‘The silence before the storm’, FHI director Paul Petersen described it. ‘A lot is happening in process and production automation.’ Over the years, efficiency and effectiveness have been the key words for the manufacturing and process industry. The current developments around Industry 4.0, Industrial Internet of Things (IIoT), Big Data and therefore also Cyber Security require concrete and at the same time strategic choices.
Jacco Opmeer (Shell Global Solutions) responded with a speech on the need for standardization in the rapidly transforming industrial sectors. Opmeer is involved in the Open Process Automation Forum (OPAF) working group on behalf of Shell.
“The industry is changing, driven by the wishes and needs of society. But it requires adjustments from suppliers to the process industry. Cooperation with end users is an important part of this. ”
Opmeer continued: “On behalf of OPAF, we want to involve our ecosystem, a group of end users, much more in the technical development and enter into cooperation. It is not about selling a product, but about developing common solutions. The suppliers are above for the same challenge as we end users: Product costs must be reduced. This puts them in a ‘squeeze’ of what they can develop for end users. Because they ultimately have to transfer the development costs to new platforms. “
Consider cybersecurity, for example. Opmeer: ”The previous levels worked well for cybersecurity. But due to the large amount of data and collaboration, we must strive for a flat and secure platform with a solid architecture. Exxon Mobil must now build its first factory in the US with the new Where they still have to integrate the interface due to the large installed base, the lack of layers requires a hybrid system to be created in collaboration with vendors.It’s all about unlocking data.
Life cycle management
The story of Hans van Engelen, ICT Group and Roel van Camp, Organon Benelux fit very well into this. Due to a security incident in 2017, Organon had to take action. The ERMD program (Enterprise Resilience and Modernization to Life Cycle Management) involved IT and OT. The global program was first rolled out locally and coordinated globally. The purpose was to prevent future incidents. But even if one unexpected takes place, how do we get back into the air so quickly. After an inventory (baseline measurement), the modernization focused on the systems. Old programs like Windows7 went out, new ones came in. Servers were made virtual. But there was also a conversion from Siemens S5 to S7. With one caveat: Make sure there are still people who can program the first one until it’s all over!
Before the conversion, everything was first tested on a simulator. There is now a continuous solution based on life cycle management.
Mark van der Zande from Krohne Nederland then pointed out the need for good hydrogen monitoring. The smaller molecules, the explosiveness of the substance and the mixture with gas make traditional gas detection impossible. The Real Time Transit model serves this purpose, where a pressure, temperature and flow meter at the beginning and end of the pipeline provides the solution. Flow can then be modulated with a digital twin. The dynamic filtering of RTTM, corresponding to face recognition on your phone, ensures that the right leak alarm comes. It also fits existing pipelines. Accuracy of course stands or falls with the number of measuring points.
In Germany, leak detection on pipelines is already mandatory.
Mark Satink & Omar Thiam (Aveva Select Benelux) dived a little further into the technology for digital twins. First of all, they emphasized the importance of organizing the data with the ultimate goal in mind. They do this on the basis of ISA so as not to have to reinvent the wheel. The data check must be bottom up to integrate it into the organization and to guarantee that the measured values are reliable. They shared their build plan, but immediately admitted that not many companies are ready to take the plunge as a digital twin in closed loop.
Paul Cobben (KPN) closed the PPA day. He outlined the benefits of technologies such as 5G, edge computing and indoor localization in the industry to achieve ‘wireless factories’.
Want to hear more about what to expect from the process industry? At the end of September, FHI organizes Wots. Together with Machevo & Bulk Association for the process industry, especially the Industrial-Processing part. This also includes various seminars.