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Optimization of chemical processes through big data
How cloud-based IoT services optimize maintenance processes in chemical plants
Connecting an existing plant presents several challenges due to the legacy nature of infrastructure and processes. Existing instrumentation devices in plants might be outdated and may not have IoT capabilities. In addition, different plants use different communication protocols for instrumentation devices, such as Modbus, HART, PROFIBUS, etc. These protocols play a critical role in successfully connecting a plant, enabling chemical processes optimizing.
Key facts
30%
of preventive maintenance is unnecessary (over-maintenance) and should be avoided with condition monitoring according to the magazine Reliable Plant.
Process overview
Digital transformation
Insights
Improved workflow efficiency through big data analytics
The lack of plant asset transparency and accurate documentation in brownfield plants complicates the maintenance process and process performance, hinders troubleshooting and increases downtime. Our IoT ecosystem, Netilion, offers several services that use big data analytics to make up-to-date asset information and easy-to-access documentation achievable.
Our expertise in the field
Our offering to enhance transparency and streamline maintenance:
- Netilion Analytics generates an inventory of all plant assets and gives information on obsolete devices.
- Netilion Health provides current health conditions of devices and gives cause and remedy information.
- Netilion Library is a file management service that organizes documents related to plant instrumentation.
- Field Xpert SMT70 is a tablet for field device configuration in hazardous areas.
Insights
Increased plant uptime in the chemical industry
Insufficient instrumentation data in existing plants hampers operations. The absence of concrete data on equipment health and conditions leads to unplanned downtime. Heartbeat Verification by Endress+Hauser shifts maintenance from a reactive to a proactive and data-driven approach, optimizing maintenance intervals and ensuring that maintenance activities are aligned with the actual condition of the equipment.
Our expertise in the field
Heartbeat Technology, enabled by connectivity and the Netilion platform, is the perfect combination to optimize maintenance and operations.
- With Heartbeat Technology a remote verification can be triggered using Netilion Health, while Netilion Library will document all verification reports.
Insights
Quick access to documentation streamlines maintenance
Quick and easy access to documentation in a chemical plant ensures operational efficiency, safety, and compliance. Instant access to device information, verification protocols or procedures, safety protocols, and raw material specifications empowers plant operators to make informed decisions and avoid errors. This streamlined access accelerates troubleshooting and maintenance, minimizing downtime.
Our expertise in the field
Netilion Library enables maintenance technicians to view, organize and share files with anyone from anywhere. Library can be combined with all sorts of tools. For example, the Library will automatically store the verification protocol with Heartbeat Technology and a remote verification. Easily accessible documentation saves users significant time and effort.
- Netilion Library saves and organizes working files and documents. It's an industrial file management service that keeps documentation safe, up-to-date and available from anywhere at any time.
- Using the IoT service Netilion Library with a Field Xpert tablet enables plant operators to access device documentation even in hazardous areas. Reports created via Health or the Field Xpert tablet are automatically saved in the Library.
Insights
Strong cybersecurity for the chemical process industries
Smart sensors, apps and cloud-based applications also come with risk. The security of the system, plant and data has the highest priority at Endress+Hauser, which is why we have successfully tested our systems against some of the most well-known security standards in the IT and OT world.
Our expertise in the field
Ensuring data security requires a trusted partner with the proper knowledge. Endress+Hauser is ready to facilitate its customers' cybersecurity compliance along their digital journey and has the qualifications to show for it.
- Endress+Hauser is certified in line with norms such as IEC 62443-4-1, ISO 27001 and ISO 27017. Learn more about our cybersecurity certification.
- Endress+Hauser is part of the CERT@VDE consortium the first platform for coordinating security issues in industrial automation.
- In a digitalized world, cybersecurity is more important than ever before. Endress+Hauser would like to share their knowledge and help make industrial facilities more secure. Our cybersecurity publication can be downloaded for free.
Benefits
Downtime and unplanned maintenance are common issues in the chemical process industry. IIoT and big data are offering exciting new possibilities to tackle these issues. Endress+Hauser has developed the concept and tools to help our chemical industry customers start digitalizing their plants safely and simply. With us as a long-term partner , you can embrace the Industrial Internet of Things
Key facts
30%
of assets installed in plants are obsolete, which puts the plant at risk of shutdown.
Key facts
90%
of our 40 million devices in the field worldwide are smart digital devices.
Takeaway
How we can optimize your chemical process
However, connecting previously developed plants brings numerous benefits, such as improved workflow efficiency in the maintenance department, plant uptime and reliability. How? An edge device collects all instrument data and transmits it from the field to the cloud, thus bypassing the plant's automation system completely. IoT software then uses big data analytics to diagnose problems, schedule maintenance activities or predict problems. Endress+Hauser has developed an entire IoT ecosystem.
- Cloud connection: Software and hardware are needed to extract and transmit data it to the cloud. At Endress+Hauser, this is accomplished with Netilion Connect, consisting of edge devices that acquire the data, a cloud platform and an API.
- Instrument diagnostics: Endress+Hauser embeds Heartbeat Technology into its instruments to provide status and diagnostic information, and to perform vital functions such as condition monitoring and in-situ verification.
- Analytical software: Netilion Analytics uses data from the device in the field to manage obsolescence and enable standardization of plant assets.
- Process Health: Netilion Health software analyzes instrumentation at the edge to determine if the production process is getting more difficult to control, if external influences negatively affect process performance, or if changes need to be made.
- Equipment documentation: Maintenance technicians need access to equipment manuals, troubleshooting instructions and other materials describing each instrument. Netilion Library logs in all pertinent information and makes it available remotely.
Endnotes
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