Mike Boudreaux, director of performance and reliability monitoring for Emerson Process Management, has published an important article in Plant Services magazine discussing some limitations of the Purdue Model incorporating the Industrial Internet of Things. There are many more applications (safety, environmental, energy, reliability) that can be solved outside the control system. They just are not described within the current model.
Interestingly, about the same time I saw a blog post at Emerson Process Experts quoting Emerson Process Chief Strategic Officer Peter Zornio discussing the same topic.
I’ve been thinking about this for years. Mike’s article (which I recommend you read–now) brought the thoughts into focus.
Purdue Enterprise Reference Architecture Model
The Purdue Enterprise Reference Architecture Model has guided manufacturing enterprises and their suppliers for 25 years. The model is usually represented by a pyramid shape. I’ve used a diagram from Wikipedia that just uses circles and arrows.
This model describes various “levels” of applications and controls in a manufacturing enterprise. It describes components from the physical levels of the plant (Level 0) through control equipment and strategies (Level 2).
Level 3 describes the manufacturing control level. These are applications that “control” operations. This level once was labelled Manufacturing Execution Systems (MES). The trade association for this level–MESA International–now labels this “Manufacturing Enterprise Solutions” to maintain the MES part but describe an increased role for applications at this level. The ISA95 Standard for Enterprise Control labels this level as Manufacturing Operations Management. It is quite common now to hear the phrase Operations Management referring to the various applications that inhabit this level. This is also the domain of Manufacturing IT professionals.
Level 4 is the domain of Enterprise Business Planning, or Enterprise Resource Planning (ERP) systems. It’s the domain of corporate IT.
Hierarchical Data Flow
The Purdue Model also describes a data flow model. That may or may not have been the idea, but it does. The assumption of the model that sensors and other data-serving field devices are connected to the control system. The control system serves the dual purpose of controlling processes or machines as well as serving massaged data to the operations management level of applications. In turn, level 3 applications feed information to the enterprise business system level.
Alternative Data Flow
What Mike is describing, and I’ve tried sketching at various times, is a parallel diagram that shows data flow outside the control system. He rightly observes that the Industrial Internet of Things greatly expands the Purdue Model.
So I went to the white board. Here’s a sketch of some things I’ve been thinking about. What do you think? Steal it if you want. Or incorporate it into your own ideas. I’m not an analyst that gets six-figure contracts to think up this stuff. If you want to hire me to help you expand your business around the ideas, well that would be good.
I have some basic assumptions at this time:
- Data is not hierarchical
- Data has many sources and many clients
- Eventually we can expect smart systems automatically moving data and initiating applications
Perhaps 25 years ago we could consider a hierarchical data structure. Today we have moved to a federated data structure. There are data repositories all over the enterprise. We just need a standardized method of publish/subscribe so that the app that needs data can find it–and trust it.
Now some have written that technology means the end of Level 3. Of course it doesn’t. Enterprises still need all that work done. What it does mean the end of is silos of data behind unbreachable walls. It also means that there are many opportunities for new apps and connections. Once we blow away the static nature of the model, the way to innovation is cleared.
Perhaps the future will get closer to a model that I’m writing a series of white papers to describe. Growing from the OpenO&M Initiative, the Open Industrial Interoperability Ecosystem model looks interesting. I’ve just about finished an executive summary white paper that I’ll link to my Webpage. The longer description white paper is in process. More on that later. And look for an article in Uptime magazine.
This is another long post—and it is a summary—running through many of the new products introduced to the press and analysts durning Emerson Exchange 2015. If any of these whet your appetite, visit the Emerson Process Website for more information.
Another place to catch up on happenings at the conference is Jim Cahill’s Emerson Process Experts blog. He also has been introducing readers to highlighted sessions.
CSI 6500 ATG protection system, a stand-alone machinery protection solution that allows users to cost-effectively introduce prediction monitoring of critical assets from the same system. Predictive intelligence is a key component to increasing availability and improving the reliability of plant assets.
These multi-functional cards can be easily reconfigured for a wide range of measurements, including the impacting or peak-to-peak data used in Emerson’s unique PeakVue technology. In addition to monitoring the start-up and coastdown of critical turbo machinery for safe operation, users will be able to utilize PeakVue technology to identify the earliest indications of developing faults in gearboxes and bearings.
With the CSI 6500 ATG, it is no longer necessary to return to the control room or open cabinets in the field to view or analyze data. The CSI 6500 ATG can be networked over wired or wireless Ethernet to deliver asset health information to authorized users through a PC or phone application.
To facilitate easy system integration with third party systems, CSI 6500 ATG is the first protection system to include a secure embedded OPC UA server.
Gas ultrasonic flow meter
A new Daniel gas ultrasonic flow meter platform elevates its well-proven British Gas design by providing two meters and transmitters in a single body to help natural gas operators and pipelines improve reliability and efficiency. Designed to maximize capital budgets by permitting two completely independent measurements with the installation of just a single flowmeter, the new 3415 (four-path + one-path) and 3416 (four-path + two-path) gas ultrasonic flow meters combine a four-path fiscal meter with an additional check meter, while the new 3417 (four-path + four-path) meter provides two fiscal meters for full redundancy and equal accuracy within one meter body. This two-in-one redundant design delivers continuous on-line verification of custody transfer measurement integrity, device health and process conditions, and improves fiscal metering confidence while ensuring regulatory compliance.
Both Daniel 3415 and 3416 gas ultrasonic meters measure flow using four horizontal chordal paths in addition to a reflective path dedicated to verification of the primary measurement, enabling improved metering insight, more informed decision making and simplified flow meter verification. For enhanced immunity to pipe wall contamination, the 3416 meter is equipped with an additional vertical reflective path to detect liquid or very thin layers of contamination at the bottom of the meter that otherwise remain completely hidden in a direct-path meter design. This allows reliable monitoring of process changes before they affect measurement, thus reducing calibration frequency and enabling maintenance to be condition-based instead of calendar-based.
Electric actuator control
DCMlink Software, a unified electric actuator control, monitoring and diagnostics platform, will allow, for the first time, Emerson customers to diagnose, configure, and monitor all electric actuators from a central location independent of protocol, actuator or host system. The software extends the useful life of field assets by providing actuator data gathering, condition monitoring, events log and prioritization of actuator alarms in a unified and consistent user interface. Actuator configuration includes custom characterization, as well as the ability to import and export historical configuration profiles.
Whether it is viewing value torque profile, live trending data or actionable alarms straight from the actuator, plant operators will be able to access detailed monitoring and diagnostics data, allowing them to take action before a fault occurs. DCMlink offers advanced control and diagnostics, including torque profile curves, initiating partial stroke test or emergency shut down and alarms in NE-107 format. Current communications support included Modbus, TCP-IP, and Bluetooth.
Version 13 (v13) of the DeltaV distributed control system (DCS) new features focus on integration, advanced alarm management, and security with an overarching design that improves ease of use and minimizes the need for specialized expertise.
DeltaV v13 delivers technologies to bring sources together for easy operator access and use. These technologies include an Ethernet I/O card (EIOC) for integrating Ethernet-based subsystems and devices, including a direct interface with smart motor control centers and substations. It improves the factory acceptance testing (FAT) experience by providing enhanced safety instrumented system simulation capabilities and easy-to-use virtualization environment.
The new DeltaV Alarm Mosaic has an intuitive alarm display that enables operators to more quickly identify, analyze, and respond correctly to the root cause of an abnormal process condition. The new release also provides trend display optimizations for better visibility of process changes.
OpenEnterprise v3.2 release adds a native interface to the AMS Device Manager asset management software, enabling users to remotely manage and maintain HART and WirelessHART devices in wide-area SCADA networks.
OpenEnterprise v3.2 together with AMS Device Manager allows asset owners to extend the reach of their predictive maintenance capability out to their remote assets, providing a powerful and proactive method of diagnosing potential device problems remotely. This results in reduced trips to the field and helps to avoid unplanned process shutdowns, improving safety, reliability, and profitability.
The native interface of OpenEnterprise v3.2 to AMS Device Manager enables the collection of wired and wireless HART digital device data over low bandwidth wide-area SCADA networks from Emerson ROC, FloBoss, and ControlWave RTUs without adding the additional complexity and expense of external HART multiplexers. Support for AMS Device Manager SNAP-ON applications, OpenEnterprise SCADA server redundancy, multiple deployment options, and data collection for up to 10,000 HART devices ensures flexibility and scalability for a wide range of remote oil and gas applications.
Machinery health in PowerGen
Emerson now offers its power generation and water/wastewater industry customers native machinery health monitoring and protection capability within the Ovation distributed control system.
Ovation Machinery Health Monitor leverages the Ovation platform through a high-performance I/O module dedicated to machinery health functions. Simply install by inserting the module into a spare I/O slot.
With the Ovation Machinery Health Monitor, operators receive alerts from a single set of common plant HMIs and no longer need to manually check machinery functions through a separate system.
The Ovation Machinery Health Monitor also reduces the risk of cyber attack by eliminating links to standalone systems and isolating process information – all of which can help facilities meet NERC CIP and other security regulations.
Costly damage to turbine blades caused by silica deposition can occur due to a poorly monitored steam purity program. The new Rosemount 2056 Silica Analyzer provides continuous accurate measurements of silica in process streams with a range of 0.5 ppb to 5000 ppb. The 2056’s usability features make it one of the easiest -to-use and high performing analyzers.
Harsh duty pressure sensing
Rosemount 3051S Thermal Range Expander with new UltraTherm 805 oil fill fluid enables pressure measurements by direct-mounting a diaphragm seal system to processes that reach up to 410°C (770°F) without requiring the challenging impulse piping or heat tracing used in traditional connection technology. In applications where ambient temperatures drop below ideal operating conditions, system response time becomes slow, resulting in delayed process pressure readings. Traditionally, this problem is solved by using heat tracing which is costly, maintenance intensive, and difficult to install. By using the new thermal range expander dual fill fluid seal, the Rosemount 3051S can reliably measure pressure at extremely high process and low ambient temperatures.
The Rosemount 3051S Electronic Remote Sensors (ERS) System now has safety certification. The ERS System calculates differential pressure through a digital architecture — and is now suitable for SIL 2 and 3 applications.
Rosemount 3051S High Static Differential Pressure Transmitter provides reliable flow measurement in high pressure applications with capabilities up to 15,000 psi (1034 bar). The transmitter’s SuperModule platform and coplanar design reduce potential leak points by 50 percent compared to traditional designs, ensuring the highest differential pressure measurement accuracy, field reliability and safety.
The Roxar Corrosion Monitoring system, consisting of wireless-based probes, will provide refineries with flexible, responsive, integrated and highly accurate corrosion monitoring.
Combined with the Emerson’s non-intrusive Field Signature Method (FSM) technology, a non-intrusive system for monitoring internal corrosion at the pipewall, refinery operators will be able to access more comprehensive corrosion information and corrosion rates, leading to improved operator insight and control over assets.
The system will also help identify and track opportunity/high TAN crudes and their corrosive elements. Such crudes are less expensive but more corrosive than others with the new system enabling the maximum amount of such crudes to be blended into the mix without increasing corrosion risk.
Wireless pressure gauge
Emerson Process Management has introduced the industry’s first WirelessHART pressure gauge. The Rosemount Wireless Pressure Gauge enables remote collection of field data.
The Wireless Pressure Gauge eliminates mechanical gauge common weak points by removing the components that inhibit the device from reporting/displaying pressure and providing up to a 10-year life, which reduces maintenance cost and time. The large 4.5-inch gauge face provides easy field visibility.
This is a long post, but it brings together several of the more important announcements from this week’s conference. I’ve seen bits of this coming as Emerson has moved its message to incorporate asset management over the past couple of years and is now taking the message to an even higher level in the customer organization. I find it interesting that it takes a holistic look at its product portfolio and then bundles it in such a way as to serve a higher purpose at the customer’s business.
Steve Sonnenberg, Emerson EVP and Emerson Process Management president, said during the opening keynote to Emerson Global Users Exchange 2015, “Managers are looking for dramatic improvements. This is not a time to be satisfied to be as good as everyone else. All are talking top quartile performance. What do you do when all the usual approaches no longer work? Top companies are finding all new approaches. “
The phrase of the day was “Top Quartile Companies.”
Then the concept of improvements in project management and execution was introduced. Jim Nyquist, president of Emerson Systems and Solutions business, added, “Projects are in crisis. 65% of industry’s projects over $1 billion are failing. 33% of projects of $500 million. It seems the larger the project the larger the overrun.”
Global market means more competition leading to increases in the scale of projects.
What’s needed to rein in this runaway stage coach? Nyquist declared that design, engineering, and project management need a reset. Budgets need a resent and predictability and reliability must be improved. Top quartile projects are completed at half the cost and half the schedule of 4th quartile companies. “Industry is at inflection point,” he predicted.
Then he announced the launch of Project Certainty, an innovative technology- and engineering-based approach for improved capital efficiency and more reliable project schedules.
Emerson’s Project Certainty begins with early engagement during engineering and design studies to define project goals and high impact strategies to meet those goals. Despite traditionally accounting for approximately 4 percent of a project investment, automation is revealing unique and repeatable ways to eliminate cost, reduce complexity and accommodate late-stage project changes, beyond the automation discipline.
For example, Project Certainty relies on the right design engineering strategy to eliminate centralized control system room requirements by 70 to 80 percent, and can eliminate piping in some applications up to 50 to 60 percent. Additionally, tens of millions of dollars in capital spare parts can be eliminated through project-wide equipment reliability analysis.
“Project Certainty also tackles complexity by decoupling the dependencies suppliers have on each other, eliminating bottlenecks and allowing concurrent work streams,” said Nyquist. “Likewise, we are addressing the complexity of data and documentation with innovative technologies that provide features like a single source of project data as well as automated documentation.”
Addressing one of the greatest project vulnerabilities, Project Certainty significantly improves project schedule performance. Technologies like Electronic Marshalling with CHARMs, and pervasive wireless field instrumentation are helping project teams accommodate inevitable last-minute design changes without impacting schedule.
“The path to Top Quartile project performance is right in front of us,” said Nyquist. “The technologies and proven methodologies are here. It will take collaboration and commitment to eliminate outdated project approaches and drive change into the industry.”
Part of this new environment is Project Data Link, a project engineering environment that helps reduce complexity and accommodate changes in capital projects. As projects become more complex with multiple contractors and stakeholders, Project Data Link helps keep projects off the critical path by efficiently and consistently translating project information, including tag databases and instrument indices, from multiple sources into project deliverables. It mitigates project risk by normalizing specifications into a single data source with traceability and an integrated change-management system.
Project Data Link gives multiple suppliers, engineering firms, and other stakeholders access to project information including specifications related to field devices and the distributed control system (including control logic and configuration). In addition, data provided in various formats are normalized so that all information is available in a single, consolidated standard view.
The integrity of project information is especially important during late project changes. The data link is always up to date, so when a change is initiated Project Data Link automatically reconciles it against what is in the system, identifies what needs to be changed, automatically sends updates to the DeltaV distributed control system and provides an audit trail of what has changed. This saves time and eliminates errors during the critical late stages of the project.
“Moving forward to improve project certainty, Emerson continues to find methods to reduce the risk of project errors, accommodate change and improve engineering efficiency,” said Randall Fong, project technical manager. “We are confident that Project Data Link will help our customers move towards on-budget and on-time projects.”
Here is yet another part of the portfolio of improving products–Smart Commissioning, a technology-enabled process that reduces automation commissioning time and effort. Smart Commissioning helps automation projects meet strict and shifting deadlines by reducing trips to the field, eliminating tasks, and accommodating late project changes. Smart Automation Commissioning builds on advances made possible by the combination of the DeltaV distributed control system (DCS) Electronic Marshalling with CHARMs and AMS Device Manager Software to remove automation from the critical path of projects.
With the release of version 13 software for the DeltaV DCS and AMS Suite, Smart Commissioning brings ease to automation project implementation. From the initial device connections to final system testing, users save money as they shave weeks off the project schedule by reducing time spent on automation commissioning activities.
Upon arrival at a project site, pre-tagged smart devices can be connected immediately to any channel in a nearby junction box — no need to wait for wiring designs to be complete. Smart Commissioning also eliminates potential errors by automatically finding and identifying all smart devices, then binding them to the configuration. To further accelerate implementation, the device configuration is pushed to all devices based on pre-configured templates. Testing is easily and safely done from the control room by using digital communication, requiring no personnel in the field for confirmation.
“With Smart Commissioning, members of the project team can more easily meet tight project timelines and are not hampered by late design changes,” said Mark Howard, vice president of project execution for Emerson Process Management. “Developed based on industry experience, this solution is another step from Emerson toward attaining project certainty for users.”
Projects in Action
Sasol, an international energy and chemical company, has selected Emerson Process Management to help automate its $8.9 billion petrochemical complex in Lake Charles, La., designed to take advantage of abundant, low cost natural gas. The automation project is one of the largest in history awarded to Emerson.
When completed sometime in 2018, the massive petrochemical complex will more than triple Sasol’s chemical production capacity in the United States. The complex includes an ethane cracker that will produce 1.5 million tons of ethylene annually, as well as six chemical manufacturing plants designed to convert the ethylene into a diverse range of chemicals. Ethylene is a key ingredient in the production of plastics, detergents, anti-freeze, and other petrochemical products.
Emerson Process Management implemented a detailed engineering and project execution plan designed to mitigate project risks, lower costs and reduce time to completion, all part of the company’s strategic Project Certainty initiative.
“For a project of this scale, managing budget and schedule risk is paramount,” said Jim Nyquist, group vice president of Emerson. “This is a great example of our Project Certainty initiative. Early engineering and design work is being used to identify opportunities for automation technology to reduce complexity, create project cost savings, and reduce schedule and cost risks. As the project moves into the execution phase, Emerson is well-positioned to implement the design, accommodate late changes and reduce on-site work – all of which speed execution without compromising quality, safety or reliability.”
Is it possible to remove automation from the critical path of a large process industry project? Not only that, but use automation to shorten the other paths of the project?
That is the goal of the latest thinking from Emerson Process Management–especially the Systems and Solutions business.
I have been at the 2015 edition of the Emerson Global Users Exchange in Denver this week. I have many details to share. I’ll get those on the plane going home this afternoon.
Before I talk about “Project Certainty”, a few thoughts on the conference.
Everyone knows how the oil & gas industry has been hit by falling oil prices (thank you shale and Saudi Arabia). The impact was first apparent in conference in our part of the industry when travel was cut and attendance at the ARC Advisory Group conference dropped. Same here. While this is still a large conference, the impact of travel budget cuts was obvious.
There were lots of sessions and around 2,500 people around, but in a more normal year there probably would have been maybe a thousand more.
But Emerson still unveiled lots of new products and initiatives.
The photo captures Emerson EVP and Emerson Process President Steve Sonnenberg and Emerson Process Systems and Solutions business President Jim Nyquist introducing Project Certainty.
What Emerson has done has been to look at all the technologies introduced and deployed over the past ten years or so and apply to the bigger picture. They have put forth an answer to how can wireless products, electronic marshaling, the CHARMS configurable I/O, and many more help companies shorten the project path if project planners use the ideas from the beginning of planning and design of a project.
The example is SASOL who is building what is in effect eight plants in Louisiana using these ideas and already showing returns.
I’ll have more on this in my next post. But this reveals some solid thinking about customers and needs by the Emerson team.
Acquisitions are always interesting news. They always signify something about the industry. Sometimes it’s consolidation in a mature industry. Sometimes it’s larger companies growing, adding technology, or adding talent.
In today’s news, there is some of each.Remember when the robot and vision markets were thriving—especially the small SCARA robots? Those days are long over. The price of vision systems plummeted. Just look at the capabilities of the camera and software in your smart phone.
The first announcement is that Omron is acquiring Adept Technology. The second is Emerson Process Management adding some interesting technology to its portfolio.
The only thing surprising to me is the acquirer, not the fact that Adept is being acquired. Those cards have been played a long time ago. Omron Corporation and Adept Technology, Inc. announced that the two companies have entered into an agreement whereby Omron will acquire Adept.
Omron plans to acquire 100% of the outstanding shares of Adept common stock through an all cash tender offer followed by a second-step merger. It will offer Adept investors $13.00 per share of Adept common stock, which represents a 63% premium over the closing price for Adept’s common stock on September 15, 2015. This values Adept at approximately $200 million. It will fund the tender offer through cash on hand.
The tender offer is expected to commence on or about September 23, 2015, and the transaction is expected to close on or about October 23, 2015. The closing of the transaction is subject to customary closing conditions, including at least a majority of shares of Adept common stock being tendered in the offer, expiration of the applicable waiting period under the Hart-Scott-Rodino Antitrust Improvements Act of 1976 and receipt of required foreign antitrust approvals. The transaction has been unanimously approved by the Boards of Directors of both companies.
Commenting on the acquisition, Yutaka Miyanaga, Omron Industrial Automation Business Company President, said, “We are delighted Adept Technology, a world leader in robotics, has agreed to join Omron. This acquisition is part of our strategy to enhance our automation technology and position us for long term growth. Robotics will elevate our offering of advanced automation.”
Rob Cain, President and Chief Executive Officer of Adept, added, “We are excited about the opportunity to join Omron, a global leader in automation. Together, our products will offer new innovative solutions to customers all around the globe.”
Following the transaction, Rob Cain will continue to lead Adept and will report to Nigel Blakeway, Chairman, Chief Executive Officer and President of Omron Management Center of America, Inc., Omron’s wholly owned United States subsidiary.
Emerson announced it has acquired Spectrex, Inc., a leading manufacturer of flame and open path gas detectors. With this addition, Emerson Process Management will have the most comprehensive line of flame, gas, and ultrasonic leak detector solutions used for safety monitoring in the industry.
Spectrex will join the Rosemount portfolio of measurement and analytical technologies. Terms of the acquisition were not disclosed.
For nearly 34 years, Spectrex has been the leader in flame and open path gas detection. It developed the world’s first ultraviolet-infrared (UV/IR) and triple infrared (IR3) flame detectors and was first to introduce xenon flash lamps in open path detector design, increasing detectors’ resilience to atmospheric conditions while reducing power consumption. These innovative advancements in safety monitoring provide a powerful solution for customers in the oil and gas, petrochemical, chemical and power industries.
“We are very excited about adding the Spectrex product line to our flame and gas detection portfolio,” said Tom Moser, group vice president of Emerson Process Management’s measurement and analytical technologies. “Emerson is committed to helping our customers protect their employees, facilities, and the environment, and we are now better positioned to serve that need.”
Spectrex and its staff are located in Cedar Grove, N.J., with sales and technical support offices in Houston, the United Kingdom, and Taiwan.