outcomes to remote operations and assets regardless of their location. We want our customers to have the same insight and intelligence on all their equipment, local or remote.”
