Integrating IT & OT for Condition Monitoring
- 2. ni.com Integrando IT y OT: Edge Computing para maximizar el ROI del mantenimiento predictivo Guillem Abril [email protected] Area Sales Manager
- 3. NI’s End-To-End Solution Architecture for IoT Decision Making and Control Data Aggregation and Management The Edge IT Infrastructure (Big Data Analytics, Mining) Edge IT (Local, Remote, Cloud) Corporate/Federated IT Data Acquisition, Control, and Analysis Systems Sensors/Actuators Acquisition Analysis and Visualization Software OT IT Analytics Platforms: Bluemix, Thingworx, etc..
- 4. …Unscheduled shutdowns, coupled with poor maintenance practices, cost global process industries 5% of total production annually, equivalent to $20B each year. —Hydrocarbon Publishing Company
- 5. Maintenance Strategy Objectives Increase Revenue • Increase uptime and service offerings • Optimize maintenance activities Decrease Cost • Reduce frequency of unscheduled downtime • Decrease warranty costs • Optimize workforce Reduce Risk • Prevent failure and unscheduled outages • Reduce worker contact with hazardous machines and environments
- 6. Data Collection and Analysis Challenge Time spent collecting data Data actually analyzed 80% 5% It is difficult to locate, hire, and train new equipment specialists to periodically collect data who can use their experience to diagnose machine issues. Source: NI customers and the International Data Corporation (IDC)
- 7. Online Monitoring Benefits Optimized Workforce • Maintenance staff spends time assessing required maintenance Fewer Gaps in Data • Continuous data collection reduces probability of data errors or missed events Improved Diagnostics • Consistent analysis and more historical trend data reduce reliance on experience of equipment specialists
- 8. NI InsightCM™ Configuration-based acquisition and data management tools Wide range of dynamic waveform and static sensor input options Deployment-ready hardware bundles available Complete accessibility to data Connectivity to third-party systems and analytics via LabVIEW Application software tailored for online monitoring applications
- 9. NI InsightCM Components Configuration & Visualization NI InsightCM™NI Monitoring Devices Infrastructure NI InsightCM Server Enterprise Applications Database Historian OPC UA- Compatible Applications Web Browser
- 10. Third-Party Application Integration Export features from InsightCM to third-party software packages running at an enterprise IT level to help drive business decisions. OSIsoft PI System OPC UA Integrates sensor data, operations, and people for real-time operational intelligence Standard, industrial communication protocol used by many enterprise software packages
- 11. Reference Architecture – NI and OSIsoft Assets Sensors and Actuators Accelerometers Oil Analysis Sensors Proximity Probes Miscellaneous Temperature Sensors Thermal Cameras Site Servers NI InsightCM Server Software OSIsoft PI System Server Software Asset Framework Data Archive PI-UFL Connector Monitoring Systems NI CompactRIO Embedded Monitoring Systems LabVIEW PI Toolkit Sends data to PI-UFL Connector Sensor Input Algorithm Control Output 3rd Party LabView Apps Corporate Monitoring and Diagnostics Center Visualization in • Condition Monitoring • Process Optimization • Energy Management • Regulatory Compliance • Predictive Analytics • Early Fault Detection • Automatic Diagnostic Big Data and Advanced Analytics
- 12. IoT Architecture: National Instruments + OSIsoft Traditional industrial or ruggedized sensors for monitoring critical assets National Instruments CompactRIO LabVIEW toolkit sends live data events as HTTP messages, using the OSIsoft Message Format (OMF) protocol Sensor configuration is done once on the CompactRIO; that configuration is sent via OMF to build PI Points and PI AF Elements Sensors are directly connected to the CompactRIO so that raw analog or digital sensor readings can be received OSIsoft Connector PC PI Connector Relay receives OMF messages and automatically both creates and updates PI AF Elements and PI Points with new data values and metadata OSIsoft PI Data Archive OSIsoft PI Asset Framework OSIsoft PI Web API and PI Coresight Server IoT data and data from other sources is compressed and archived in real- time PI AF organizes and templatizes data and applies event framing, analytics, and notifications PI Coresight allows cross-browser, cross- platform access to all current and historical data, metadata, and calculations User phones, tablets, laptops, and desktops Raw data, calculations, metadata, and event frames are read back into the CompactRIO, via the PI Web API, for edge computing and analysis National Instruments InsightCM InsightCM provides industry- leading full-fledged condition- monitoring capabilities* *
- 13. Applications NI’s monitoring technology and NI InsightCM in use for industry applications
- 14. Fossil Power Plant Monitoring Largest Power Generation Holding Company in US 38 GW Fossil Generation Capacity
- 15. Fossil Power Plant Monitoring 30,000 sensors 10,000 machines 2,000+ devices ~60 plant servers 1 federated M&D center Turbines (Critical) Oil Sensor Vibration Sensor Vibration Sensor NI Monitoring Device Leak Detection Sensor Pressure Sensor Temperature Sensor NI Monitoring Device Balance of Plant Assets Wired or Wireless TheEdge NIInsightCM Server Access Point Wireless Business Network Sensors Monitoring Devices IT Infrastructure
- 16. Automated Failure Predictions of Pumps 16,000 Employees 5 Billion Annual Revenue 220+ Years in Business
- 17. IIoT Smart Pump Asset health monitoring (NI Monitoring Devices) Monitor temperature, pressure, flow, vibration, power Historian database for their maintenance needs (OSIsoft) Contextualization, data integrity. Access to the critical data. Predictive analytics (PTC ThingWorx) What is going to fail and when? Compute capabilities (HPE Edgeline) More compute power needed for predictive analytics Domain expertise (Flowserve) Diagnostic and engineering/physical model knowledge used in system for analysis
- 18. Automated Failure Predictions for Pumps HPE Edgeline PTC ThingWorx LabVIEW and CompactRIO Flowserve Pump Pressure Temperature Power Vibration Flow Data NI InsightCM™ … … OSI soft PI
- 19. Demo