Last week was where industrial automation and information technology met along with my vice–soccer.
Emerson Automation Solutions–Digital Transformation, IT/OT collaboration, corporate acquisitions (GE Intelligent Platforms, once known as GE Fanuc, joins the fold), WirelessHART applications expand, flow control data becomes an integral part of digital transformation.
Hewlett Packard Enterprise (HPE)–Refinery of the Future tour of the Texmark refinery that I’ve written about before and CenterPoint Energy where digital boosts the electrical utility industry.
Marketers may still talk of IT/OT convergence as something coming. In many forward thinking plants it is here. Texmark CEO Doug Smith talks freely about the kick in the pants delivered by his insurance carrier that propelled him and his team toward finding innovative solutions to operations challenges.
I sometimes joke that “I’m the point of convergence of IT and OT”, or at least my blog and writing are.
Don’t believe hype or nay-sayers. The collaboration is real–among suppliers, partner ecosystems, managers, engineers. And real benefits are accruing.
Have you joined the 21st Century?
Foxboro and Triconex looks to be on the path to health under Schneider Electric. Its annual user conference is this week in San Antonio. I‘d love to be there, but personally more important is “grandparent duty” that I’m on this week. So, I had the opportunity to talk with Gary Freburger, leader of the group, and Peter Martin, VP of marketing, to get an update and view of what I’ll be missing.
Gary Freburger began with the market rebounding due to current oil pricing. Business is starting to get strong. IA product line has done well and the process business also did well going up 6% in the first half of the year. He’s expecting majority of growth over the next two years. Schneider Electric is still investing around EcoStruxure system. Foxboro is continuing on the path they discussed with us at the last user conference—how to get more value from control systems going from “necessary evil” to value add in the eyes of customer executives. The strategy is to turn data and connectivity into a business driver. The goal is enabling better decisions and improving profitability.
Freburger discussed cooperating with OPAF for a comprehensive strategy. Then he dropped in an interesting tidbit—cooperation with AVEVA. I’ve wondered about how AVEVA with the inclusion of previous Schneider Electric software would work with the Foxboro side of things. He told me they now have and end-to-end relationship to improve time to market. He noted as oil prices dropped customers thought “what can I afford to do?” Now, all have reset expectations. As oil prices rebound, they have not changed expectations. Some interesting applications and strategies include AVEVA auto populate control system, digital twin of facility, operations feedback our systems to AVEVA’s, then customer asset management upgrade works easier.
Martin discussed how Schneider is trying to change the question—from how to do control to how do we help customers solve problems that impact business? He pointed out that they’ve been doing digitization for years. What’s new is how to drive this new approach. 40 years ago controls was a solution-driven business; then with digitization the industry went from solutions to technology-driven. The times now require a need to flip flop. Solutions oriented but with today’s portfolios taking it to a much higher level. The speed of industrial business has increased—what was stable, e.g. cost of electricity—is stable no longer. The speed means IT world can’t keep up. Built-in real-time accounting control helps plants go beyond control to profitability. Foxboro is still dedicated to taking the use of technology to the next level.
During the conference (while I am writing from the forests in southern Ohio while the grandkids are in bed), Schneider Electric announced the release of EcoStruxure Foxboro DCS Control Software 7.1.With expanded capabilities and an enhanced HMI, the updated software simplifies engineering and enhances the user experience, while expanding the ability of EcoStruxure Foxboro DCS to drive measurable operational profitability improvements, safely.
The EcoStruxure Foxboro DCS is an open, interoperable and future-proof process automation system that provides highly accurate and effective control over a manufacturing plant’s operational profitability. It is the only process control system that provides measurable operational profitability improvements and a future-proof architecture, enabling a measurable 100 percent ROI in less than one year.
EcoStruxure is Schneider Electric’s open, interoperable, IoT-enabled system architecture and platform. This includes Connected Products, Edge Control, and Apps, Analytics and Services. EcoStruxure has been deployed in 480,000+ sites, with the support of 20,000+ system integrators and developers, connecting over 1.6 million assets under management through 40+ digital services.
EcoStruxure Foxboro DCS Control Software 7.1 runs on Windows 10 and Windows Server 2016, to provide maximum flexibility while ensuring robust cybersecurity. When planning upgrades, Schneider Electric customers can mix Windows XP, Windows 7 and Windows 10 on the same system, allowing flexibility in scheduling and timing for upgrades. Customers can upgrade individual sections of the plant in any order, at any pace, to best accommodate plant production schedules. With Microsoft support for Windows 7 due to end in 2020, transitioning to Windows 10 allows EcoStruxure Foxboro DCS customers to benefit from the strongest operating system with the most up-to-date cybersecurity features.
Among other new and updated features, the continuously current EcoStruxure Foxboro DCS Control Software 7.1 now includes:
• EcoStruxure Field Device Expert that improves efficiency, safety and profitability, while considerably reducing time for startup and restarts. It includes:
◦ Intelligent Commissioning Wizard, to reduce commissioning time up to 75 percent by automating HART device commissioning and documentation processes.
◦ Device Replacement Wizard to significantly reduce time and expertise to replace or commission HART devices, either individually or in bulk.
◦ Bundled HART DD library for increased security, faster device deployment, eradication of version mismatch and elimination of cybersecurity risks previously created by moving documents from the HART consortium web page into the system.
• New HMI Bulk Graphics Editor for increased operational efficiency and reliability by greatly reducing engineering hours and improving quality during testing. Use in major projects shows that replicating hundreds of displays with the new Bulk Graphics Editor saves months of man hours and improves quality by delivering highly predictable results. The Bulk Graphics Editor makes migrating from the classic FoxView HMI to the new Foxboro DCS Control HMI easier, requiring far fewer engineering hours, which reduces the time and cost to transition between technologies.
• Control Editors Activity Monitor for increased efficiency by improving communication, workflow and collaboration.
• Real-time asset health condition monitoring for increased reliability.
• Future-proof technology supporting the latest FTD 2.0 standard, which improves compatibility with digitized field devices from Schneider Electric and third-party vendors.
• New migration path, along with the new HMI Bulk Graphics Editor, simplifies the transition from existing FoxView HMI displays to the EcoStruxure Foxboro DCS Control Software 7.1 HMI platform for a continuously current and future-proof system. An upgrade migration path is available from previous Control Software Versions 5.x, 6.x and 7.0. After upgrading, users can tap into newer technologies that improve productivity, cybersecurity, efficiency and profitability.
Did Honeywell Process Solutions (HPS) short-circuit the Open Process Automation work? Inquiring minds wonder. Once again, some news and analysis of a conference that I couldn’t attend—three of these the same week in June.
HPS and ExxonMobil sent this release. Subsequently, I talked with some sources at competitor companies who broached the question to me—did this news short-circuit the ExxonMobil-led effort for a new process control solution? An interesting caveat is that there is more than one group within ExxonMobil—and they don’t necessarily agree.
From the first release:
The Open Process Automation group was initiated by ExxonMobil who was trying to find a better (less expensive) upgrade path for its control systems that had fallen behind that of its competitors. The oil & gas supermajor still has in operation a significant number of older systems installed as far back as the 1980s—systems that have served the company well for more than 30 years, but as older electronic components have been replaced by more modern alternatives, spare-parts shortages and looming obsolescence put ExxonMobil and other owner operators in a difficult place.
When facing obsolescence, rip-and-replace is clearly the option of last resort—incurring high costs, protracted downtime and the loss of all the intellectual property invested in developing a system’s displays, databases, control strategies and third-party interfaces, according to David Patin, distinguished engineering associate – control systems, ExxonMobil Research & Engineering.
The company’s installed base of Honeywell TDC 3000 systems, in particular, looked to be facing a critical shortage of spare parts in the year 2025, Patin explained. “So in 2011 we met with Honeywell regarding the future of TDC 3000,” Patin began, addressing a plenary session of the Honeywell Users Group Americas 2018 conference this week in San Antonio.
Unwilling to settle for rip-and-replace, “We challenged Honeywell to develop and prove a method to migrate TDC forward,” Patin said. The two companies established a joint task team to investigate the problem.
ExxonMobil’s wish list of deliverables included avoiding wholesale system replacement (especially the I/O); preserving the company’s intellectual property investment; allowing for on-process migration of system components (meaning without shutting down the process); enabling new capabilities not currently possible with TDC; and unifying TDC with Honeywell’s current state-of-the-art Experion platform.
This last item encapsulated a desire for a solution that would “be usable by a younger workforce, yet stand the test of time,” Patin said. “I picture a third-grader who’s also a future TDC engineer,” he said. “They just don’t know it yet.”
Also implicit in ExxonMobil’s requirements were continued “rock solid” reliability and security, Patin added.
Since the technical obstacles to bringing TDC forward hinged on hardware obsolescence, notably controller microprocessors and communications chips that would no longer be available, the team settled on an emulation approach that would effectively abstract TDC system functionality from the specifics of the older hardware.
And in February 2018, seven years after that first meeting of the minds—and two years ahead of schedule—Honeywell answered ExxonMobil’s challenge with the release of Experion LCN R501.1. The Experion LCN, or ELCN, effectively emulates the TDC system as software. “It’s 100% binary compatible and interoperable with the old system,” Patin explained. “Current TDC code runs unmodified in this virtual environment, greatly reducing the technical risks. Intellectual property such as application code, databases and displays are preserved.”
In the end, the Experion Station, Server, ACE and APP nodes can take the shape of Windows-based “physical” applications or virtual machines. Application Modules, Network Gateway and Network Interface Module functionality is redeployed on Universal Embedded Appliances or as virtual appliances. Only the Enhanced PLC Gateway cannot be readily virtualized because the emulation of serial network connectivity is not well behaved, Patin explained. “This means you can build an almost 100% virtualized or 100% physical system—or somewhere in between.”
With the new solution, LCN and UCN messages are now encapsulated in standard Internet Protocol. “All the old networks now exist as logical constructs on Fault Tolerant Ethernet,” Patin said. “We’re no longer locked into proprietary networks.”
And to address the challenge of on-process migration, Honeywell has also introduced several bridge devices that effectively facilitate the virtualization of TDC system node functionality—without the need to interrupt the process under control.
Virtualization of the TDC environment has come with some added benefits, including the ability to use Honeywell’s cloud-based Open Virtual Engineering Platform to engineer TDC solutions; lower cost, smaller footprint training simulators; peer-to-peer integration of virtualized HPM controller nodes with current-generation C300/ACE nodes; support for OneWireless (ISA 100 and WirelessHART) connectivity; and integration with ControlEdge and Unit
“It’ll be a game-changer,” said Patin. “We don’t know all that’s possible as yet.”
Other benefits include a drastic reduction—or elimination—of spare parts, as well as reductions in cabinet space requirements. “We’ve gone from two nodes to six in a single cabinet,” Patin said. “We’ve not fully realized unification with Experion, but that process has begun.”
Overall, Patin gave high marks to the Honeywell team for its response to ExxonMobil’s needs. “The challenge was met, and expectations exceeded,” he said. “The need to replace an entire system is eliminated, future component issues are virtually eliminated (pun intended), intellectual property is preserved and on
process migration is supported.
“ELCN technology essentially resets the odometer on your TDC 3000 investment,” Patin added. “It’s the best example of Honeywell’s commitment to continuous evolution that I’ve ever seen. And if it were a final exam, I’d give Honeywell an A on this one.”
<End of release>
HPS also announced Safety Manager SC, the next generation of its flagship Safety Manager platform. Its modular, scalable design enables it to function as a single platform for all enterprise safety applications, allowing customers – who are often using four or five different safety systems – to consolidate and reduce their training and engineering costs, and spare parts inventories.
Safety Manager SC incorporates a new Series C-based controller and Honeywell technologies such as LEAP, Universal Safety IO, offline simulation and Experion integration, which collectively simplify safety system engineering, development and testing.
“Our customers increasingly want integrated safety and control solutions and the simplicity of partnering with one supplier for all their needs,” said Tim LeFevre, global customer marketing manager for safety systems, HPS. “We deliver exactly that by combining unrivaled expertise in distributed control systems (DCS) and safety systems with deep integration know-how. Honeywell is one of the few vendors that can support the full safety lifecycle.”
The ability of Honeywell Connected Plant’s offerings to deliver higher levels of safety, reliability, efficiency and profitability will continue to be the primary discussion point at the 43rdHoneywell Users Group (HUG) Americas symposium. More than 1,300 delegates from across the oil and gas, chemical, pulp and paper, and metals and mining sectors are attending the event, which features numerous displays of the newest technologies along with dozens of Honeywell- and customer-led sessions and technical discussions.
Throughout the conference, Honeywell will showcase how turning data into actionable insight requires more than just upgrading technology; it requires a system for capturing, retaining and sharing knowledge that allows both the plant and its workers to perform at their best every day.
“Digital transformation has to be about more than just moving data into the cloud,” said John Rudolph, president of Honeywell Process Solutions (HPS). “It ultimately has to be about the outcomes, including driving increased productivity and savings for our customers while allowing them to increase knowledge capture, knowledge sharing and knowledge retention among their employees.”
Rudolph was named president of HPS on May 31, 2018, succeeding Vimal Kapur, who was named president and CEO of Honeywell Building Technologies. Rudolph led the Projects and Automation Solutions, and Lifecycle Solutions and Services businesses for HPS over the past six years, driving significant growth. Rudolph also has held leadership roles with TAS Energy, General Electric and Ingersoll Rand.
Here is a revealing comment from the press release about HPS’s strategy and direction—something we’ve all been wondering about. “HUG attendees will be able to see and experience the Company’s ongoing transformation into a software-industrial provider.”
Announcements in brief:
- Thermal IQ – Enables maintenance engineers and plant managers to more effectively monitor and manage their thermal process equipment, minimizing unplanned downtime and maximizing uptime.
- Uniformance Cloud Historian – This software-as-a-service cloud hosting solution for enterprise-wide data capture, visualization and analysis helps customers improve asset availability, optimize processes and increase plant uptime.
- Asset Performance Management – Integrates asset and process data for actionable insights to improve asset performance and plant profitability.
- Immersive Competency – This cloud-based simulation offering uses a combination of augmented reality (AR) and virtual reality (VR) to train plant personnel on critical industrial work activities, empowering them to directly improve plant performance, uptime, reliability and safety.
- Personal Gas Safety – This solution integrates with Honeywell’s leading plant control system to protect workers and speed emergency response in case of hazardous leaks or worker injury.
- Intelligent Wearables – This hands-free, wearable technology allows industrial workers to more safely, reliably and efficiently accomplish their tasks in the plant or the field. It uses a head-mounted visual display that responds to voice and brings live data, documents, work procedures, as well as health and safety information into view and can connect field workers with remote experts in real time.
- Experion Batch – Combines Experion distributed control, batch automation, and new visualization technology for improved efficiency, quality and throughput.
- Measurement IQ for Gas – Provides measurement under control by transforming metering operations with 24/7 real-time condition-based monitoring.
Critical infrastructure control systems have been under cyber attack for years. Need we mention Stuxnet, the attack that brought the issue to the public eye? Pressure has been mounting on controls, automation, and IoT suppliers to protect a nation’s assets.
Siemens and eight partners signed a joint charter for greater cybersecurity at a recent Munich conference.
- Ten action areas for greater cybersecurity
- Call for dedicated government ministries and chief information security officers
- Independent certification for critical infrastructures and solutions in the Internet of Things
The Charter of Trust calls for binding rules and standards to build trust in cybersecurity and further advance digitalization. In addition to Siemens and the Munich Security Conference (MSC), the companies Airbus, Allianz, Daimler Group, IBM, NXP, SGS and Deutsche Telekom are signing the Charter. The initiative is further welcomed by Canadian foreign minister and G7 representative Chrystia Freeland as well as witnessed by Elżbieta Bieńkowska, the EU Commissioner for Internal Market, Industry, Entrepreneurship and Small and Medium-sized Enterprises.
“Confidence that the security of data and networked systems is guaranteed is a key element of the digital transformation,” said Siemens President and CEO Joe Kaeser. “That’s why we have to make the digital world more secure and more trustworthy. It’s high time we acted – not just individually but jointly with strong partners who are leaders in their markets. We hope more partners will join us to further strengthen our initiative.”
The Charter delineates 10 action areas in cybersecurity where governments and businesses must both become active. It calls for responsibility for cybersecurity to be assumed at the highest levels of government and business, with the introduction of a dedicated ministry in governments and a chief information security officer at companies. It also calls for companies to establish mandatory, independent third-party certification for critical infrastructure and solutions – above all, where dangerous situations can arise, such as with autonomous vehicles or the robots of tomorrow, which will interact directly with humans during production processes. In the future, security and data protection functions are to be preconfigured as a part of technologies, and cybersecurity regulations are to be incorporated into free trade agreements. The Charter’s signatories also call for greater efforts to foster an understanding of cybersecurity through training and continuing education as well as international initiatives.
“Secure digital networks are the critical infrastructure underpinning our interconnected world,” said Canadian foreign minister Chrystia Freeland. “Canada welcomes the efforts of these key industry players to help create a safer cyberspace. Cybersecurity will certainly be a focus of Canada’s G7 presidency year.” The matter is also a top priority for the Munich Security Conference. “Governments must take a leadership role when it comes to the transaction rules in cyberspace,” said Wolfgang Ischinger, Chairman of the Munich Security Conference. “But the companies that are in the forefront of envisioning and designing the future of cyberspace must develop and implement the standards. That’s why the Charter is so important. Together with our partners, we want to advance the topic and help define its content,” he added.
According to the ENISA Threat Landscape Report, cybersecurity attacks caused damage totaling more than €560 billion worldwide in 2016 alone. For some European countries, the damage was equivalent to 1.6 percent of the gross domestic product. And in a digitalized world, the threats to cybersecurity are steadily growing: According to Gartner, 8.4 billion networked devices were in use in 2017 – a 31-percent increase over 2016. By 2020, the figure is expected to reach 20.4 billion.
Let me try to summarize a number of other news items gleaned from the ARC Forum featuring edge computing, IIoT Platforms, and technology. When ARC’s Paul Miller told me it would be the best ever, he turned out not to be exaggerating. More people, more news.
Stratus Technologies, known for years for secure servers, released an edge computing device. Interest in computing at the edge of the network has blossomed lately, with many companies releasing products. Lots of choices for users.
Integration Objects, firmly within another important trend, introduced an Industrial Internet of Things (IIoT) Platform. I’m beginning to see articles about users latching on to these platforms rather than building their own ad hoc connections among IoT devices and applications.
UL discussed standards with me during the show. The company known for developing safety standards and then testing for compliance has developed also a security standard. And it tests to it for compliance.
HIMA is another company combining safety and security technologies. There is so much in common between the two–especially thought processes and planning.
Yokogawa has extended and rebranded its process automation offering, now called Synaptic Business Automation. Among other things, it has refined the dashboard into a “karaoke” style.
Bentley Systems discussed the combining of engineering design tools with digital photography and other digital technologies to better represent the engineering and design of a plant. This is the most cutting edge technology I saw during the week, but I cannot do it justice in a paragraph. I encourage a tour of the Website.
Just when I thought I’d never write about Controllers, here comes a very interesting announcement from Emerson Automation Solutions [note new name]. Taking direct aim at its competitors who have moved aggressively from discrete control into process systems, Emerson announced launch of the DeltaV PK Controller.
This controller targets fast-growth industries traditionally less reliant on large-scale automation. The next-gen controller provides scalable automation control to all process industries, particularly parts of the life sciences, oil and gas, petrochemical, and discrete manufacturing industries that have relied on complex, non-integrated programmable logic controllers (PLCs) with limited operational capabilities. The fit-for-purpose DeltaV PK Controller is the process industry’s first controller that manufacturers can scale down for skid units or scale up to be natively merged into the DeltaV DCS in a larger plant.
These industries tend to use PLCs for smaller applications, which can create disconnected “Islands of Automation,” and limits plant production improvements. The DeltaV PK Controller bridges small and large control applications. Organizations can leverage the DeltaV PK Controller for effective, easy-to-implement standalone automation control akin to a PLC but with the features of a full-scale DCS, including advanced batch production, recipe management, execution, and historization. Users can then choose to leave the DeltaV PK Controller standalone, or natively merge it into their DeltaV DCS. This capability eliminates operational complexity and dramatically improves the performance, safety, and efficiency of their entire project and operational lifecycle.
“The DeltaV PK Controller delivers a business-effective solution for organizations of all sizes to improve automation control and integration,” said Jessica Jordan, Emerson product manager. “The controller is capable of powerful standalone control for advanced automation on skids today while still being able to easily integrate into a full-scale DCS for total plant production control.”
The DeltaV PK Controller is the latest addition to Emerson’s Project Certainty initiative, targeting radical transformation in capital project execution. The new controller will simplify capital projects by enabling OEM skid-builders to design and produce skids in the same way they do today, while eliminating the costs, time, and risks associated with integrating a PLC into their control system.
The DeltaV PK Controller was designed from the start with connectivity, particularly into the IIoT, in mind. The scalable controller leverages an assortment of communication protocols, including the first Emerson controller with a built-in OPC UA server. It is also the first Emerson controller with six Ethernet ports and can operate using any Emerson DeltaV I/O type, including DeltaV Electronic Marshalling, traditional marshalled I/O, wireless I/O, and integrated safety instrumented systems. In addition, it has built-in protocols to communicate with Ethernet devices such as drives and motors. Together, these features make connectivity easier at every stage and help plants achieve operational benefits of cloud-based tools and analytics through the IIoT. The DeltaV PK Controller also features built-in redundancy for controllers, communication, and power supplies, allowing organizations to improve uptime without adding to complexity or footprint.