A Highly Effective Approach to Modernization and Digitalization of Brownfield Sites

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PHOENIX CONTACT Deutschland GmbH

Data Mining on the Wireless Network

Phoenix Contact provides extensive support including the application of RFID markings across an entire company as a full-package service along with installation of suitable wireless infrastructure including implementation of an effective IT security strategy which is obviously vitally important. In addition to standard solutions such as GSM, 3G, 4G and Bluetooth, the portfolio also includes Wireless Hart and the proprietary Trusted Wireless. WLAN can be deployed with a reasonable amount of effort, making cluster management feasible in an industrial environment. Hybrid solutions which combine existing cabling and SHDSL technology can be efficient if long distances are involved such as fire alarm systems at a large plant.

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If you want to make your plant fit for the future, you should not stop at this point. Consider taking the next step by setting the stage for Production 4.0 and continue to build the necessary efficiency and momentum. This means making use of available field data. Too many companies fail to exploit this treasure trove and fall behind in the race to maximize process efficiency and produce products at competitive prices. Most actually have the basics in place, namely fieldbus or Hart enabled field devices which are capable of supplying a wealth of diagnostic data in addition to the measurement values.

From Simple Online Measurement to Big Data

The size of the task is presumably the reason for the failure to utilize the information available: multiple sources, a large volume of data and crucially the problem that you cannot handle everything at once. Here again, it is important to define priorities. Answers are needed to two key questions: Is personal safety less than optimal at any point, and is there equipment which regularly requires unscheduled maintenance or even causes production stoppages? Systematic analysis of all vulnerabilities with the support of experts from Phoenix Contact should include an assessment of the effort involved with repetitive activities, for example on-the-spot checks. Inspection rounds which are particularly time-intensive such as the monitoring of wells on a large site can often be avoided simply by using online measurement and a modem.

The answer is very similar when safety issues are involved. Workers should always have the assurance that emergency safety showers are functional at all times and not just right after the last regular inspection round. Continuous monitoring ensures that this is the case. An additional useful function is notification to the first aid team as soon as the shower is used. Data acquisition and transmission can save lives.

At old plants (and in new ones as well), there are many other similar opportunities to improve safety and increase availability: For example, a simple Namur limit switch indicates the position of manual valves. Anyone who wants to know whether trace heating systems is working before the media in the pipe freezes and production comes to a complete halt can find out for sure with the aid of a simple current measurement. Not much more cost and effort is needed for continuous leakage detection. Besides regularly spaced monitoring stations, all that is needed is any suitable means of data transmission which makes it possible to quickly detect and localize any leaks.

Web Services Feed Smart Maintenance Tools

Processing a diversity of signals which feed into intelligent transmitters over and above the actual measurement values is more demanding. Making effective use of this data creates new opportunities to improve equipment efficiency, product quality and process management. Valves, positioners and rotating equipment such as pumps and compressors also supply a wealth of diagnostic information. It makes good sense to thoroughly analyze this data and derive recommended action, for example preventive maintenance. This however goes beyond the capabilities of standard maintenance tools which are normally used by maintenance teams. These tool do not have sufficient computing capacity. Even large process control systems reach their limits, because they are performing other tasks.

It makes sense to tap into the virtually unlimited computing power of a (public or private) cloud. Artificial intelligence can play a very useful role. With the Proficloud coupler, data can be transmitted easily over OPC UA. The data can be properly interpreted by IT experts and their smart tools, and new set values can be returned over Profinet.

Alternatively, the equipment manufacturer can be given access. In the best case scenario, the manufacturer can provide a deeper insight based on the diagnostic data, variables and disturbance levels acquired from many other similar pieces of equipment. With the aid of big data analysis and web services, in some cases the manufacturer may be able to substantially increase equipment efficiency, for example by notifying the user that the pump should be replaced during the following month and when maintenance is needed on which valves to prevent performance degradation.

In this way, smart technology and artificial intelligence brings “old plants” up to the same standard as any greenfield production site.

Is there a silver bullet for bringing production performance up to a competitive level? On the next page, read an interview with Stephan Sagebiel, Head of Industry Management Process at Phoenix Contact.

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