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2017 DIGITAL REPORT

IIoT: OPERATIONS & IT


IIOT: OPERATIONS & IT
Click the video link below for an overview on the IIoT: Operations & IT Digital Report from
Plant Engineering, Content Manager, Bob Vavra.

Welcome to our new digital report, focusing on the relationship be-


tween your operations team and the Industrial Internet of Things, or
IIoT.

Youre already collecting a tremendous amount of data on your plant


floor, but studies show very little of that data is actually used to un-
derstand the current state of your operation and to affect changes
that can improve productivity, quality and safety. The transformative
nature of IIoT will offer manufacturing operations team a greater in-
sight to what is happening now on your plant floor, and offer a look
at what might happen next.

This digital report will explore several aspects of how IIoT will trans-
form manufacturing in the coming years. Among the topics well
cover here are how to use IIoT to improve operations, how to do
a better job of data analysis by using new technologies and new
software, and how manufacturers are already using IIoT to affect
changes in their operation.

This CFE Media digital report should serve as a way to begin the
discussion in your plant about ways to leverage new technology and
new strategies to increase productivity on the plant floor. We believe
IIoT can help manufacturers understand and act more quickly and
precisely to generate greater operational success. Those manufac-
turers who begin today to take advantage of IIoT will gain a competi-
tive advantage in a global manufacturing environment. This digital
report provides you with the tools to start that initiative today.
CONTENT
Use IIoT to improve operations 4

Case Study: Hirotec America 9


Digital Report brought
to you by:
Industrial Internet of Things (IIoT) benefits,
examples
15

Enabling IIoT requires communication protocol


translation
21

Data analysis: A key requirement for IIoT 27

IoT - The merger of IT and industrial 33

Process historians can be an integral part of


the IIoT
42
USE IIoT TO IMPROVE OPERATIONS
Data analytics for IIoT: More data is just more data. Data analysis software is the key to extracting insights
and creating value from the Industrial Internet of Things (IIoT) opportunities in production facilities. See two
implementation examples and the four needs of data analytics.

T
Use IIoT to improve hanks to a new generation of wired and wireless sensors, data can now be
operations economically generated and gathered in quantities never previously available
Case Study: and then sent to process control and monitoring systems via plant networks or
Hirotec America through the Internet. Data can then be used to improve automated real-time
Industrial Internet of control and to help plant engineers and operators make better decisions regarding opera-
Things (IIoT) benefits, tion and maintenance. It is also available to data analysis software, which can be used by
examples plant personnel to increase efficiency, diagnose equipment problems, and improve safety.
Enabling IIoT requires
communication proto- As a result of this opportunity for new insights, terms such as the Internet of Things
col translation
(IoT), the Industrial Internet of Things (IIoT), big data, and Industrie 4.0 are now com-
Data analysis: A key mon. Recent advances in sensors, connectivity, and data analysis software combine to
requirement for IIoT
make it easier and less expensive to acquire, send, store, and analyze information. But
IoT - The marger of IT no matter the terminology, the objective is the same: better insights faster.
and industrial

Process gisotrians can Green and brownfield applications


be an integral part of For the sake of simplicity, there are three common scenarios in which the IIoT, to
the IIoT
choose one of the terms, can improve plant operations. They may be summarized as
brownfield, greenfield, and servicization. All three scenarios can be described indepen-
dently, but will frequently co-exist within the same plant.

Brownfield refers to existing plants and operations where new sensors are added to
existing control or plant networks. Common brownfield scenarios include adding a

CFE Media Digital Report: IIoT: Operations & IT 4


Figure 1: Getting the most from avilable informa- wireless system and sensors to expand
tion requires collecting data, trasmitting it via wired operator visibility and asset monitoring ca-
or wirless methods, analyzing it with software, and
pabilities or adding sensors to replace the
making it avilable to engineers via smartphones,
eyes and ears of engineers being transi-
tablets, and computers. Image courtesy: Seeq
Use IIoT to improve tioned to centralized remote
operations monitoring centers or integrat-
Case Study:
ed operations facilities.
Hirotec America
Greenfield scenarios are de-
Industrial Internet of
Things (IIoT) benefits, ployments in plants or facilities
examples just coming online with IIoT
Enabling IIoT requires
projects. This is the most
communication proto- common scenario for smart
col translation city or public sector projects,
Data analysis: A key and its where the association of IIoT with cloud-based monitoring systems originates
requirement for IIoT because the project isnt designed around an on-premise control and monitoring sys-
IoT - The marger of IT tem. The key difference with most greenfield deployments is this lack of a control sys-
and industrial tem infrastructure, but there are many examples of these systems monitoring remote
Process gisotrians can tank farms, pump stations, and vehicles as a complementary system for an existing
be an integral part of facility.
the IIoT

Cash in on services
Finally, servicization is one of several monikers describing the inclusion of a remote
monitoring capability for an asset. This is the future of your personal vehicle-unless
you already have a Tesla and your vehicle information is piped continuously back to
the dealership-and of many assets in process plants. Vendors of pumps, valves, and

CFE Media Digital Report: IIoT: Operations & IT 5


many other asset types are introducing subscription services for monitoring equipment
installed on customer promises. The business benefit is asset reliability and uptime,
but the real driver is the opportunity for the vendor to provide expertise in asset perfor-
mance and management.
Use IIoT to improve
operations All of these models follow a common architecture of sensor, communications network,
Case Study:
and analysis that is very familiar to the process industry and noted by many prominent
Hirotec America industry speakers. Even the difference between the brownfield and servicization mod-
els may be summarized as a question of where the data lands for analysis-at the plant
Industrial Internet of
Things (IIoT) benefits, or with the asset vendor.
examples

Enabling IIoT requires


But familiarity with the IIoT architecture and vendor advocacy over what is or isnt a
communication proto- part of the IIoT architecturecloud systems, fog computing, big data, and Internet
col translation standards being the most common examplesshould not obscure the fact that there
Data analysis: A key are new opportunities for improved plant performance enabled by these new technolo-
requirement for IIoT gies, and available at drastically lower price points.
IoT - The marger of IT
and industrial The key question for manufacturers with existing plants then becomes: How do we
Process gisotrians can bring our facilities forward into a smarter state? The answer may require any or all of
be an integral part of the IIoT deployment models mentioned, but should always be framed in the context of
the IIoT the end benefit: better insights faster.

Start with sensors


Sensors are the starting point in the data collection process. They monitor operation of
the things in the IIoT: pumps, valves, and other assets. Their cost of implementation
and use is dropping rapidly, making it cheaper to acquire more data. Plant personnel

CFE Media Digital Report: IIoT: Operations & IT 6


were once limited to 4 to 20 mA, HART, or various fieldbus protocols to connect these
sensors to control and monitoring systems and software. But today, they can use many
types of wired and wireless data connection methods, often employing multiple net-
works simultaneously in one plant (see Figure 1).
Use IIoT to improve
operations These sensors and connections are what enable new data from new sources to be ac-
Case Study:
cumulated quickly and inexpensively, and, as shown, theres a wide range of modern
Hirotec America networking options for deployment. Battery-powered transmitters require no signal or
power wiring infrastructure, so they can be installed in locations far away from a pro-
Industrial Internet of
Things (IIoT) benefits, cess units wired signal termination points. They can also operate safely for years in
examples hazardous and other areas.
Enabling IIoT requires
communication proto- Wireless instrumentation also makes it possible to monitor a wide variety of equipment
col translation and systems previously too difficult or expensive to reach with wired solutions, such as
Data analysis: A key 4 to 20 mA or fieldbus. Pump monitoring is an excellent example because these assets
requirement for IIoT are found in most every process plant in large numbers and because their reliable op-
IoT - The marger of IT eration is critical.
and industrial

Process gisotrians can Learn more about brownfield IIoT monitoring and the four requirements for data analytics.
be an integral part of
the IIoT

CFE Media Digital Report: IIoT: Operations & IT 7


Click the video link below to view a video provided by Kepware

CFE Media Digital Report: IIoT: Operations & IT 8


CASE STUDY:
HIROTEC AMERICA
Automotive Parts Supplier Launches IoT Initiative in Six-Week Sprints Powered by Indus-
trial Data from Kepware

The customer
HIROTEC AMERICA is part of the HIROTEC Group Companies, a $1.6 billion corpora-
Use IIoT to improve
operations tion with over 60 years of mass production experience and engineering discipline. With 26
facilities in nine countries around the world, HIROTEC Group is globally recognized as a
Case Study: premier automation manufacturing equipment and parts supplier.
Hirotec America

Industrial Internet of For over 50 years, top vehicle producers like General Motors and Mazda have used HIRO-
Things (IIoT) benefits,
examples
TECs proven, high-quality industrial manufacturing concepts and systems. The parts and tool-
ing supplier designs and builds roughly 7 million doors and 1.5 million exhaust systems a year,
Enabling IIoT requires making it one of the largest private production companies in todays global automotive market.
communication proto-
col translation
HIROTEC is a leading tier-one component and tooling supplier for the Automotive Indus-
Data analysis: A key try, giving us a very unique perspective on how both sides of the industry operate, said
requirement for IIoT
Justin Hester, Senior Researcher, HIROTEC. Weve used this insight to benefit both our
IoT - The marger of IT business and our customers by designing and building a wide array of state-of-the-art
and industrial solutions that are based on proven concepts. In our dedication to our customers success,
Process gisotrians can we pride ourselves on our ability to supply the highest-quality automotive equipment and
be an integral part of services to customers around the world.
the IIoT

The challenge
Operational downtime is a significant issue facing Original Equipment Manufacturers
(OEMs). In most cases, the machinery involved runs without condition-based monitoring
essentially operating until a failure occurs. At that time, appropriate personnel are con-
tacted to assess the situation and make the repairs as expeditiously as possible to prevent

CFE Media Digital Report: IIoT: Operations & IT 9


dramatically delaying production schedules. Outside factors like weather or traffic patterns
might also add to possible downtime scenarios and lead to organizational inefficiencies
and/or misallocation of resources.

HIROTEC sought to eliminate this trend of reactive maintenance and lost opportunities by
Use IIoT to improve
operations
utilizing the information and systems it had on hand to gain deeper insight into its opera-
tions and processes. The automotive supplier had long collected industrial data from sen-
Case Study: sors and machines across customer production facilities and its own systems to support
Hirotec America
its decisions and track business progress. However, volumes of this data were manually
Industrial Internet of separated and stored across multiple sourcesmaking it inaccessible to collective and
Things (IIoT) benefits,
examples systematic analysis. In order to improve quality, reduce downtime, and optimize produc-
tion schedules, HIROTEC needed to implement a modern, automated solution that could
Enabling IIoT requires
communication proto-
gather maintenance and operational information into one source and offer actionable rec-
col translation ommendations to its quality professionals.
Data analysis: A key A lack of data was never an issue for us, said Hester. As one of the largest automotive
requirement for IIoT
manufacturing suppliers in the world, we collect volumes of datasets on a daily basis. The
IoT - The marger of IT problem we were faced with was transitioning from a data-heavy organization to a data-
and industrial
smart organization. We realized that in order to bolster profits from untapped machine-
Process gisotrians can generated information, we needed to look towards modern solutions that automated the
be an integral part of
the IIoT process and enabled timely, data-driven decisions.

The approach
Recognizing the need for connectivity, data access, and scalability, executives at HIROTEC
worked to develop a competitive strategy to capitalize on the potential benefits of the Inter-
net of Things (IoT). The initiative began with identifying the fundamental technologies that
would fuel the IoT effort.

CFE Media Digital Report: IIoT: Operations & IT 10


After evaluating several traditional IoT offerings from traditional industrial automation ven-
dors, HIROTEC found that many solutions were restricted to a single business aspect,
protocol, or standard. Not wanting to waste time and effort integrating multiple solutions
across several business functions, HIROTEC finally turned to Kepwares KEPServerEX
Use IIoT to improve
and the ThingWorx IoT Platformboth solutions from PTCto enable company-wide
operations device-to-cloud connectivity through one overarching toolset. Working together to deploy a
Case Study: single source of smart solutions for the IoT, the ThingWorx platform would be able to pro-
Hirotec America vide analytical insight into HIROTECs data through industrial data streamed from the IoT
Gateway for KEPServerEX, an advanced plug-in capable of pushing information from KEP-
Industrial Internet of
Things (IIoT) benefits, ServerEX into Big Data and analytic software applications.
examples
To support the companys long-term IoT vision, HIROTEC collaborated with representatives
Enabling IIoT requires
communication proto-
at PTC to build an IoT framework supported by short, six-week Agile sprints. Where a full
col translation IoT implementation may have taken years to generate a proof of concept, the Scrum mod-
el provided company executives with visible and quantifiable progress in just weeks.
Data analysis: A key
requirement for IIoT
We see and speak with many manufacturing organizations, and it is clear they are inter-
IoT - The marger of IT ested in the Internet of Things. They see the potential and would like to do something with
and industrial
the technology. Despite the desire that exists, many remain frozen because the prospect
Process gisotrians can of a full-blown implementation is so daunting and uncertain, said Hester. This is why we
be an integral part of
the IIoT advocate so strongly for the short-sprint model we have adopted at HIROTEC. We dont
want to boil the ocean; we want to start with low-hanging, solvable problems and build out
our case and experience.

HIROTECs North American shop in Detroit, Michigan was chosen as the test bed for the
first small sprint because of the unique data types generated among its eight Computer
Numerical Control (CNC) machines. Kepwares IoT Gateway for KEPServerEX collects data
CFE Media Digital Report: IIoT: Operations & IT 11
from the CNC machines and streams it in real-time to the Cloud, where the ThingWorx IoT
Platform provides analytics and data visualizations. This solution gives HIROTEC labor-free
access to a customized visualization of both the operations and conditions of its industrial
devices and systems.
Use IIoT to improve
operations When first embarking on our IoT journey, HIROTECs core objective was to remain flex-
Case Study: ible in our ability to connect things, said Hester. The offerings and expertise by Kepware
Hirotec America and PTC have enabled us to stay true to our goal by effortlessly adapting to our business
processes and developing the right IoT strategy for our teams. The IoT Gateways ability to
Industrial Internet of
Things (IIoT) benefits, seamlessly put data into ThingWorx to generate real-time insight into operations fuels our
examples sprint framework and allows us to stay nimble in our decision making.
Enabling IIoT requires
communication proto- The results
col translation Since implementing Kepwares IoT Gateway and the ThingWorx IoT Platform, HIROTEC
Data analysis: A key has gained increased visibility into the processes of its CNC shop and deeper insight into
requirement for IIoT operations. The company realized early on that having access to CNC machine uptime
IoT - The marger of IT data significantly impacted the shops scheduling process, which was previously set on
and industrial conjecture and after-the-fact analysis. Manufacturing leadership can now leverage real-time
Process gisotrians can data from the shop floor and tie it to the scheduling ERP system, optimizing the scheduling
be an integral part of of parts to CNC modules.
the IIoT

This process also provides greater insight into asset and resource allocation by automati-
cally formulating smarter questions about current needs and priorities and determining
the most effective course of action. Because of this, HIROTEC has improved productivity
across the shop and increased its ROI.

CFE Media Digital Report: IIoT: Operations & IT 12


The company has also improved collaboration between its Operations and Information
Technology (IT) departments. By working daily with Research & Development engineers,
IT teams quickly gained access to corporate roadmaps and strategic goals, and were em-
powered to contribute at a more strategic level. Not only has the development of cross-
Use IIoT to improve
functional teams improved communications across the entire business, but the added
operations perspective helps promote quicker and more efficient responses to IT jobs.
Case Study:
Hirotec America HIROTEC anticipates its IoT efforts to impact every aspect of its businessfrom Opera-
tions and IT to financial forecasting, customer relations, and sales. As it moves forward with
Industrial Internet of
Things (IIoT) benefits, sprint projects, HIROTEC will continue to see what is useful about the varied sets of con-
examples textualized data and use it to create common business processes and analyses. The auto
Enabling IIoT requires
parts supplier eventually plans to use this insight to create an IoT-ready production line and
communication proto- enable remote equipment monitoring and management from a centralized dashboard to
col translation promote predictive and proactive maintenance.
Data analysis: A key
requirement for IIoT In just six short weeks, weve gained more visibility into our operations than ever before,
IoT - The marger of IT reinforcing our investment and belief in the power of the IoT, said Hester. With data-cen-
and industrial tric knowledge generated from KEPServerEX and ThingWorx, we can now make smarter
Process gisotrians can and timelier decisions that not only impact our CNC shop, but also help us identify how we
be an integral part of can operate more efficiently and profitably across all of our facilities.
the IIoT

Organization
HIROTEC AMERICA is part of the HIROTEC Group Companies that have worldwide sales
in excess of 1.6 billion dollars and 26 facilities across 9 countries. For over 50 years, HI-
ROTEC AMERICA has been providing innovative and highly flexible closure manufacturing
solutions.

CFE Media Digital Report: IIoT: Operations & IT 13


Solution
KEPServerEX
o IoT Gateway Advanced Plug-In
o Manufacturing Suite
Use IIoT to improve ThingWorx IoT Platform
operations

Case Study: Callout quote


Hirotec America When first embarking on our IoT journey, HIROTECs core objective was to remain flex-
ible in our ability to connect things, said Hester. The offerings and expertise by Kepware
Industrial Internet of
Things (IIoT) benefits, and PTC have enabled us to stay true to our goal by effortlessly adapting to our business
examples processes and developing the right IoT strategy for our teams. The IoT Gateways ability to
Enabling IIoT requires seamlessly put data into ThingWorx to generate real-time insight into operations fuels our
communication proto- sprint framework and allows us to stay nimble in our decision making.
col translation

Data analysis: A key Organization impact and benefits


requirement for IIoT Improved visibility into the processes of the CNC shop and gained deeper insight into
IoT - The marger of IT operations
and industrial Added the ability to leverage real-time data from the shop floor and tie it to the schedul-
Process gisotrians can ing ERP system, optimizing the scheduling of parts to CNC modules
be an integral part of Increased productivity and ROI by gaining greater insight into asset and resource alloca-
the IIoT
tion
Improved collaboration between Operations and Information Technology (IT) depart-
ments, reducing downtime and enabling more efficient responses to IT jobs
Reduced costs, effort, and development time by selecting proven, interoperable tech-
nologies
Provided quick proof-of-concept into the value of IoT via short, six-week Agile sprints

CFE Media Digital Report: IIoT: Operations & IT 14


INDUSTRIAL INTERNET OF THINGS (IIoT)
BENEFITS, EXAMPLES
Industrial Internet of Things (IIoT) technologies, applied for monitoring valves in a refinery, used wireless
acoustic transmitters to improve regulatory compliance and reduce hydrocarbon losses by $3 million annu-
ally due to timely detection and repair of faulty valves. The project paid for itself in five months, with an esti-
mated annualized return on investment (ROI) of 271% annualized over 20 years. See four IIoT benefits.

T
Use IIoT to improve he Industrial IoT (IIoT) is much more advanced than the commercial IoT, primarily
operations
due to the prevalence of connected sensors in the industrial world, which are
Case Study: the things in the IoT. Hundreds of millions of connected wired and wireless
Hirotec America
pressure, level, flow, temperature, vibration, acoustic, position, analytical, and
Industrial Internet of other sensors are installed and operating in the industrial sector, and millions more are
Things (IIoT) benefits, added annually, increasing value with additional monitoring, analysis, and optimization.
examples
This is part of the June Control Engineering cover story on Industrie 4.0 and Industrial
Enabling IIoT requires Internet of Things to help make smarter factories.
communication proto-
col translation
These sensors connect to a variety of higher level software platforms, both on- and off-
Data analysis: A key site. On-site connections are often via a local intranet, creating an Industrial Intranet of
requirement for IIoT Things. Offsite connections are usually made through the Internet, often via a cloud-
IoT - The marger of IT based storage system.
and industrial

Process gisotrians can


These higher level software platforms include control and monitoring, asset manage-
be an integral part of ment, and specialized data-analysis systems. At remote data-analysis centers, sophis-
the IIoT ticated big data analytics are performed by dedicated experts to reveal patterns, prob-
lems, and solutions.

Four IIoT benefits


The IIoT connects sensors to analytic and other systems to automatically improve per-
formance, safety, reliability, and energy efficiency by:

CFE Media Digital Report: IIoT: Operations & IT 15


1. Collecting data from sensors (things) much more cost effectively than ever be-
fore because sensors are often battery-powered and
Figure 1: Wireless access point is a wireless
key component in a WirelessHART
mesh network, part of an Emerson
Use IIoT to improve 2. Interpreting this data strategically using big data
Process Management installation at
operations analytics and other techniques to turn the data into
Ergon Refining. Sensor data is sent
Case Study: to the Emersons AMS Suite soft-
actionable information
Hirotec America ware with ValveLink, Smart Meter
Industrial Internet of Verification, and other specialized 3. Presenting this actionable information to the right
Things (IIoT) benefits, data-analysis applications. Image person, either plant personnel or remote experts,
examples courtesy: Emerson Wireless and at the right time
Enabling IIoT requires
communication proto- 4. Delivering performance improvements
col translation when personnel take corrective action.
Data analysis: A key
requirement for IIoT Here are some of the ways the IIoT is moving
IoT - The marger of IT from concept to reality.
and industrial

Process gisotrians can IIoT in action


be an integral part of IIoT technology was implemented at Ergon
the IIoT
Refinings Vicksburg, Miss., facility. This IIoT
implementation connects vibration, acoustic,
level, position, and other sensors to an asset
management system via both a wired fieldbus
network (Foundation Fieldbus) and a wireless
network (WirelessHART). [Foundation Field-

CFE Media Digital Report: IIoT: Operations & IT 16


Figure 2: Remote wirless access to DeltaV bus and Highway Addressable Remote Trans-
software is possible via a Panasonic Tough- ducer Protocol (HART) protocols are governed
book. In an IIoT implementation at Ergon by FieldComm Group.] The wireless network
Refining, mobile workers view sensor and connects instruments to the plants control and
other data on handheld industrial PCs con- monitoring systems via a wireless mesh network
Use IIoT to improve nected to a plantwide Wi-Fi network. The
operations consisting of wireless instruments and access
AMS software analyzes sensor data and
Case Study:
points (Figure 1).
transforms it into actionable information.
Hirotec America AMS allowed consistent setup and reduced
Sensor data is sent to asset management soft-
Industrial Internet of commissioning costs, along with reduced
ware with specialized data-analysis applica-
Things (IIoT) benefits, call-outs through the use of an AMS Alert
examples Monitor. Image courtesy: Emerson Wireless tions for valves and smart meters. The software
Enabling IIoT requires
analyzes sensor data and transforms it
communication proto- into actionable information. Control room
col translation operators view this information on human
Data analysis: A key machine interfaces (HMIs), and mobile
requirement for IIoT workers view it on handheld industrial
IoT - The marger of IT PCs connected to a plantwide Wi-Fi net-
and industrial work (Figure 2).
Process gisotrians can
be an integral part of Capital expenditures were reduced be-
the IIoT cause wireless cut sensor installation
costs, and ongoing operational benefits
included increased capacity and avoided
capital investments through wireless
tank monitoring. The asset management
software allowed consistent setup and

CFE Media Digital Report: IIoT: Operations & IT 17


reduced commissioning costs, along with reduced call-outs through the use of alarm
management software. Safety was improved by automating vibration monitoring in
hard-to-reach locations which were previously checked via manual rounds, and en-
ergy was saved with wireless steam trap monitoring.
Use IIoT to improve
operations Ergon now has wireless infrastructure in place for data collection, analysis, and distri-
Case Study:
bution. This existing infrastructure makes it quick and inexpensive to add more wire-
Hirotec America less sensors to deliver further operational improvements.
Industrial Internet of Steam trap savings
Things (IIoT) benefits,
examples Steam trap monitoring via wireless acoustic transmitters is a leading IIoT application.
Enabling IIoT requires
communication proto- When traps fail to open, high-pressure steam leaks out, so more steam has to be pro-
col translation duced by boilers.
Data analysis: A key
requirement for IIoT Depending on the price of steam at a facility, a single failed-open steam trap can
IoT - The marger of IT waste $30,000 worth of steam each year.
and industrial

Process gisotrians can When traps fail to close, they dont remove water droplets from the steam. These wa-
be an integral part of ter droplets, moving through piping and equipment at a high rate of speed, can rup-
the IIoT ture steam lines and cause turbines to throw blades. Repairs are very expensive, and
downtime is often significant.

Most plants monitor their steam traps manually via annual checks. This is very costly
in terms of labor, misses many problems, and in the worst case can allow failed traps
to operate for years.

CFE Media Digital Report: IIoT: Operations & IT 18


Acoustic sensors and specialized software systems detect steam trap problems au-
tomatically and alert plant personnel so they can take action. In the past, these sen-
sors were wired back to software systems, but the preferred modern method is to use
wireless acoustic sensors connected back to software systems via a wireless mesh
Use IIoT to improve
network, creating an IIoT.
operations

Case Study:
These wireless sensors are battery-powered and can operate for up to 10 years be-
Hirotec America tween battery changes. Compared to wired sensors, installation takes place much
more quickly at significantly lower costs, and required plant downtime for installation
Industrial Internet of is greatly reduced or eliminated.
Things (IIoT) benefits,
examples

Enabling IIoT requires


One corn milling plant was experiencing a 15% annual steam trap failure rate, with
communication proto- 12.5% of the plants steam traps responsible for 38% of the steam loss. The plant
col translation addressed this issue using wireless steam trap acoustic sensors and accompanying
Data analysis: A key analytics. The payback period was just a few months, and the annual savings were
requirement for IIoT $301,108.
IoT - The marger of IT
and industrial Flare gas monitoring
Process gisotrians can Another IIoT example is monitoring valves controlling gas flows to flare stacks in refin-
be an integral part of eries. Using wireless acoustic transmitters, one refinery improved regulatory compli-
the IIoT ance and reduced hydrocarbon losses by $3 million annually due to timely detection
and repair of faulty valves. The project paid for itself in five months, with an estimated
annualized return on investment (ROI) of 271% annualized over 20 years.

The IIoT is here today, and plants are using it to realize value from the hundreds of
millions of connected sensors currently installed and the millions more coming on-

CFE Media Digital Report: IIoT: Operations & IT 19


line each year. Many of these sensors
are wireless because they can be in-
stalled more quickly and at less cost
than their wired equivalents, often with
no required downtime. These low-cost
wireless sensors and accompanying
Better Data, analytics can dramatically improve plant
performance, increase safety, and pay
Better Decisions for themselves within months.

Bob Karschnia is vice president of wire-


less, Emerson Process Management.
Kepwares software supports connectivity to thousands of
devices and data sourcesproviding real-time industrial
data to all of your applications and enabling smarter
decision making throughout the enterprise.

Learn more at kepware.com/CE

IIoT: Operations & IT 20


ENABLING IIoT REQUIRES COMMUNICATION
PROTOCOL TRANSLATION
As implementations of Industrial Internet of Things (IIoT) and Industrie 4.0 frameworks commence, network
communication protocol translations are needed; Hilscher is providing network gateways and other commu-
nications from the plant floor to the enterprise and cloud for manufacturing data analysis, as company exec-
utives explained to Control Engineering, Plant Engineering, and Oil & Gas Engineering publications recently.

I
Use IIoT to improve mplementations of Industrial Internet of Things (IIoT) and Industrie 4.0 frameworks are
operations progressing, and translations of major industrial network communication protocols
Case Study: enable the flow of data that becomes actionable information with analysis. Hilscher
Hirotec America is among many companies providing network gateways and other communications
Industrial Internet of from the plant floor to the enterprise and cloud for manufacturing data analysis. Company
Things (IIoT) benefits, executives explained the necessity of efficient data translations to Control Engineering,
examples
Plant Engineering, and Oil & Gas Engineering publications on Feb. 2.
Enabling IIoT requires
communication pro- Hilscher representatives at the Hilscher North America facility in Lisle, Ill., said the com-
tocol translation
pany devices aim to make it easier for end users, device manufacturers, and machine
Data analysis: A key builders to access the benefits of Industrial Internet-connected manufacturing. Enabling
requirement for IIoT
technologies include Hilschers recently introduced netIOT solutions for Industrial Cloud
IoT - The marger of IT Communication, which extract data parallel with current control networks and deliver it
and industrial to cloud-based analytical services without compromising existing systems or services.
Process gisotrians can
be an integral part of Cloud reality today
the IIoT
Armin Phringer, Hilscher business development manager, said these products are
designed to help make industrial cloud benefits a reality today. Hilscher North America
CEO, Phil Marshall, also addressed the benefits of such connectivity, explaining how
Hilscher, which began as a system integration firm in 1988, quickly moved into produc-
ing network communication devices. Now with 250 employees, Hilscher provides com-

CFE Media Digital Report: IIoT: Operations & IT 21


Armin Phringer, Hilscher munications for all fieldbuses and industrial Ethernet protocols,
business development he said.
manager, said these
Hilscher products will
Hilscher netX network controller translates 22 protocols, trans-
help with translations
Use IIoT to improve necessary for greater ef-
fers, and converts data. It can connect with everything, Mar-
operations ficiencies in the Industrial shall said.
Case Study: Internet of Things. Image
Hirotec America courtesy: Mark T. Hoske, Hilscher created its own chip nine years ago and will produce
Control Engineering, CFE the eighth this year, Marshall said, in total offering 22 protocols
Industrial Internet of
Media and 33 communication stacks, including masters and slaves
Things (IIoT) benefits,
examples and common hardware and software interfaces.
Enabling IIoT requires
communication pro- No network wars; connect as needed
tocol translation The goal is to get machine builders, system inte-
Data analysis: A key grators, and end users Out of the network wars,
requirement for IIoT and allow them to connect easily to as much as
IoT - The marger of IT they need.
and industrial

Process gisotrians can Products include netRapid, a control system on a


be an integral part of chip with a 32-pin DLL socket and coprocessor.
the IIoT The netJack can be installed by the end user in a
knockout slot.

With various combinations and mounting possi-


bilities, 150 models are offered in IP20 and IP67
packaging, including nine PC cards with the same

CFE Media Digital Report: IIoT: Operations & IT 22


Hilscher North America driver interface. The netHost has software-based programmable
CEO, Phil Marshall, also logic controller (PLC) masters for slotless systems, and netSCA-
addressed the benefits of
DA offers view and control capabilities with a web browser.
such connectivity, explain-
ing how Hilscher network
Use IIoT to improve communication devices
These devices help IIoT get data off the wire. Products are
operations provide communications vendor independent and legacy proof, Marshall noted. You
Case Study: for all fieldbuses and dont have to retrofit the control system to get data to the
Hirotec America industrial Ethernet pro- cloud, he said, noting Hilscher can do that for existing and
tocols. Image courtesy: future PLCs, without touching or adding communications re-
Industrial Internet of
Mark T. Hoske, Control sponsibilities to PLCs.
Things (IIoT) benefits,
examples Engineering, CFE Media

Enabling IIoT requires The new Hilscher netIOT line includes netIOT In-
communication pro- terface Modules, netIOT Edge-Gateways, and
tocol translation netIOT Service. See additional product informa-
Data analysis: A key tion linked at the bottom of the article.
requirement for IIoT

IoT - The marger of IT Continuous improvements


and industrial Phringer said customers can:
Process gisotrians can
be an integral part of Use existing infrastructure in plants
the IIoT Deploy reference architectures from Industrial
Internet Consortium (IIC) and Industrie 4.0,
vetted for all implementations
Use cyber-physical systems as a virtual twin
Leverage standards and start again, in a cy-
cle of continuous improvement.

CFE Media Digital Report: IIoT: Operations & IT 23


A Hilscher demonstration The IIC Reference Architecture includes an edge tier with de-
showed vibration monitor- vices such as actuators, scanner, sensors, motors, controls;
ing for drives, with stain
a platform tier; and connections to the enterprise and cloud.
gauges, and transfer of
Field includes existing real-time infrastructure, Phringer said,
data from the edge into the
Use IIoT to improve cloud and analytic services.
and the edge bridges information technology (IT) and opera-
operations Hilscher plans to be the en- tional technology (OT), then connects to higher level systems.
Case Study: abler of field data in Indus- This is a valid model, laid out in great detail for all test beds,
Hirotec America trial Internet based archi- Phringer said.
tectures. Image courtesy:
Industrial Internet of
Mark T. Hoske, Control Industrie 4.0 uses a three-dimensional RAMI 4.0 model,
Things (IIoT) benefits,
examples Engineering, CFE Media where functional layers are in line with plant floor people, and
Enabling IIoT requires physical objects enable
communication pro- IIoT functions.
tocol translation

Data analysis: A key Installations: Flatter,


requirement for IIoT faster
IoT - The marger of IT A Hilscher demonstration
and industrial showed vibration monitor-
Process gisotrians can ing for drives, with strain
be an integral part of gauges, and transfer of
the IIoT data from the edge into
the cloud and analytic ser-
vices. Hilscher plans to be
the enabler of field data in
Industrial Internet based
architectures. CourtePilot

CFE Media Digital Report: IIoT: Operations & IT 24


installations underway are moving to dissolve hierarchical control architectures, Ph-
ringer said, flattening structures and connecting the plant directly to enterprise re-
source planning (ERP) systems. Cyber-physical systems are created as a virtual twin to
each real system, and each physical object has an administration shell. A virtual repre-
Use IIoT to improve
sentation of objects holds the model to simulate the process behavior.
operations

Case Study:
The models can be put on existing wire in the plant without disturbing the PLC, using
Hirotec America presently available protocols such as OPC UA (Unified Architecture), DDS, and MQTT,
as well as TSN (Time Sensitive Network), an emerging Ethernet standard designed to
Industrial Internet of
Things (IIoT) benefits, bring one real-time Ethernet structure to the many-flavored protocol soup of today.
examples

Enabling IIoT requires We see OPC UA gaining momentum. MQTT is expanding quickly beyond its IBM ori-
communication pro- gins, Phringer said, as IIoT is bringing new standards for engineering and to cloud-
tocol translation based architectures, with vertical integration from sensor into the cloud.
Data analysis: A key
requirement for IIoT Phringer said hes observed a change in recent months where companies are mov-
IoT - The marger of IT ing beyond prior concerns about safety, security, and privacy risks. IBM is working on
and industrial a major pilot installation, expected to be announced at Hannover Messe, and Hilscher
Process gisotrians can is supplying network protocol translators. A bottle-filling application was shown at SPS
be an integral part of Drives in Nurnberg, Germany, fall 2015.
the IIoT

Faster, smarter
The IoT seems likely to move along more quickly, with clear and well-thought-through
roadmaps, improving overall equipment efficiency (OEE), as all companies seem eager
to understand what they can do with data in the cloud, Phringer suggested. IoT is a
game changer in our industrial business.

CFE Media Digital Report: IIoT: Operations & IT 25


Rittal Takes The Internet of Things Protocols used for field to cloud com-
Beyond the Borders of Possibility munication at present are OPC UA and
MQTT, and more will be offered, he
IT and Industrial Converge At the Edge of the Network
From subway tunnels to cruise ships to the manufacturing floor, Edge network computing, supported by Rittal, is enabling the said. In addition to cloud analytics, IIoT
Internet of Things and revolutionizing the speed of control and data analysis. Information from sensors, scanners, tags and
other devices cascade without latency into edge-focused servers. Mission-critical decisions are implemented, saving time,
structures will provide access to devic-
resources and energy. es in field via tablets and smartphones
for better maintenance and diagnostics.
Where IT and Self-Sufcient
Industrial Meet Transportation Mark T. Hoske, content manager,
From self-driving cars and commercial
trucks to subway cars, transportation
Control Engineering, CFE Media,
needs to be connected in real-time to
GPS satellites, control centers and
mhoske@cfemedia.com.
logistic operations.

Interconnected
Energy
Everything from oil platforms
and pipelines to wind turbines
and solar panels provide instant
analysis of performance and
uptime from the edge to the
cloud to centralized operations.
Edge Computing
Mission-critical data is close
to the gateway. High density
computing with a small Smart Manufacturing
footprint. Data analysis from Sensors and scanners provide real-time
the floor in near-real time. intelligence and analytics of machinery
and inventory to guarantee optimal
performance of equipment and facilities.

www.RittalEnclosures.com
(800) 477-4000

IIoT: Operations & IT 26


DATA ANALYSIS:
A KEY REQUIREMENT FOR IIoT
Industrie 4.0 data analytics: A proliferation of data analysis solutions are designed to help industry benefit
from the Industrial Internet of Things (IIoT), explained Suzanne Gill, editor-in-chief for Control Engineering
Europe, from the 27th Honeywell User Group EMEA event in Madrid.

T
Use IIoT to improve he dramatic change in fortunes of the oil and gas sector in the past few years
operations has had a wide-ranging impact across many industry sectors, resulting in an
Case Study: increasing requirement for engineers to show a good return on any technol-
Hirotec America ogy investment. This has led many to consider doing things differently, with
Industrial Internet of automated solutions becoming more relevant and much easier to justify.
Things (IIoT) benefits,
examples
At the annual Honeywell User Group (HUG), which was held in Madrid in November
Enabling IIoT requires 2015, Honeywell placed a heavy emphasis on data analysis solutions. Knowledge is
communication proto- the theme of this HUG event because our customers run some of the most complex
col translation
industrial operations in the world, and they require better knowledge to improve pro-
Data analysis: A key cess safety, reliability, security, and sustainability, said Vimal Kapur, president of Hon-
requirement for IIoT
eywell Process Solutions (HPS). He said the influx of new engineers replacing those
IoT - The marger of IT now reaching retirement age do not have the same wealth of experience relating to
and industrial
the often aging control technology still in use at many process plants; more intuitive
Process gisotrians can control solutions are required to help inform decisions about process efficiency im-
be an integral part of
the IIoT
provements.

Technology change
The pace of technology change is much faster today, continued Kapur. Systems
traditionally would have become obsolete every 5 to 10 years. However, the underly-
ing operating system technology used today is changing much more rapidly so there
is a need to update systems more regularly.

CFE Media Digital Report: IIoT: Operations & IT 27


There is also increasing interest in cyber security issues and the IIoT. At this point the
IIoT is throwing up more questions than answers, said Kapur. Customers will not be
throwing away their existing systems to implement IIoT, so we need to help them un-
leash the power that they already have. I believe that control systems will become the
Use IIoT to improve
heart of the IIoT, which will rely on process data for operation, maintenance, and opti-
operations mizationand that data comes from the control system.
Case Study:
Hirotec America
Vimal Kapur, president of Honeywell Process Kapur said the IIoT will give engineers the abil-
Solutions (HPS), at the annual Honeywell ity to host applications in a more centralized
Industrial Internet of User Group (HUG), in Madrid in Novem-
Things (IIoT) benefits, environment. With different source applications
ber 2015, explained the importance of data
examples
analysis to improve process safety, reliability,
becoming centralized in the cloud, it will no
Enabling IIoT requires security, and sustainability. Image courtesy: longer be necessary to maintain the same ap-
communication proto- Control Engineering Europe plication multiple times, and upgrades will be
col translation much easier to achieve. It will
Data analysis: A key also allow less skilled engi-
requirement for IIoT neers to manage applica-
IoT - The marger of IT tions. I believe that the IIoT
and industrial will allow for greater efficien-
Process gisotrians can cies and increased uptime.
be an integral part of It offers nothing new, just a
the IIoT way of doing things differ-
ently, he said.

In the cloud
According to Kapur, Honey-
well is enabling customers to

CFE Media Digital Report: IIoT: Operations & IT 28


Bruce Calder, chief technology leverage the benefits of cloud-based applications and
officer for Honeywell Process solu- this, he says, is helping to lower engineering costs and
tions, at the annual Honeywell User
optimize scheduling during the front-end engineer-
Group (HUG), in Madrid in Novem-
ing design (FEED) stage, where time savings of up to
ber 2015, reiterated the point that
Use IIoT to improve the IIoT concept is nothing new to
four months have been achieved along with up to 30%
operations the process industry. Image cour- reductions in engineering costs. We have seen an in-
Case Study: tesy: Control Engineering Europe crease in projects executed in the cloud environment-
Hirotec America almost 2,000 projects since
April 2015, said Kapur.
Industrial Internet of
Things (IIoT) benefits,
examples Bruce Calder, chief technol-
Enabling IIoT requires
ogy officer for Honeywell
communication proto- Process solutions, reiterated
col translation the point that the IIoT con-
Data analysis: A key cept is nothing new to the
requirement for IIoT process industry. We have
IoT - The marger of IT been doing it for decades,
and industrial he said. We already have
Process gisotrians can the capacity to make use of
be an integral part of this information to benefit
the IIoT plant performance. However,
ever more connected devices and systems are generating vast amounts of data, and
the next big change will be how this data is managed.

One-third of process and manufacturing industry executives from around the world
surveyed by Honeywell said that they already are using data analytics to improve busi-

CFE Media Digital Report: IIoT: Operations & IT 29


ness performance. Two-thirds said that they are using data analytics capability to
monitor assets to drive a proactive maintenance program. Two-thirds also said that
they were investing heavily in IT infrastructure to collect more data from their facilities
or remote assets.
Use IIoT to improve
operations There is a huge interest in data, continued Calder. However, alone it has no value.
Case Study:
It needs to be translated into actionable information. Honeywell can now offer many
Hirotec America solutions that help aggregate data, enabling it to be used to monitor applications and
identify potential safety and performance issues.
Industrial Internet of
Things (IIoT) benefits,
examples Cyber security solutions
Enabling IIoT requires
Honeywell also is investing heavily in cyber security solutions. The next cyber security
communication proto- offering from the company will be a risk manager which uses the unified design lan-
col translation guage that runs across products. It will provide an intuitive dashboard solution that
Data analysis: A key offers at-a-glance cyber security information as well as provide the necessary informa-
requirement for IIoT tion and work practices to correct plant deficiencies.
IoT - The marger of IT
and industrial Key solutions demonstrated at the HUG event included process solution suites that
Process gisotrians can provide pre-engineered solutions with embedded UOP knowledge. Benefits are said
be an integral part of to include early validation of UOP process automation designs and reduced project
the IIoT risk, leading to earlier start-up of operations.

Another new offering was an alarm and operations management software family, said
to offer advanced capabilities for alarm system compliance, monitoring, and rational-
ization. Expanded process performance analysis software was also on display, dem-
onstrating how it can provide real-time digital intelligence by collecting process and

CFE Media Digital Report: IIoT: Operations & IT 30


event data and use asset-centric analytics and visualization technology to turn plant
data into actionable information.

Remote collaboration app


Use IIoT to improve
A new mobile solution designed to connect remote plant managers, supervisors, and
operations engineering staff to real-time plant performance is also in the spotlight. Explaining fur-
Case Study:
ther, Calder said: The new product is an IOS native app that delivers process notifi-
Hirotec America cation to users. It gives access to historical events and trends, providing collaboration
capabilities for engineers wherever they may be. It can connect to many different data
Industrial Internet of
Things (IIoT) benefits, sources across the Honeywell portfolio to offer notification on a variety of events.
examples [See the Digital Edition Exclusive article: Technology developments using IIoT, real-
Enabling IIoT requires
time data to help workers in the field.]
communication proto-
col translation Platform independence
Data analysis: A key The growing demand for products that easily interconnect and share data in mean-
requirement for IIoT ingful and effective ways has resulted in increased interest in platform-independent
IoT - The marger of IT architectures for data exchange, and the Platform Industrie 4.0 trade organization has
and industrial stated that OPC UA is the only standard relevant for the reference architecture model
Process gisotrians can for Industry 4.0, which has resulted in a huge increase in interest and activity for OPC
be an integral part of UA solutions.
the IIoT

Commenting on this subject Kapur said: Today we communicate between the plant
and the control system through different communication mechanisms. There is no one
standard. There is a need for a common language that allows devices and equipment
to talk to the control system. OPC UA is a key standard enabling this communication.
Honeywell is a key provider of OPC UA and is working with different organizations to

CFE Media Digital Report: IIoT: Operations & IT 31


find out how the standard can become a scalable application right down to the sensor
level for data aggregation.

Expanding on this subject, Calder said: OPC UA is the leading contender to be the
Use IIoT to improve
device interface protocol for the language of the IIoT. To enable this connected world
operations Honeywell also has invested heavily in the instrumentation business-from field devices
Case Study:
to gas measurement control, we are developing products with leading accuracy that
Hirotec America can openly and securely communicate.
Industrial Internet of
Things (IIoT) benefits, Suzanne Gill is editor-in-chief of Control Engineering Europe.
examples

Enabling IIoT requires


communication proto-
col translation

Data analysis: A key


requirement for IIoT

IoT - The marger of IT


and industrial

Process gisotrians can


be an integral part of
the IIoT

CFE Media Digital Report: IIoT: Operations & IT 32


IoTTHE MERGER OF IT AND INDUSTRIAL

I
T and Industrial are not exactly merging, but the borders between the two have
become fluid. They arent oil and water, but creating a miscible solution between IT
and their industrial counterparts takes cooperation, understanding and ownership.
To review the benefits and challenges of this cooperative, and the considerations
Use IIoT to improve
operations
to put it into place, well start with the why.

Case Study:
Hirotec America The barriers to moving the controls closer to the actual equipment have fallen away.
Edge computing can provide the proper environment for IT in any environment: from
Industrial Internet of
Things (IIoT) benefits, polar to tropical, remote land-based to cruise ships at sea. In IoT, enclosures house
examples the components controlling hundreds of thousands of data points. The durability and
Enabling IIoT requires
gasket sealability of enclosures allow IT equipment safe harbor in contaminant filled
communication proto- production. The equipment formerly housed in a 100,000 square foot data center can
col translation now contained in a couple of enclosures. Given the shift in data management, and the
Data analysis: A key logistical strategy required to accomplish this, why is data moving towards the site and
requirement for IIoT away from the data center?
IoT - The marger of
IT and industrial Latency and flexibility
Process gisotrians can
Data, in its most effective platform, must be accessible to the people who need it, in
be an integral part of real time. One hundred percent of the time. Accessibility with reduced latency brings
the IIoT responsiveness to a higher level. The data is not 20, 200 or 2000 miles away, or even
in the cloud, awaiting analysis before it is transmitted back to the area where it is
needed. It is on site, with the controls as close as practical to the actual equipment.

Changes can be made, if needed, in minutes, rather than hours. The deployment of
sensitive IT allows a level of remote monitoring which was previously impossible. This

CFE Media Digital Report: IIoT: Operations & IT 33


flexibility of bringing these resources into effective action allows adaptability in the pro-
cess and responsiveness to the site.

Modularity
Use IIoT to improve
You start with two edge enclosures. If the parameters of the process change, unless
operations your enclosures are adaptable and expandable, you may find yourself in the market for
Case Study:
a third or fourth enclosure. With modularity within the structure, if a power load needs
Hirotec America to be increased and the corresponding cooling system must be upgraded, a properly
designed modular enclosure can be refitted to meet different demands. This modularity
Industrial Internet of
Things (IIoT) benefits, allows for variants within the enclosure, but it also moves us to the next point of scal-
examples ability.
Enabling IIoT requires
communication proto- Scalability
col translation Scalability flows from the modularity of the enclosure. Additional enclosures and equip-
Data analysis: A key ment added can be bayed at the site. Simple plug and play connections between
requirement for IIoT bayed enclosures create and expand on demand capability.
IoT - The marger of
IT and industrial Redundancy & resiliency
Process gisotrians can These work hand in hand. Any IoT/IT installation must have complete redundancy and
be an integral part of resiliency. Redundancy, referred to as N+X, defines the duplication of critical compo-
the IIoT nents and having a spare or standby unit available. Resiliency, expressed as a percent-
age (i.e. 99.9%, 99.999%, etc.) defines a systems capability to provide an acceptable
level of service in the face of system faults or interruptions. Maintaining the highest lev-
els of redundancy and resiliency are critical as IoT systems are deployed further away
from the safety and stability of the data center.

CFE Media Digital Report: IIoT: Operations & IT 34


Challenges in localized IT
The challenges in IoT pushed closer to operations are similar to those in an enterprise
data center. You still have the same considerations of climate control, physical security
and cyber security, cabling, fire suppression, reliability and serviceability. Depending
Use IIoT to improve
upon the remote location, environmental factors and accessibility may also be a factor.
operations

Case Study:
Adoption rates and speeds vary by industry. While spending on IoT is projected to
Hirotec America reach $500 million by some trend watchers, manufacturing has been broadly charac-
terized as slow to adopt.
Industrial Internet of
Things (IIoT) benefits,
examples Reasons cited for slow adoption have included questions over up-front costs, ROI and
Enabling IIoT requires
plant machinery retrofitting or replacement. Despite these questions, U.S. manufactur-
communication proto- ers are warming up the idea.
col translation

Data analysis: A key According to a Price Waterhouse Cooper study among U.S. manufacturers:
requirement for IIoT

IoT - The marger of 35% are currently collecting and using data generated by smart sensors to enhance
IT and industrial manufacturing and operating processes.
Process gisotrians can
be an integral part of 34% believe it is extremely critical that U.S. manufacturers adopt an IoT strategy in
the IIoT their operations.

38% currently embed sensors in products that enable end-users and customers to
collect sensor-generated data.

Those manufacturers who do adopt IoT will be in good company. At 27%, manufactur-

CFE Media Digital Report: IIoT: Operations & IT 35


ing actually tops the list of four major industries that currently make up the $14 trillion
IoT market.

Embracing the IoT


Use IIoT to improve
What is the holdback in adoption? SAE International the global association of more
operations than 128,000 engineers and related technical experts reports that many engineers
view the absence of IoT standards as a hurdle for achieving interoperability and finding
Case Study:
Hirotec America technical solutions for critical issues.
Industrial Internet of
Things (IIoT) benefits, Because machine-to-machine communication happens in real time between the floor,
examples edge devices, data centers and any manner of remote monitoring devices deployed
Enabling IIoT requires
anywhere on the globe, the benefits of IoT adoption can be seen in time and money
communication proto- saved through:
col translation

Data analysis: A key predictive maintenance


requirement for IIoT

IoT - The marger of reduced down time


IT and industrial

Process gisotrians can


real-time information closer to the people and equipment that need it
be an integral part of
the IIoT climate control and environmental stability

monitoring and information sharing between global management systems and factory
control systems

increased revenues from add-on services

CFE Media Digital Report: IIoT: Operations & IT 36


On the latter point, that wealth of sensor-to-machine data collected has the potential to
lead to new product development and additional sales opportunities.

Use IIoT to improve


A considered adoption
operations Despite some challenges for manufacturing when it comes to IoT adoption, most ex-
Case Study:
perts agree the pros outweigh the cons. Does this mean a facility manager should im-
Hirotec America mediately begin linking an entire operation to the Internet of Things? Probably not. In
fact, experts suggest starting small, like with predictive maintenance for the HVAC sys-
Industrial Internet of
Things (IIoT) benefits, tem. For instance, Intel recommends installing low-cost sensors and communications
examples capability in air conditioners in order to collect and share data that will predict when the
Enabling IIoT requires
units need maintenance. (Intel, by the way, told PC World that it saw $9 million in cost
communication proto- savings at its plant in Penang, Malaysia using IoT technology.)
col translation

Data analysis: A key However, a manufacturer decides to integrate IoT into its operation, experts at SAE
requirement for IIoT International say that a vital foundation in creating robust IoT standards is schemathe
IoT - The marger of process for tagging information for digital consumption, but which is retrievable and
IT and industrial readable both by humans and machines.
Process gisotrians can
be an integral part of Tech Beacon has also eliminated the guesswork in building an IoT architecture with a
the IIoT checklist of four recommended stages and their essential components.

1. All of the networked things, i.e. wireless sensors and actuators

2. Internet gateways and data acquisition systems to aggregate sensor data and for
analog-to-digital data conversion

CFE Media Digital Report: IIoT: Operations & IT 37


3. Edge IT systems to process data before it moves to the data center or cloud

4. The data center or cloud, where data is analyzed, managed, and stored on tradi-
Use IIoT to improve
tional back-end data center systems
operations

Case Study:
In its report published last month titled, The Industrial Internet of Things Volume G1:
Hirotec America Reference Architecture, the Industrial Internet Consortium condensed a typical IoT sys-
tem into five functional domains:
Industrial Internet of
Things (IIoT) benefits,
examples 1. Control domain the collection of functions that are performed by industrial con-
Enabling IIoT requires
trol systems, such as a control room in an electricity utility plant.
communication proto-
col translation 2. Operations domain the collection of functions responsible for the provisioning,
Data analysis: A key management, monitoring and optimization of the systems in the control domain.
requirement for IIoT

IoT - The marger of 3. Information domain the collection of functions for gathering data from various
IT and industrial domains, most significantly from the control domain, and transforming, persisting
Process gisotrians can and modeling or analyzing those data to acquire high-level intelligence about the
be an integral part of overall system. An example of an application of this domain would be changing the
the IIoT route of a fleet of freight trucks based on weather, traffic and the condition of the
goods in the trucks.

4. Application domain the collection of functions implementing application logic


that realizes specific business functionalities.

CFE Media Digital Report: IIoT: Operations & IT 38


5. Business domain the functions that enable end-to-end operations of IoT sys-
tems by integrating them with traditional or new types of industrial internet systems.
Examples include Enterprise Resource Planning (ERP), Customer Relationship Man-
agement (CRM), and Product Lifecycle.
Use IIoT to improve
operations Since Accenture Research estimates IoT spending will reach $500 billion by 2020,
Case Study: end-users of manufactured goods will expect to see the benefits passed down to them
Hirotec America whether in the form of lower prices, faster product delivery or better product tracking.
Industrial Internet of
Things (IIoT) benefits, Even if manufacturers start small, adopting IoT can literally save the life of the opera-
examples tion. As customers become more accustomed to the benefits of greater automation,
Enabling IIoT requires theyll be less patient with a manufacturer that is slow to upgrade facilities for IoT, even
communication proto- as far as to seek another supplier.
col translation

Data analysis: A key SAE International even cautions against competing on old measures like speed, price
requirement for IIoT and product quality. IoT has introduced a new standard in manufacturing that makes
IoT - The marger of it critical for companies to incorporate new technologies that offer greater intelligence
IT and industrial and the ability to monitor, learn, and fix problems.
Process gisotrians can
be an integral part of Who is in charge?
the IIoT
The last sentence illuminates the greatest challenge of all. You have your operations
manager. You have your IT manager. In this consolidation of resources and blurring of
processes, who claims ownership of the process? Where does the buck stop?

A standard operating procedure which combines the expertise of both operations and
IT must be developed, agreed upon and consistently implemented. This convergence

CFE Media Digital Report: IIoT: Operations & IT 39


require skill sets to be shared. The potential for access to so much plant data, then,
will force manufacturers (operations managers, IT managers and corporate headquar-
ters together) to assign and understand data ownership. Literally ask: Who owns this
data? and see to it that all hands-on-deck know who is responsible for what, what
Use IIoT to improve
the issue reporting protocols are, whos responsible for issue resolution and all related
operations SOPs.
Case Study:
Hirotec America The fallout from a factory data breach of any kind, whether intentional or by mistake,
could cost a line or an entire operation millions in lost assets, according to a report
Industrial Internet of
Things (IIoT) benefits, on IoT by National Instruments. It could even cost more just ask anyone victimized
examples by any recent data breach; or the company breached.
Enabling IIoT requires
communication proto- Erasing blurred lines
col translation With the immediacy required in all aspects of life today, second chances are doled out
Data analysis: A key infrequently. Finding an acceptable balance of responsibility while maintaining produc-
requirement for IIoT tivity will be the tipping point for ongoing profitability. Individual corporate cultures will
IoT - The marger of need to determine their best balance, blending their own unique mix of internal talent
IT and industrial and external resources, if needed, to maintain the competitive edge for the future.
Process gisotrians can
be an integral part of
the IIoT

CFE Media Digital Report: IIoT: Operations & IT 40


Click the video link below to view a video provided by Rittal

CFE Media Digital Report: IIoT: Operations & IT 41


PROCESS HISTORIANS CAN BE AN INTEGRAL
PART OF THE IIoT
Process historians are still cutting-edge tools even though they have been around for many years. They can
form the foundation of distributed, cloud-based enterprises and can integrate with the Industrial Internet of
Things (IIoT).

P
Use IIoT to improve rocess historians are the first step up the automation pyramid beyond process
operations
controls and are the foundation for turning data into information. Process
Case Study: historians provide the data necessary for powerful data analysis tools to do
Hirotec America
their job. Following the current technological trends, they can even be moved
Industrial Internet of out of datacenters and into the cloud.
Things (IIoT) benefits,
examples
Process historian essentials
Enabling IIoT requires At its most basic level a process historian is a database used to store time-series
communication proto-
col translation
data from an industrial process. Data is collected either on a cyclical basis of usually
1 to 10 sec, or as data points change. Actual values, the associated timestamp and
Data analysis: A key other information such as data integrity are written to the historian each time data is
requirement for IIoT
collected.
IoT - The marger of IT
and industrial
Once the data is in the historian, it can be accessed in a handful of ways. Many ven-
Process gisotrians dors offer data analysis packages that can be used in con-
can be an integral
part of the IIoT junction with the historical data for trending, reporting, and
various database query capabilities. Most historians also
can be queried directly using existing database systems,
such as structured query language (SQL) or stored proce-
dures. Other tools (big data analysis or machine learning
algorithms) can be applied to the data to find interesting
insights not easily obtainable through other methods.

CFE Media Digital Report: IIoT: Operations & IT 42


One option available in the past few years is to move a process historian out of the
plant and into the cloud using a hosted software as a service (SaaS). Some vendors
offer historian as a service plan where a historian is configured on a remote machine
and data access into and out of the historian is included with a subscription to the
Use IIoT to improve
service. Historians also can be configured on cloud-based computing services that
operations are managed by information technology (IT) departments.
Case Study:
Hirotec America Both options generally include things like service level agreements (SLAs) to define
overall uptime and automated backup/recovery options. The one caveat to cloud-
Industrial Internet of
Things (IIoT) benefits, based historians is the increase of the distance between the process and the histori-
examples cal data, which requires additional networking resources as well as adding a potential
Enabling IIoT requires
hurdle to accessing the data in the event of intermittent network failure.
communication proto-
col translation It is possible, though, to have the best of both options. This is especially true for com-
Data analysis: A key panies that have remote systems installed all over the world. To make it work, though,
requirement for IIoT local historians need to collect data from the system and feed that data to a supervi-
IoT - The marger of IT sory level historian.
and industrial
Process gisotrians This provides all of the benefits of the cloud while eliminating the risk of network out-
can be an integral ages leading to data loss with local data storage that can be synced as network con-
part of the IIoT nections come back online. This approach is very popular with solar companies that
are managing thousands of facilities around the world and need to provide data to
their customers and power utilities with a minimal amount of interruption.

Leveraging information
A historian by itself is not a tremendously useful tool. As described in Oil & Gas Engi-

CFE Media Digital Report: IIoT: Operations & IT 43


neerings 5-part Intelligent Automation Series, the real power of a historian happens
when the data is combined in the historian with analysis tools that turn the data into
information.

Use IIoT to improve


The first tool, usually supplied with historians, is trending. Trends display time series
operations data and the overall trajectory of data points in relation to one another. Most trend
Case Study:
tools provide basic statistical analysis capabilities including averaging, integration, and
Hirotec America range configurations to show when values have exceeded desired limits.
Industrial Internet of
Things (IIoT) benefits, In addition to trending tools, many historians include the ability to query historical data
examples using SQL tools. This opens the door for more advanced statistical analysis and al-
Enabling IIoT requires
lows historical data to be distributed to other programs using application program-
communication proto- ming interfaces (APIs). This makes getting process data into reports or Microsoft Excel
col translation an easy task for users.
Data analysis: A key
requirement for IIoT Integrating IIoT with process historians
IoT - The marger of IT Historians can also be used to collect and store information from IIoT devices acces-
and industrial sible through open platform communication (OPC) and MQ telemetry transport (MQTT)
Process gisotrians protocols and, using the various integration capabilities described above, can provide
can be an integral information back to IIoT devices.
part of the IIoT

One example of this type of integration using the API interface approach is in use by a
company that manufactures golf course irrigation pump stations. Each system in the
field has a local PC running a historian and a webserver. The webserver is configured
with a reporting and trending interface accessible via browsers and mobile devices. It
also has an API exposing historical data to third-party SaaS system.

CFE Media Digital Report: IIoT: Operations & IT 44


The API can be queried with different parameters such as describing date ranges,
specific data points to transmit, and login and security tokens to prevent unauthorized
access to the system. The SaaS application integrates with other data sources includ-
ing weather information, irrigation sensors, and GPS units on landscaping equipment
Use IIoT to improve
to provide a cohesive monitoring system for all of the activities required to maintain a
operations golf course.
Case Study:
Hirotec America Building the information pyramid
Using a process historian can be the first step towards a fully connected enterprise.
Industrial Internet of
Things (IIoT) benefits, Process data can be exposed to business systems, made available for statistical anal-
examples ysis, and integrated with third-party systems using APIs.
Enabling IIoT requires
communication proto- Some questions users should ask include: What data would be useful to collect? How
col translation can this data be made available to and consumed by other systems? What tools will
Data analysis: A key be most useful to analyze the data today and a year from now as the data becomes
requirement for IIoT an indispensable tool? What experience and ideas can IT and system integration part-
IoT - The marger of IT ners bring to the table to build systems to provide context for the data? And finally, if a
and industrial company isnt using a process historian, why not start now?
Process gisotrians
can be an integral Alex Marcy, P.E., is the owner and president of Corso Systems, a system integration
part of the IIoT firm based in Chicago, Ill.

CFE Media Digital Report: IIoT: Operations & IT 45


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CFE Media Digital Report: IIoT: Operations & IT 46


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