Digital Transformation for Process industries – An integrated Approach
Technology continues to evolve and bring new ideas and opportunities. The progress in IoT and Industry 4.0, has made it easier to integrate the data across the layers from the sensors, relays (L1) to the Analytics / ERP systems (L4). Hence, the world of opportunities opens up where data can be converted into meaningful information and analyzed for quick decisions. In addition, Process Simulations, Digital twins, AI /ML algorithms further expand the horizon for developing new use cases, setting up new units, de-bottlenecking and planned maintenance activities. These directly impact the bottom line and deliver Return on Investment in 1 – 2 years.
Thus a digital journey needs to be thought through for phased interventions across the plant operations.?These interventions span across the three main areas of the plant – a) Production, Maintenance and c) Technical Services. Since these areas are interconnected, each intervention can impact one or more of these at the same time.
Some of the major data related problems today’s manufacturing sector is tackling:
Any planned digital journey needs to address these challenges and provide simple and valuable solutions to the organizations.
1.??????Data Aggregation – Aggregating the data from multiple data sources like sensors, relays, meters, PLC, SCADA systems is the first step to get the complete visibility of plant operations. While supporting the industry standard protocols, ?today’s technology of hardware and software brings the data from remote locations as well and gives the opportunity to get sneak view into each parameter by the second.
2.??????Data Encryption and Storage – With the thousands of parameters / tags that need to be monitored across the plant, the data storage could become a challenge both from infrastructure and security point of view. Time series based data Historian, one of many options, can store the data at frequencies of upto 1 Sec, encrypt the same and store in a central sever for easy access as needed. Connectors enabling communication with multiple make and models of PLCs / DCS, Historian can bring the data of the complete plant onto one single platform.
3.??????Data Processing and Visualization – Once the data is available on a single platform, Processing and calculations become easier. Manufacturing companies need detailed and complex processing of data to manage the daily operations and meet the operational, financial and environmental targets they have set for themselves. These calculations need sophisticated and easy to manage algorithms with minimal human intervention while ensuring 100% accuracy.
Automated reports, simplified dashboards, Flexible analytical views are the need of the hour; The key need to be met is flexibility to do varieties of analytics, easy access on mobile devices, access to historical data and collaboration among the operational teams.
Production – Digitalization of operator logbooks can be the first of many steps to capture the field data while giving the power of analysis and data based decision making to the teams. PID monitoring and Soft Sensors reduce the response times during emergency situations and helps identify process anomalies or disruptions.
Technical Services - Simplified dashboards and automated reports improve the confidence on data and drives team collaboration. Monitoring cost and specific energy consumption at the granular level drives improvement opportunities to drive sustainability. Statistical Analysis, Simulations, Scenario comparison, Condition based monitoring open new ideas to stabilize operations and improve productivity at reduced costs.
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Maintenance – Digital maintenance logbooks, Checklists, online Analyser Management, 360 view of Assets all together give a powerful view of the asset performance and overall health to the maintenance teams. Static or Rotary assets need very close supervision to ensure optimal operation and extend the life. Having a digital version of the critical assets can help in preventive and planned maintenance reducing the costs of down time and associated costs.
These digital investments need a well defined governance and active involvement of the key stakeholders to drive the change and adopt the new ways of working. A dedicated project team, ?clearly defined milestones and parameters of success need to be adopted to make the digital projects a success. The expected benefits can be multi-fold
a)??????Early detection of anomalies
b)?????Self-service analytics on mobile devices
c)??????Reduced energy consumption
d)?????Reduced efforts in reporting and analytics
e)?????Stable operations
f)???????Compliance to regulatory guidelines
g)??????Improved asset life
h)?????And many more… ?