OSIsoft Discusses Digital Twin

OSIsoft Discusses Digital Twin

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.
OSIsoft Discusses Digital Twin

OSIsoft Appoints New Senior Management

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.”

SCADA in the Cloud Developer Acquired by Emerson

SCADA in the Cloud Developer Acquired by Emerson

When I was as-a-service offerings in the wake of my trip to HPE Discover 2019, I mentioned Inductive Automation as an example in the industrial market. There is actually another company. I’ve never heard about it—bad on my part. It’s called Zedi Solutions. I didn’t know if it was just the Canadian way of pronouncing “z” (we Americans say “zee” and there rest of the English-speaking world says “zed”) or a play on “Jedi”. Well, there’s a rocket with a window on its Web page.

Zedi Solutions is a company no more. Emerson’s methodically growing digital transformation presence was just enhanced through the acquisition of its cloud-based supervisory control and data acquisition (SCADA) platform.

Emerson states that the acquisition of Zedi’s software will enable it to help oil and gas producers increase production and lower operating costs through cloud-based monitoring, control and optimization.

“As world energy demand continues to grow, helping our vital oil and gas market customers maximize their resources is a top priority,” said Lal Karsanbhai, executive president of Emerson’s Automation Solutions business. “Through our vast portfolio of automation technologies, we are helping the industry navigate ever-changing market dynamics and operational challenges. The addition of Zedi strengthens our ability to help customers leverage the latest advances from the field to the refinery.”

Zedi’s technology is currently enabling customers to monitor more than 2 million sensors and thousands of devices and applications. By combining Zedi’s scalable cloud platform and applications expertise with Emerson’s extensive applications, controller, instrumentation and flow metering portfolio, this acquisition expands opportunities for Emerson across the global oil and gas production market.

“Oil and gas producers today are challenged to meet production targets while controlling costs, and they are looking for opportunities to transform operations and make their teams more effective through digital solutions like analytics and mobility,” said Jim Nyquist, group president of Emerson’s systems and solutions business. “This important investment bolsters our portfolio and ability to help Emerson’s customers achieve Top Quartile performance through emerging Industrial Internet of Things technologies.”

Emerson and Zedi’s software and automation businesses share a common vision of automating the production process through edge and cloud analytics and machine learning. The combined software and expertise of the two companies will provide producers with scalable and easily deployable end-to-end connected solutions to optimize and manage their operations.

Zedi’s software and automation businesses are based in Calgary, Canada, with approximately 155 employees in North America.

Emerson tried the SCADA acquisition route many years ago with the acquisition of Intellution. It subsequently sold that company to GE and it became a foundation for GE Digital. The company just wasn’t a fit at the time. Even though I don’t know Zedi, I have a feel that this will work out far better for Emerson. For one thing, times and markets have changed. For another, Emerson is already more advanced in software than it was 20 years ago.

OSIsoft Discusses Digital Twin

Cloud-based Database Platform Complements PI System

Digitalization requires digital data, which in turn requires a place to robustly store that data. OSIsoft PI System must be the most widely used industrial historian database. Last November I wrote about the company bringing its PI System to Amazon Web Services (AWS). 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.

Given how deep I’ve been led into IT over the past few years, this advancement from OSIsoft becomes part of a significant trend of blending IT and OT just above the control layer. In fact, if you segregate off the actual “control” part of automation, that system itself has become an important element of Internet of Things (IoT) blending into the overall IT infrastructure. If you are not thinking the big picture in today’s industrial environment, then you will be missing important paths to profitability.

Back to today’s OSIsoft news. The OSIsoft Cloud Services (OCS) in a capsule:

  • 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.”

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.

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.”

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.

OSIsoft Discusses Digital Twin

Cloud-based Platform Complements PI System

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..

OSIsoft Discusses Digital Twin

Innovation—A Word Often Loosely Used

People send about a dozen press releases per day to me, only slightly fewer on weekends. Many boast innovation in products, services, or pricing models. The word comes dangerously close to over use.

Siemens, however, consistently shows how users in a large variety of settings use the fruits of its own innovation of bringing together PLM, IT, automation, and industrial control for their own innovation.

My last post from the recent Siemens Innovation Forum discussed design and manufacture digitally using Siemens PLM and 3D printing. I also discussed a young woman using Siemens CAD and her own hard work to engineer a new prosthetic foot for a veteran of Afghanistan.

Next up at the Forum was Mayor Buddy Dyer of Orlando speaking on smart cities and the many places technology—principally from Siemens—were helping build infrastructure, water/wastewater controls, microgrids, and other elements of his administration’s smart cities work. Orlando has progressed far from its sleepy tourist-town roots.

Dr. Norbert Gaus, Head of R&D in Automation and Digitalization, AI at Siemens presided over an interlude with an example of robot picking utilizing AI + Digital Twin. Both are important components of an innovative manufacturing future.

The program jumped a level from travel by prosthetic foot to highways to aircraft carriers. Bharat Amin, VP & CIO of Newport News Shipbuilding discussed the entirely new way of building large ships using Siemens PLM, digital twin, digital thread, and electronic devices. This new workflow eliminated carrying huge piles of drawings to the site. The armloads of blueprints were replaced by a digital tablet.

People who have accomplished a digital turnaround always have timely advice for those of us beginning projects. Amin’s list: Start with people; Cultivate disruption; Nurture trust and relationships; Cut through bureaucracy; Go against the grain; Have an entrepreneurial spirit; Be willing to take risks.

Chester Kennedy, CEO Bridg—a microelectronics manufacturer, took Digital Twin from huge war ships to silicon wafers—microelectronics. He began with an MES to track through the entire process. The idea being that if they could find a flaw maybe at step 14 and scrap the part before investing more time and process only to find it at a later stage, they would save a ton of money. The digital twin idea is developing for work on security. At the beginning, Bridg just wanted an RFP for MES. Siemens came in and offered to go beyond Camstar (MES) to work in partnership to look at the system from design to physics and material science to workflow. The company needs security confidence by its customers, so it’s adding blockchain to help catch any potential sabotage within the microelectronics at manufacture.