Implementing HTML 5 in Plants - Web Technology User Guide

HTML5 is a web technology relatively new in automation but will help running plants better. It is particularly important during #COVID19. Imagine being able to do your work from the control room, fleet monitoring center, your desk, the boardroom, or your home during rotating shifts or lockdown. This could be reliability, maintenance, integrity, energy, HS&E, or production related activities. Whoever, whatever, whenever, from wherever. But just to be clear, HTML5 doesn’t mean it has to be the public Internet or cloud. Conceptually anyone can tell you the solution is the world wide web and a mobile device. But let’s take a detail look at the readymade solutions available. Here are my personal thoughts:

Justification

The people in all operational departments in the plant: reliability, maintenance, integrity, process energy, HS&E, production, and quality all need information to carry out their various activities in the plant. They need this information not just in the control room, which they may not even visit on most days, and not only at their desk either as they don’t spend much time sitting there. They need this information while doing their job, at the job site, and don’t want to spend time or get distracted having to go elsewhere to get it. Having information at your fingertips is at the heart of the productivity improvements with new data-driven ways of working. During a crisis like COVID-19 it is important to remote many plant activities to keep people safe and plants fully operational. Digital technologies are being deployed to bridge the gap when personnel cannot work side by side.

Limitations of apps

Client-server system architecture has been in used in automation for decades; a central server aggregating the information, and multiple workstation clients where people work. The operator workstation is a classic example of a client software on a computer. Vibration analytics for your machinery protection system is another. I will be using the terms app, application, application software, and software interchangeably in this essay. Client software is created for a specific operating system (OS) like Windows or Linux for workstations, as well as iOS or Android for mobile devices. Windows apps in turn may be implemented using Microsoft Windows COM, .NET, or .NET Core. Most automation software is not available for all of these operating systems. For instance, many automation apps are only available for Windows. Moreover, they may only be available for the latest version of Windows. I am sure you’ve come across this problem before. If your personal phone, work tablet, or home computer is not Windows you are not able to work from it. Another problem is some apps don’t fit on small screens so they become hard to use.

Web-based user interface

Another approach is web-based user interfaces. This is still a client-server architecture. With this approach the server with the information to be displayed includes a webserver, and the client-side device like a computer or phone uses a simple web browser that displays the user interface. That is, the webserver generates a Hyper Text Markup Language (HTML) file. The client-side web browser reads the HTML file and renders the interface as a graphical web page.

Use of web browser means there is no need to install an app on the client side. This saves time avoiding local software installation, updates, and license management, and reduces app clutter.

Web pages are OS independent, so the client side can be any kind of device like phone, tablet, laptop, or desktop running iOS, Android, Mac OS, or Windows etc. – and it may be a version of the operating system which is very old.

Web-based interfaces enables parallel work by virtually any number of users.

Web pages travel easily across the Internet enabling global collaboration from different plants, offices, and home offices.

Therefore a web-based user interface enables work by anybody with a web browser, on all kinds of software tools with webserver, without traveling to a particular workstation, during particular hours. That is, anyone, anything, anytime, from anywhere.

Note that a web-based user interface through a web browser is not always the best option. The world-wide web and web browsers were primarily created to consume information; reading text, looking at images, watching videos, and listening. As was smartphone and tablets, which don’t have tactile keyboards. Web pages can also be used for simple text entry, selection from drop down list, and check boxes. However, web-based user interfaces are not great for more complex data entry and editing such as formatting or precision drawing.

Early HTML limitations

Early versions of the HTML technology did not support multimedia such as animation, audio, video, and vector graphics. Users had to install and maintain multiple plugin players for multimedia extensions. This could be one of the reasons why web-based interfaces were not very common in automation in the past.

HTML 5 Technology

HTML version 5 (HTML5) is the latest version of HTML. HTML5 is a web standard used for all kinds of purposes such as personal social media, online digital commerce, entertainment, and marketing. HTML is also already in use by corporate IT in business operations in the office admin since years ago. For instance, the ERP system managed by IT uses HTML5. Office applications like SharePoint also uses HTML5. Now the I&C department in many plants is also deploying HTML5 in operational technology (OT) systems like the historian, analytics, and device management system.

HTML5 supports the multimedia features like animation, audio, video, and vector graphics missing in earlier versions of HTML. Thanks to HTML5, web browsers can now render very sophisticated graphical user interfaces to show information in an attractive and intuitive format making work easy.

With HTML5 the user interface automatically adapts to different screen size, resolutions, aspect ratios, and orientation. This makes HTML5 ideal for information that is displayed in a mix of formats such as a wall screen in a fleet monitoring center, a workstation on a control room, a laptop on an office desk, a tablet in the boardroom, or a phone on the go anywhere in the world.

HTML5 is a technology hidden down in the engine room of the systems. The user, such as a maintenance technician, reliability engineer, or energy manager need not know how to write HTML5 code. They just use the web browser to get the information they need to do their job.

You, the software user, do not need to know how to write HTML5 code

HTML 5 System Architecture

Webservers and web browser clients can sit at any level in the ISA95/Purdue model architecture. Level 0 and 1 tend to be hardware with embedded webservers. Level 2-4 tend to be software. HTML5 is communicated using the Hyper Text Transfer Protocol (HTTP) and the secure SSL/TLS variety Secure HTTP (HTTPS). HTTPS is firewall friendly which makes it a popular protocol for making plant data accessible from outside the plant; such as from the office environment, or anywhere. That is, HTML5 enables global collaboration and work from home. Therefore it is particularly important to enable plants to stay operational while part of the plant’s personnel work-from-home during social / physical distancing and lockdown measures.

The most interesting fact is that HTML5 and web browser doesn’t necessarily mean internet or cloud. Many plants use HTML and web browsers within the perimeter of the plant, on premises, simply because it is a convenient tool.

HTML5 and web browser doesn’t necessarily mean internet or cloud, it is often on-prem

At level 4 the ERP typically has a webserver. Many ERP functions such as your expense claims are done from a web browser. There may also be Business Intelligence (BI) visualization of ERP data with a web-based user interface for reporting.

At level 3 the historian has a webserver for the graphical user interface. This may be used for creating web-based operational dashboards displaying information from the historian. Similarly higher-level analytics for larger equipment also have web-based dashboards.

At level 2 detail analytics software for corrosion, vibration, and instrumentation etc. has web-based dashboards for point details.

At level 1 the automation devices like controllers and I/O such as wireless gateways have embedded webservers enabling management from a web browser.

At level 0 very few field instruments today have embedded webservers, but they do exist in Ethernet enabled devices, but those are rare. Especially in the heavy industries. In the future field instruments will use 2-wire (single pair) Ethernet-APL networking and these instruments will have built-in webservers so they too can be managed from a web browser.

The plant may already have many web-based apps, but personnel may still be required to return to their desk to use them for various reasons. Thus they are not getting full productivity value out of it. The mobile “anywhere” element must be enabled. Therefore consider getting your I&C department to deploy plant-wide Wi-Fi to provide network connection for mobile devices throughout the plant.

It is important to remember the web browser must have connection to the webserver in order to work. If there is no connection you can’t do the work. This is an important consideration when using web interfaces for data entry. If there is no connection, you can’t submit the data to the server so if not careful it may get lost. Therefore web-based user interfaces are primarily used to consume data. Engineers have a knack for figuring out which is the best solution. Again, some plants are getting their automation vendor to deploy industrial Wi-Fi throughout the site to provide a good network connection for mobile devices also in the plant where mobile network reception may not be great.

Operational Activities – Operational Software

So what kind of plant operations tasks can you do from a web-based software from a web browser? Many. Tasks that can be carried out from anywhere on-the-go, including from home, on any device with a web browser include:

• Operational dashboards
• Equipment analytics
• Corrosion analytics
• Vibration analytics
• Intelligent Device Management (IDM)
• Asset Performance Management (APM)
• Networking hardware management

Operational Dashboards

Operational dashboards have web-based user interfaces to give all plant personnel the information they need to do their job better even when they are away from their desk; outside in the plant, in a meeting, or working from home. The operational dashboards are personalized, containing the real-time information people need to meet their KPIs at the end of the month. That is, the maintenance engineer’s dashboard is different from that of an energy manager and so on. The information in the operational dashboard comes from underlying analytics apps which in turn gets its data from a foundation of advanced sensors and many subsystems around the plant such as the control system, machinery protection system, safety system, package unit PLCs, and motor control system. Personnel working from home can support and direct personnel still in the plant.

Equipment Analytics

High-level equipment analytics apps have web-based user interfaces to let maintenance engineers and technicians pinpoint which equipment like pumps or compressors will need overhaul or simple attention soon, which heat exchangers will soon need cleaning and which ones don’t, and which steam traps need replacing and so on. They get predictive analytics even when they are away from their desk; outside in the plant, in the workshop, or working from home. The user interface is specialized for each type of equipment; with information relevant to each equipment class. Yet the equipment-level screens are designed with a common look and feel, so once you can use one, you can use all. That is, the pump dashboard is different from the steam trap dashboard and so on. From the equipment dashboard they can zoom into equipment alarm summary and then zoom further into equipment detail. The information is uncovered by the analytics apps which gets its data from a foundation of advanced sensors and subsystems around the plant. Experts working from home can guide personnel on duty at site, even plan for a turnaround.

Remember, before you connect the dots you must collect the dots; no point have analytics and web interface if you don’t put in the sensors to collect the data first. Sensors are the foundation of digitization.

Before you connect the dots you must collect the dots

Corrosion Analytics

Detail corrosion analytics apps have web-based user interfaces to let the integrity manager and engineers pinpoint which pipe section will need replacement, if crude mix can be optimized, or corrosion inhibitor injection can be improved. They can do wall thickness and corrosivity analytics even when they are away from their desk working from home. Personnel working from home can plan for the activities to be performed at site once they return, at the next turnaround, or schedule urgent pipe section replacement if need be. From the corrosion dashboard they can zoom into corrosion alarm summary and then zoom further into pipe section position detail.

Vibration Analytics

A vibration analytics app with a web-based user interface enables the reliability engineers to pinpoint which bearings, foundations, or other parts of rotating equipment will need replacement, alignment, or lubrication soon. They get predictive analytics even when they are away from their desk; outside in the plant, in the workshop, or working from home. Vibration experts working from home can prioritize the tasks to be performed at site by the maintenance crew on urgent basis, at the next turnaround, or sometime in between. From the vibration dashboard they can zoom into machine train alarm summary and then zoom further into machine journal details.

Intelligent Device Management (IDM)

An Intelligent Device Management app with a web-based user interface enables the instrument technicians and engineers to identify instrumentation or valves which are due for calibration or need overhaul soon, with manufacturer’s recommended action, or need to be replaced. They get status overview even when they are away from their desk; outside in the plant, in the workshop, instrument lab, or working from home. Valve and instrumentation experts working from home can identify the tasks to be performed by the onsite crew.

Asset Performance Management (APM)

An Asset Performance Management app with a web-based user interface enables engineers to navigate process equipment and instrumentation to access their data even when they are away from their desk; outside in the plant, in the workshop, or working from home. As personnel zoom into further detail, the equipment analytics and vibration analytics user interface mentioned above opens.

Networking Hardware Management

Most devices with Ethernet connection such as networking hardware including wireless sensor network gateways come with embedded webserver. Networking is core infrastructure for digitalization. This enables the network administrator to manage the device through a web-based user interface. This may include basic settings that allows the device to join the network, but can also include detail configuration and troubleshooting tools. This enables network engineers and technicians to do their work away from their desk; outdoor in the plant next to the device, on a workbench, or working from home. Wireless network experts working from home can make necessary changes or identify problems to be fixed by the onsite crew.

Other Apps

Many other apps have web-based user interface. For instance the ERP/CMMS system which enables you to raise and manage workorders from a laptop, tablet, or smartphone while in the plant, admin building, or from home. Same goes for the permit to work system, SharePoint for access to documents such as drawings and procedures. BI software with web interface allows managers to visualize trends in operations and maintenance spend from ERP transactional data.

In the future, FDI device packages for device dashboards will be a combination of HTML5 user interface and EDDL device description.

Migration for the Fourth Industrial Revolution (4IR)

Digital transformation in existing plants is enabled by deploying a second layer of automation, a digital operational infrastructure (DOI) for monitoring and optimization as per the NAMUR Open Architecture (NOA) for Industrie 4.0 (Industry 4.0), on the side of the DCS for the core process control. Most software with web-based user interface, such as those described in this essay, are part of this new DOI. That is, most systems are coming into place where no system existed before so it is not migration. It is simply deployment into an existing environment.

However, there are cases of migration of existing applications around the core process control as well, such as historian clients. Historians until recently have been using only full-fledged Windows client apps for graphics visualization of data, but now plants are increasingly also deploying web-based clients for visualization. The underlying data server remains the same, with the addition of a webserver.

New Tools and New Digital Ways of Working

Like Microsoft CEO Satya Nadella said in the Q3 2020 earnings call; “we have seen two years' worth of digital transformation in two months” - because of COVID-19. However, working remote is not a temporary stopgap measure just for COVID-19. It will stick. Working from home address the immediate pressing needs, but long-term we will see experts supporting the plant from other remote locations will become common. New ways of operating the plant includes automating manual data collection through fully instrumented equipment and providing remote display through HTML5 to manage activities around the plant.

Schedule a meeting today with all the operational departments to discuss the opportunities for work-from-home and using remote experts for assistance. Forward this essay to the managers of the operational departments now.

And remember, when exploring your vision with vendors, always ask for product data sheet to make sure the product is proven, and pay close attention to software screen captures in it to see if it does what is promised without expensive customization. Well, that’s my personal opinion. If you are interested in digital transformation in the process industries click “Follow” by my photo to not miss future updates. Click “Like” if you found this useful to you and “Share” it with others if you think it would be useful to them.