Honeywell released three announcements while I am still recapping the ARC Forum. There are one or two more to go. Thèse regarded maintenance management, simulation, and safety under the umbrella of Connected Plant.
The first is a new offering as part of Honeywell Connected Plant that allows customers to more effectively manage the maintenance and operations of their industrial equipment. The new Honeywell Connected Plant Asset Performance Insight connects the customers’ assets and equipment to the cloud, and applies analytical models from Honeywell and its partners, so that customers can avoid unplanned downtime and unnecessary maintenance.
“In today’s competitive business climate, in which asset capacity is often sold out, equipment performance is key to increased profitability,” said Richard Shaw, general manager, Honeywell Connected Plant. “With operational and maintenance-induced equipment failures accounting for most of the unplanned downtime, industrial companies are looking to digital transformation and IIoT to make sense out of huge amounts of data. Honeywell Connected Plant and our new Asset Performance Insight will help our customers operate more strategically and effectively.”
Honeywell designed the Asset Performance Insight solution to be rapidly deployed to customers through pre-configured templates. These templates are based on the company’s deep industry experience and real-world customer challenges enhanced with advanced analytics. The offering can also be configured and tailored to customers’ specific needs, making it extremely flexible.
The second is a cloud-based simulation tool that uses a combination of augmented reality (AR) and virtual reality (VR) to train plant personnel on critical industrial work activities. With as much as 50 percent of industrial plant personnel due to retire within the next five years, the Honeywell Connected Plant Skills Insight Immersive Competency is designed to bring new industrial workers up to speed quickly by enhancing training and delivering it in new and contemporary ways.
Honeywell’s advanced training solution combines mixed reality with data analytics and Honeywell’s 25 years of experience in worker competency management to create an interactive environment for on-the-job training. It uses Microsoft’s HoloLens, the world’s first and only self-contained holographic computer, and Windows Mixed Reality headsets to simulate various scenarios for Honeywell’s C300 controller – such as primary failure and switchovers, cable and power supply failure – that train and test personnel on their skills.
“Megatrends such as the aging workforce are putting increased pressure on industrial companies and their training programs,” said Youssef Mestari, program director, Honeywell Connected Plant. “There is a need for more creative and effective training delivered through contemporary methods such as Immersive Competency, ultimately empowering industrial workers to directly improve plant performance, uptime, reliability and safety.”
Simulating specific job activities through virtual environments, which are accessed through the cloud, Honeywell’s solution offers a natural way to interact and communicate with peers or a trainer. Similar to a flight simulator, trainees can safely experience the impacts of their decisions. This approach improves skill retention versus traditional training methods by up to 100 percent and reduces the length of technical training by up to 66 percent. Additionally, the employees’ training progress is tracked as part of a formal competency management system.
And wrapping up is a new solution for real-time safety monitoring of workers in plant and remote operations. Honeywell Connected Plant Skills Insight Personal Gas Safety helps to protect lives and enable faster response in case of hazardous leaks or worker injury.
The solution’s wearable gas detectors monitor gas, radiation and dust, and are tightly integrated with Honeywell’s distributed control system, Experion® Process Knowledge System (PKS). In case of harmful exposures, man-down or panic alarms of workers in the field, accurate, automated alarms now alert control room operators in real time. In addition, safety teams can take advantage of powerful tools embedded in Experion PKS to provide detailed trending, reporting and data analysis of the gas detectors to further ensure safe operations.
“Monitoring worker safety and ensuring proper response to emergencies are top priorities for industrial producers,” said Adrian Fielding, marketing director, Integrated Protective Solutions for Honeywell Process Solutions (HPS). “Personal Gas Safety gives plant operators eyes and ears in the field to improve their situational awareness, helping avoid potentially life-threatening conditions while also providing workers with the assurance that help will be on the way quickly if they need it.”
So last week I shared an update on Schneider Electric from the ARC Forum–mostly on cybersecurity. A helpful marketing person guided me to the press release with all the data that updated the software side of the week’s news–specifically asset performance management. For the most part the discussion did not center on product updates but on “increasing momentum surrounding customer adoption”. In other words, Schneider wanted to highlight an area of software not often brought to center stage and show that it is a growth area.
Kim Custeau (I misspelled her name in my last post, I believe–thank you autocorrect), Asset Performance Management Business Lead, shared how investments in the cloud, advanced machine learning, and augmented reality, coupled with new partnerships, have empowered customers.
“Defining and executing an asset performance strategy is a critical component to improving productivity while safeguarding business continuity,” she said. “We have been delivering proven, industry leading asset performance solutions for nearly 30 years, and continue to invest in a long-term strategy to drive innovation in this area. Our focus is to provide real value to our customers by empowering them to maximize return on capital investment and improve profitability. We are proud to see our customer results speak for themselves with significant savings.”
Machine learning and prescriptive analytics:
- Duke Energy prevented an estimated $35 million cost from early warning detection of a steam turbine problem
- Ascend Performance Materials now responds faster to alerts saving an estimated $2 million through avoided plant shutdowns
- BASF is implementing AR to improve asset performance, reliability, and utilization while increasing production efficiency and safety because technicians leverage an augmented digital representation of the asset.
Cloud and Hybrid Deployment:
- WaterForce partnered with Schneider Electric to develop and IIoT remote monitoring and control system in the cloud that allows farmers to operate irrigation pivots with greater agility, efficiency, and sustainability.
- MaxGrip and Schneider Electric announced a partnership to expand APM consulting and add Risk-based Maintenance capabilities. The APM Assessment is a first step for industrial companies to evaluate asset reliability and digital transformation strategy.
- Schneider Electric and Accenture completed development of a Digital Services Factory to rapidly build and scale new predictive maintenance, asset monitoring, and energy optimization offerings. As a result, a large food and beverage company saved over $1 million in maintenance costs
Cybersecurity, digitalization, and asset performance management headlined the various press events with Schneider Electric at the recent ARC Forum. I took notes from Kim Cousteau’s presentation on APM at the main press conference and expected a follow up press release for details. I have not received one yet.
Remember the “reverse acquisition” of Aveva where Schneider Electric placed all of its software divisions into Aveva and then took a 60% share in the company? The deal is about to close. Schneider spokespeople assured me that digitalization is proceeding apace with the leveraging of Aveva design through construction applications into operations and maintenance applications—Schneider’s strong suit. This, on paper, brings the company into the competitive marketplace with Siemens and its UGS acquisition of several years ago. This is an interesting area to watch.
Schneider called a special press event, with lunch, to talk specifically about cybersecurity. This response to an incident in which the company’s Triconex safety system earned some publicity—but not always accurately portrayed. The incident was a cyber attack that caused a situation that the safety system caught and initiated a safe shut down.
However, the event caused renewed concern for cyber defense. ARC Vice President, Larry O’Brien, said, “This is a wake up call for people to follow existing security standards.” Gary Freburger, who heads that division of Schneider, said, “It’s everybody’s job.”
We received this official statement from Peter Martin, vice president of business innovation and marketing, Schneider Electric
At Schneider Electric, we heartily encourage all collaborative efforts to strengthen cybersecurity. The growing problem of cybersecurity is not specific to any single company, institution or country. Rather, it’s a threat to business and public safety that can only be addressed and resolved when suppliers, customers, integrators, developers, standards bodies and government agencies work together. This collaboration starts with common standards, agreed-upon rules, appropriate funding and active cooperation. It extends beyond national borders and transcends competitive interests.
Schneider Electric continues to work diligently with our customers, partners, developers and industry peers to make the shift from reactive to proactive cybersecurity management through compliance with evolving industry standards, agreement that cybersecurity is a journey not a destination, and a commitment to standing together in the face of cyber threats.
Today, we commend the signatories to the “Charter of Trust.” It’s another important step toward ensuring that the promise of digital transformation and automation will prevail over the threat of cyberterrorism.
Regarding APM, Kim Cousteau discussed a new release of Avantis that expanded machine learning from the power industry to oil & gas. For maintenance, it incorporates a team system for operator rounds and improved workflow. It incorporates augmented reality and virtual reality (AR/VR) “because workers are so new and need help to get up to speed. Look for updated analytics to aid in catching anomalies ahead of failure. She cited a customer who has been tracking savings from this feature alone and is up to $65 million.
I am still stung by a comment and ensuing discussion made by a maintenance manager during a talk I gave a few years ago. The talk was an early IoT description of networks, data, information, and the like. The guy raised his hand and said, “The engineers in my plant tell me that this stuff doesn’t work. So just forget about it!”
Emerson Automation developed a strategy called Top Quartile Performance and a service plan called Operational Certainty in order to operationalize Industrial IoT to benefit customers. This report comes from Covestro, one of the world’s largest polymer companies, which has selected Emerson to provide Industrial Internet of Things (IoT) technologies to help achieve its goals of minimizing risk and improving uptime at nine high-utilization plants.
As part of the $14 million, five-year contract, Emerson will provide remote monitoring and predictive maintenance to help Covestro optimize these manufacturing facilities for improved production, safety and reliability.
The Emerson program is a tenet of Covestro’s comprehensive digitization program called [email protected] that considers and implements new Industrial IoT strategies and operating procedures to deliver improved performance and meet defined financial targets. Covestro’s reliability program will leverage strategies, solutions and technologies in Emerson’s Operational Certainty program designed to help manufacturers achieve Top Quartile performance. Emerson data shows that Top Quartile companies spend half as much on maintenance compared to average performers and operate with an additional 15 days of available production each year.
Emerson will remotely monitor and maintain 40 of its DeltaV distributed control systems at Covestro plants in China, the United States and Germany. Remote teams at Emerson’s Innovation Center in Austin, Texas, will monitor and provide best practices-based maintenance strategies for local Emerson teams to implement at each Covestro plant. “By collaborating with Emerson to stay proactive about plant availability, we can drive toward always-on production and continue to satisfy customers in our high-demand market,” said Klaus Schaefer, chief technical officer, Covestro.
The Emerson-Covestro agreement reflects an emerging business model in industry, where manufacturers rely on a strategic supplier’s software solutions and deep automation expertise to monitor and execute maintenance, equipment health or energy management programs, allowing customers to focus their attention on critical operating functions that drive plant performance.
“Covestro and Emerson have a shared focus on driving Top Quartile operational performance,” said Jamie Froedge, president of Emerson’s Process Systems and Solutions business. “Connecting Covestro’s global product manufacturing expertise with our remote and local service capabilities allows the right expert to be available, real time, to ensure reliable operations.”
An enterprise computing and IT infrastructure company user event seems a weird place for a discussion of the Internet of Things and the Refinery of the Future. But there I was moderating a bloggers’ Coffee Talk with Doug Smith, CEO, and Linda Salinas, plant manager, of Texmark Chemicals, along with an executive of Hewlett Packard Enterprise (HPE) and one from PTC (ThingWorx).
HPE invited me to Madrid, Spain, (and paid my expenses) as an Operations Technology blogger to participate in Influencer sessions, interview a number of technologists, and experience its Discover Madrid user conference. Several times during each of the three days November 28-30 we participated in coffee talks. These were Live Streamed by Geekazine. This is a link to the first day. My session was toward the beginning of the first day, and I appear at the end of day three.
Telling the IoT Story
Texas toll manufacturer Texmark Chemicals teamed with HPE and Aruba to build a Refinery of the Future featuring advanced IIoT capabilities. The results: better process analytics, increased up-time, uninterrupted productivity, satisfied customers, and safer workers.
Every IoT implementation I have seen so far relied on predictive maintenance as the justifying application. Here, the first priority was safety. Then came predictive maintenance, improved operations, and consistent quality.
Texmark produces dicyclopentadiene (DCPD), a polymer precursor for everything from ink to boats. DCPD manufacturing processes involve flammable materials requiring stringent safety measures — and as demand increases, so does the complexity of the supply chains that rely on it.
Its manufacture involves heat and highly reactive chemicals, making safety a top priority. And as demand for DCPD grows, the global supply chain becomes increasingly complex, requiring ever more stringent controls, granular visibility, uninterrupted productivity, and regulatory oversight. Texmark must ensure its workers adhere to Process Safety Management (PSM) procedures at all times, and that its facility is managed in ways that put worker and community safety first.
As a contract manufacturer, Texmark must be prepared to adapt to customer requirements, which can change with little advance warning.
And it must continually drive plant efficiency and productivity. Historically, Texmark has depended on physical inspections of process equipment to ensure all systems remain in working order. However, these plant walk-downs can be time-consuming and labor-intensive. Texmark has 130 pumps in its plant, and spends nearly 1,000 hours a year on walk-downs and vibration analysis.
Depending solely on physical inspections also carries risk, because it relies on employees who — based on years of experience — can tell if a pump is starting to malfunction by recognizing slight variations in its noise and vibrations. But what happens if an employee with that skill is out sick, or reaches retirement age? Texmark needs ways to institutionalize that type of intelligence and insight.
Texmark’s vision for next-generation worker safety, production and asset management hinges on the emerging promise of the Industrial Internet of Things (IIoT): sensored devices combined with advanced analytics software to generate insights, automate its environment, and reduce the risk of human error.
The IIoT architecture must eliminate the need to transmit device data over a WAN, but instead support analytics at the edge to deliver real-time visibility into equipment and processes.
Texmark launched a multi-phase project to implement an end-to-end IIoT solution. Phase 1 and 2 established the digital foundation by enabling edge-to-core connectivity. Aruba deployed a secure wireless mesh network with Class 1 Div 1 access points and ClearPass for secure network access control. Aruba beacons provide location-based services for plant safety and security purposes. The wireless solution cost about half of what it would have cost to deploy a hardwired network.
For its edge analytics, Texmark selected the HPE Edgeline Converged IoT platform, an industrialized solution that supports robust compute capabilities. HPE Pointnext implemented the system as an HPE Micro Datacenter, which integrates its compute and networking technology within a single cabinet. HPE also upgraded Texmark’s plant control room to enable seamless edge-to-core connectivity and high-speed data capture and analytics, and to meet Texmark’s safety and security standards. The Edgeline system runs Texmark’s Distributed Control System software, integrating its operations technology and IT into a single system.
Phase 3 builds on the foundation established by these technology solutions to support Texmark’s use cases: predictive analytics, advanced video analytics, safety and security, connected worker, and full lifecycle asset management.
Texmark’s new IIoT solution will help make its workers even safer. It can monitor fluid levels, for example, reducing the risk of spills. It can alert Texmark immediately if a system starts to malfunction, enabling the company to respond before workers or production are endangered. And in the event of an emergency, it can help protect workers by ensuring Texmark knows their precise location and movements within the facility.
Other benefits will improve the company’s bottom line. Texmark can use data from IIoT sensors to identify which systems require hands-on evaluations, for example, so it can conduct physical inspections in a more focused and efficient manner.
The new IIoT solution makes it easier for the company to plan inspections and maintenance. To work on distillation columns, Texmark must often take systems offline and erect costly scaffolding. Improved maintenance planning will reduce these associated costs by at least 50%.