by Gary Mintchell | Dec 7, 2017 | Automation, Internet of Things, Operations Management, Safety, Wireless
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%.
by Gary Mintchell | Aug 24, 2017 | Automation, Internet of Things, News, Process Control
Using technology to help plant managers and plant teams make their plants more profitable. In fact, they can even track and prove their profitability enhancements.
The Foxboro User Group met this week in Foxborough, MA at the company headquarters. Aside from the opportunity to meet with a number of company executives for in-depth discussions, there were two significant news releases. And, by the way, Foxboro claims a 100% return on investment with its new DCS in less than a year.
Why it’s important: This signals the culmination of a lot of strategic thinking at Foxboro about helping operators and others in a plant make decisions based on profitability as well as operating parameters.
First the new DCS.
Schneider Electric has improved the capabilities of its EcoStruxure Foxboro DCS, the company’s flagship distributed control system. EcoStruxure is Schneider Electric’s IoT-enabled, open and interoperable system architecture and platform.
With patented, customizable real-time accounting (RTA) models built in, the EcoStruxure Foxboro DCS not only allows the industrial workforce to evaluate the real-time financial performance of an industrial operation directly at the equipment asset level, it also empowers them to more easily identify the impact their actions and decisions have on the profitability of the operations they control. The RTA models can be manipulated and adapted to suit a variety of industrial operations across multiple segments, enabling a wide range of customers to reap far more value from their existing systems.
“For the most part, by the time business managers receive their monthly updates from whatever enterprise resource planning systems they use, the information is no longer relevant to the operational business decisions they need to make, or should have made,” said Peter Martin, vice president, Innovation and Marketing, Process Automation, Schneider Electric. “The EcoStruxure Foxboro DCS breaks the mold because our RTA models help control value asset to asset, all the way up the enterprise. By aligning process control with the hierarchy of the plant, we can provide far more visibility into the financial performance of every plant asset and asset set. That allows plant personnel to understand the impact their decisions have on the business and business leaders to understand the impact their decisions have on the operation, in real time.”
Along with the RTA models, the continuously current EcoStruxure Foxboro DCS features high-capacity, high-availability control processors; more powerful, fit-for-purpose I/O; intuitive, role-based engineering tools; and enterprise-wide analytical tools and capabilities. Additionally, its hardened cybersecure design and secure integration with the company’s market-leading Triconex safety systems protect the facility’s critical assets and allow for continuous production. Moreover, its automated, enterprise-wide, real-time condition monitoring and predictive maintenance capabilities minimize unplanned shutdowns, maximize uptime and lower maintenance costs by 30 percent or more.
EcoStruxure Foxboro DCS works in tandem with EcoStruxure Profit Advisor, Schneider Electric’s new software solution that applies the company’s RTA models to help the industrial workforce diagnose and analyze the profitability of processes throughout the plant. Whereas EcoStruxure Profit Advisor connects to any process historian to mine both historical and real-time data, the EcoStruxure Foxboro DCS takes the next step by building the algorithms into the process controllers themselves, thereby extending real-time accounting capabilities to every point in the process.
Maintenance Advisor
Of great interest to maintenance and reliability organizations, but also plant managers, is the improved Maintenance Advisor and Condition Advisor. Working in tandem, these bring information from the field relative to the condition of assets. This information can be used for information or integrated into workflow for actions.
The company’s new EcoStruxure Maintenance Advisor software, with embedded EcoStruxure Condition Advisor, bridges the gap between operations and maintenance, providing predictive maintenance and decision support for plant-wide assets.
Delivered in a single unified dashboard, EcoStruxure Maintenance Advisor monitors the real-time health of plant-wide assets to detect abnormal operating conditions. It then automatically provides actionable, easy-to-understand alerts with the proper context, along with potential reasons for the abnormal condition and possible actions to rectify it.
New EcoStruxure Condition Advisor for OPC DA enables real-time, automated condition monitoring of any OPC DA-compliant asset, such as intelligent electronic devices, motor starters and drives. This new capability complements existing Condition Advisors, which monitor the condition of Fieldbus Foundation, HART and Profibus process instruments.
by Gary Mintchell | Jul 5, 2017 | Automation, Internet of Things, Operations Management, Technology
Siemens Automation held its annual Users Conference the end of June at the Boca Raton Resort in Florida. Digitalization comprised the underlying theme, however connectivity technologies highlighted the important announcements and discussions.
MindSphere holds the top place as the most important Siemens technology at this time. Users and Siemens professionals highlighted two use cases at the conference both centering on condition monitoring / predictive maintenance.
The other connectivity announcement concerned PCS 7, the Siemens DCS. The company unveiled new I/O featuring Profinet connectivity. The new, denser I/O includes a user-configurable product, as well as traditional digital and analog modules. Ethernet connectivity featuring Profinet held center stage in the press announcement.
Siemens introduced MindSphere to me at Hannover 2016. Its evolution has been swift. Now dubbed an Internet of Things platform, it includes a set of APIs and libraries. It includes an “App Store” open to 3rd party developers in addition to Siemens apps. If you are a developer, just register and app and pay a royalty based on data or connections.
MindSphere placed in context is similar to what I’ve seen from Cisco, Dell EMC, GE, Microsoft, and SAP. I’m sure there are more and that we’ll see more in the future. Dell EMC’s platform is open source. MIMOSA, an industry standards organization provides a similar platform called the OIIE based on standards containing no proprietary components.
All of these platforms are important for maintenance and reliability professionals, as well as for plant management, engineering, and operations because of the increased data and visibility into operations and assets. This will result in improved planning, more efficient operations, and increased percentage of uptime.
Components of the platform include:
• MindSphere Apps – Siemens and 3rd party ; data analytics
• MindSphere Sphere – Azure, SAP, AWS, etc.
• MindSphere Connect – open standards, right now OPC UA, gateway, integrated with S7, build your own connectivity
by Gary Mintchell | Jun 22, 2017 | Automation, Technology
When I travel to various conferences, there are certain technology themes that are strengthening connections the Internet of Things for manufacturing. We witnessed several of these this week. Here is a quick outline of some important announcements.
Why should we invest in IoT products and technologies? I hear this often. Like as not the answer will be predictive maintenance.
Augury has developed a unique technology for sensing situations that can predict upcoming failures. It must be solid technology with a solid management team. Why do I say that? Take a look at the funds investing in the company this week.
Augury Secures $17 Million Series B Funding Round
Augury, an Industrial Internet of Things (IIoT) technology company, announced that it has closed a $17 million Series B funding round co-led by Eclipse Ventures and Munich Re / HSB Ventures, the venture arm of Hartford Steam Boiler (HSB) and Munich Re. Augury will use the funding to strengthen Original Equipment Manufacturer (OEM) relationships, develop strategic partnerships and further establish itself as the leader in mechanical diagnostics.
This round of venture capital funding for Augury comes after a successful Series A raise completed in August of 2015. Additional investors in the current round include Sound Ventures, First Round Capital, Lerer Hippeau Ventures and Pritzker Group Venture Capital.
“Augury is by far the leading provider of mechanical diagnostics in the commercial and industrial sectors,” said Lior Susan, Managing Partner, Eclipse Ventures. “This investment perpetuates the commercial application of IIoT technology into what will become an inevitable part of predictive maintenance technology. We are confident that Augury will continue to redefine and lead the future of diagnostics in the Industrial Internet of Things.”
Augury’s existing OEM relationships include Grundfos, Armstrong and PSG Dover. Additional industry-leading customers include Johnson Controls, Trane, Carrier, Mueller, Aramark and AECOM. As they expand their market reach, Augury will continue to exponentially grow their mechanical malfunction dictionary, thus improving their diagnostics capabilities. This injection of capital will help to solidify Augury’s market leading position as a real-time, intelligent Predictive Maintenance (PdM) solution.
“We are building a long-lasting company with the goal of diagnosing everything that has moving parts, effectively creating the mechanical nervous system of the IoT,” said Saar Yoskovitz, CEO of Augury. “Equipment manufacturers and other market leaders in the industrial sector are increasingly turning to PdM as a critical component for their IIoT strategy. This funding will enable Augury to become a driving force towards the connected era of tomorrow.”
“Insurance companies are playing a significant role in the deployment of IIoT solutions,” said Jacqueline LeSage Krause, Managing Director, Munich Re / HSB Ventures. “This investment in Augury further strengthens HSB’s leadership position in IoT and insurance.”
Cloud and the Edge
The cloud is a consistent topic of conversation. Sophisticated technologists are now discussing connectivity and bandwidth and edge computing/cloud relationships. Here is an interesting take.
Vapor IO, the next generation platform for edge clouds, announced Project Volutus, which enables cloud providers, wireless carriers and web-scale companies to deliver cloud-based edge computing applications via a network of micro data centers deployed at the base of cell tower sites. The company also announced today that Crown Castle, the nation’s largest provider of shared wireless infrastructure, has made a minority investment in Vapor IO to accelerate the project’s development and deployment.
Project Volutus is a “data center as a platform” service, powered by Vapor Edge Computing. Project Volutus offers fully-managed micro data centers at the base of cell towers, literally at the true edge of the wireless network. It combines Vapor IO’s patent pending hardware and software technology with the nation’s extensive network of cell towers and dense metro fiber to build and operate self-driving, distributed edge data centers in major metropolitan locations.
“Zettabytes of machine to machine communication and new application types will require a shift in how the industry thinks about data centricity and the delivery of edge services,” said Cole Crawford, CEO and founder of Vapor IO. “Project Volutus is the most cost-effective way to deliver cloud applications that benefit from last mile wireless proximity and sub 10-millisecond round trip latency. By locating Vapor IO’s technology at tower locations and connecting to dense metro fiber, we will provide the fastest, most economical way for cloud providers, telecom carriers and web-scale companies to deliver next generation edge services in every major US city.”
In addition to supporting traditional cloud applications, Project Volutus allows carriers to incorporate virtual Radio Access Networks, including those based on Intel Corporation’s FlexRAN reference design, for speed and scale when upgrading their networks. By cross-connecting the radio network directly to edge services and the internet, Project Volutus eliminates multiple network hops and facilitates a new breed of low-latency edge applications.
Eye Tracking Research
OK, eye tracking technology can be creepy if the company sneaks it in on you during your browsing sessions. But research into how people look at and interact with their various screens is valuable in the development of improved HMI and other visualization screens. Here is a company taking it into virtual reality for research.
Tobii Pro, the global leader in eye tracking research solutions, announces a new solution for conducting high-end, eye tracking research within immersive virtual environments (VR) – Tobii Pro VR Integration.
The research tool, based on the HTC Vive headset integrated with Tobii eye tracking technology, comes with the Tobii Pro software development kit (SDK) for research applications. Researchers can collect and record eye tracking data from a VR environment with pinpoint accuracy and gain deeper insights on human behavior.
Eye tracking research in immersive VR is transforming how studies can be conducted and opens up entirely new possibilities in psychology, consumer behavior, and human performance.
Through VR, researchers have complete control over a study environment which allows them to run scenarios that previously would have been too costly, risky or difficult to conduct in real life.
“Combining eye tracking with VR is growing as a research methodology and our customers have started to demand this technology to be part of their toolkit for behavioral studies. The Tobii Pro VR Integration is our first step in making eye tracking in immersive VR a reliable and effective research tool for a range of fields. It marks our first major expansion of VR-based research tools,” said Tom Englund, president, Tobii Pro.
Tobii Pro VR Integration is a retrofit of the HTC Vive business edition headset with a seamless integration of Tobii eye tracking technology. It is capable of eye tracking all types of eyes, collecting binocular eye tracking data at 120 Hz (images per second). The solution allows study participants to move naturally while wearing the headset without compromising the user experience or the output of the eye tracking data.
by Gary Mintchell | Jun 15, 2017 | Asset Performance Management, Internet of Things, Operations Management
GE has a new CEO coming soon. Jeff Imelt led the industrial push that led to Predix and Industrial Internet of Things, services based upon data, predictive maintenance. He spurred development of GE Digital and the transformation into a software company (check out the TV ads).
The company has announced some extensions to Predix. But we need to wonder where the new CEO will take the company. One software entrepreneur I know unleashed on the company in a LinkedIn post hoping that the new guy would trash Predix and build “something better.” We’ll have to wait and see, of course.
First a little context for one of the announcements.
The facility electrical engineer and I were speculating on an idea of linking measurement of electricity usage at perhaps the bus level for different areas of the plant with machine performance. Perhaps he could detect a machine problem through electrical changes. That was somewhere around 1993.
I quoted something, but we never did it.
Here are the high points of the announcements:
- GE Digital announces integration of ServiceMax field service management solution and Asset Performance Management portfolio to transform service operations, reduce cost and eliminate unplanned downtime
- GE Ventures launches Avitas Systems, a new venture that will transform inspection services with advanced robotics, data analytics and artificial intelligence
- GE Power releases Predix-powered ‘Digital Utility’ to connect real-time machine and operations data with energy trading to drive more profitable utilities businesses
The asset optimization organizations within a plant have a variety of new tools to take them beyond maintenance into an enhanced role. Growth of the Internet of Things and analytics capabilities especially leading into predictive and eventually prescriptive strategies are the keys to the future.
