With the proliferation of smart equipment and IIoT devices, the focus is on safety, reliability, and profitability with sustainability.

Industrial Automation: AI Process Automation & Smart Factories! - https://www.youtube.com/watch?v=8JlthRlG-ug

The Industrial Internet of Things (IIoT) has enabled a paradigm shift in automating industrial processes and operations. During the last few years, the combination of IIoT with industrial automation has unleashed a wave of innovations that led to the proliferation of smart devices that help capture every bit of data during operations, enabling scrutiny of the minutest details to gain valuable insights. So what are the latest technology trends dominating the process industries in general, oil & gas in particular?

“The process industry is experiencing transformative technology trends that are reshaping the landscape. The focus is on safety, reliability, and profitability with sustainability – at the very core. The convergence of the Internet of Things (IoT) and artificial intelligence (AI) is driving significant changes. Companies are leveraging the enabling features of big data analytics, cloud technology, and predictive maintenance to unlock the potential of data for improved operational efficiency,” says Ashish Gaikwad, Managing Director, Honeywell Automation India Limited and VP GM, UOP and HPS India.

Honeywell partners with its customers to address the challenges of connecting different departments and operators across the enterprise for real-time data analytics to enhance plant safety, operational efficacy, and performance visibility to the top management, for a very large and complex operational setup. “Additionally, augmented, and virtual reality technologies enhance worker safety, enable remote operations, and transform learning experiences. Manufacturing Execution Systems (MES) – if designed correctly and with these new emerging technologies in collaborative partnership with the technology companies, which also have industry domain and experience – can greatly impact the business decision making at speed, accuracy, and enhanced profitability. In line with the technology trends, Honeywell's contributions are driving innovation, improving operational efficiency, and promoting sustainability in the oil and gas industry,” he adds.

To Hemal Desai – VP Marketing at Endress+Hauser India, the current trends in process industries are similar to what other industries are also experiencing. “Digitalisation is a big trend, the need to be more productive with fewer people. The workforce trend is happening in this industry. There is a big move toward ESG (environmental, social and governance) companies looking to ensure that they are producing oil and gas and refining it and piping it as efficiently as possible, it's a big trend as of recently. The decarbonisation topic is happening as well.

The industry will continue to grow as there is a need globally for energy. It is seen as a drastic increase on the gas side of the market, more than on the oil side,” he says.  As a global leader in measurement instrumentation, services and solutions for industrial process engineering, Endress+Hauser provides process solutions for flow, level, pressure, analytics, temperature, recording and digital communications, optimising processes in terms of economic efficiency, safety and environmental impact. Another factor today is ‘Global energy transition’ – the conscious effort of countries, industries, and even individuals to select the right energy mix with the aim to minimise negative effects on the environment, another big trend. “Industries where emissions are hard to avoid are taking additional measures to ensure that they can capture CO2 before it is released into the atmosphere. The transition refers to a switch from traditional fossil fuels to renewable energies such as solar, wind, hydrogen, biofuels, and biogas with a net-zero balance,” says Hemal Desai.

“Industrial process manufacturers and especially oil & gas around the world are entering a period in which new digital technologies augment people and processes to an unprecedented degree. New, commoditised computing resources in the cloud (and at the edge) and artificial intelligence (AI) are changing how people work. Approaches such as the Industrial Internet of Things (IIoT) and Industry 4.0 have helped pave the way for digital transformation across a broad swath of industrial sectors,” says Peter Reynolds, Contributing Analyst, ARC Advisory Group, about the current trends.

Before joining ARC, Peter was Refinery automation & engineering manager and Director responsible for the Enterprise IT, Supply Chain strategy and multi-year plan for one of Canada's largest refining and marketing companies. According to him, digital transformation spans industrial products, operations, value chains, and aftermarket services. It augments people and knowledge through expanded use of sensors, data, and analytics. “ARC Advisory Group believes that most industrial process companies globally will undergo a digital transformation to some degree or other, with many already actively piloting advanced technologies,” he emphasises.

According to Sachin Vaidya, Regional General Manager, Digital ABB Process Industries, predicting digital trends is continuous as technology evolves and improves. Leaders must scan the horizon and identify the most critical areas to pay attention to ensure their companies are fit for the future. “Artificial intelligence and advanced analytics have been touted as the key value drivers behind digital transformation. Another critical trend is fully autonomous operations. This can include functions like advanced process control that handle multi-variable controls to steer the process to the most optimal setup. One could employ autonomous machines to operate in hazardous environments. Assistive technology such as augmented reality (AR) and virtual reality (VR) for remote operations has been available for some time; however, many companies still need to adopt and prepare for it, he says. For ABB, Process Automation is #2 in the market globally.

ABB’s Process Automation business offers a range of solutions for process and hybrid industries, including our industry-specific integrated automation, electrification and digital solutions, control technologies, software and advanced services, as well as measurement and analytics and marine offerings. “Holistic energy management is far from new, but the objectives and optimisation models are changing fast. In the future digital enterprise, everything is connected. Data flows seamlessly between operational and business systems, enabling new capabilities for Data-driven decision-making,” adds Sachin Vaidya.  
 
With robots now becoming simpler to program and use thanks to artificial intelligence and machine learning, these have also made inroads in process industries to help perform tasks more efficiently and replacing employees in dangerous roles. How are such robotic applications enabled by AI helping oil exploration and extraction with processes like well imaging, etc., offering visibility and transparency across the entire oil & gas value chain?
 
“Honeywell believes in industry-collaboration and co-innovation with our customers. This is how the best technology-applications are born. Honeywell has its own portfolio of robotics applications and AI capabilities and we can work equally comfortably with other partners. Honeywell Connected Plant (HCP) suite of applications is based on this approach and HCP offers solutions to its customers that enable an effective digitalisation in manufacturing industries. This transformative solution helps improve the efficiency and profitability of their operations. HCP technologies enable seamless integration of the entire value chain — from supply to the end consumer. This improved collaboration has enabled us to cater to fast-changing market demands and needs,” says Ashish Gaikwad.
 
“Endress+Hauser is continually enhancing the capabilities of sensors and instrumentation, incorporating greater intelligence and the ability to transmit data to the cloud. Through the utilisation of wireless technology and standards such as Wireless HART, the integration and security concerns are effectively addressed, while eliminating the limitations of traditional wired connections,” says Hemal Desai. “Additionally, the implementation of two-wire Ethernet, such as HART IP, optimises the utilisation of existing copper infrastructure to facilitate increased data transmission from the field without significant investment in capital or engineering resources. As the efficiency of data transfer, whether wireless or wired, continues to improve, companies will experience enhanced performance of their AI tools with minimal additional effort,” he explains.
 
According to Peter Reynolds, new technology can provide detailed logging-while-drilling using high-definition (HD) images for reservoir description and completion optimisation. Oil field services companies can develop detailed fracture characterisation and completion optimisation in conductive drilling fluids for all well types, including horizontal and highly deviated wells. “In unconventional and carbonate reservoirs it is critical for geologists to fully understand the fracture networks that may challenge drilling operations and those that will contribute to production, thus helping to prevent drilling risks, optimise completion design and potentially increase production. The HD service has been field tested extensively in reservoirs in the Middle East, Europe and Africa, as well as unconventional reservoirs in North America. More than 45 job runs have been completed, confirming that high-definition images can be obtained reliably in conductive mud environments while drilling in oil and gas carbonate, sandstone and unconventional reservoirs,” he elaborates.
 
To what extent can AI be implemented in the Oil & Gas Industry for optimum performance and safety?

Franziska Rostan, Process Industry Management, Beckhoff Automation, believes operations in the process industry are often complex and time-consuming, and this technology can help to optimise these processes and increase plant safety. “In today's market, users must adopt and implement modern technology appropriately in order to remain competitive in the future. There is still a lot of potential for improvement, particularly in the process automation sector. In order to tap into this potential, plant operators have the opportunity to integrate innovative and new technology, such as machine learning, which is part of artificial intelligence, into the automation system,” she emphasises. Implementing predictive maintenance using artificial intelligence can significantly reduce plant downtime. Here, plant data such as temperature, pressure, and vibration are recorded and analysed via AI algorithms. This analysis can identify potential problems in both the process and the plant components. In order to be effective, this approach requires long-term data collection to provide sufficient training data for the AI algorithms. “Using predictive maintenance with AI means that deviations from ideal conditions for the plant can be detected. When these deviations are detected at an early stage, maintenance work can be planned and carried out in good time, before major damage occurs to the plant and the operating personnel are faced with dangerous situations. This helps to maximise plant availability, increase productivity, and enhance safety, explains Franziska. For example, the TwinCAT Vision image processing solution from Beckhoff also enables the acquisition, processing, and evaluation of images in real time. Cameras can be integrated into the automation environment to capture and analyse visual information and incorporate it into the control process.

“The digital revolution has brought about significant changes in industries worldwide, including the oil and gas sector. Honeywell has introduced software solutions that enable remote monitoring and execution of process operations, utilising the power of Honeywell Forge AI. This proactive approach detects issues and involves both customers and Honeywell experts through wearables, video assistance training, and access to on-call experts. Honeywell Forge is built on secure cloud technologies with robust cybersecurity and data privacy features, offering flexible deployment options based on customer needs, says Ashish Gaikwad.

The petroleum industry, as per says Hemal Desai, is increasingly recognising the need for AI implementation, given its transformative potential. In particular he mentions AI, which can revolutionise the industry's health, safety, and environmental (HSE) practices. The integration of AI can bring various benefits in areas such as predictive maintenance, environmental monitoring as well as compliance monitoring. “AI implementation holds immense potential to transform the petroleum industry, particularly in the areas of workplace safety, predictive maintenance, hazardous operation automation, environmental monitoring, and compliance management. Embracing AI technologies will enable the industry to enhance its overall performance, mitigate risks, and achieve sustainable growth,” says Hemal Desai.

“Across the board, owner-operators are realizing that the largely reactive nature of conventional asset management strategies alone is inadequate for maintaining the equipment uptime necessary to maximise production and profitability,” says Peter Reynolds. Increasingly, Artificial Intelligence, or predictive maintenance is recognised as a new solution that helps provide much earlier warning of impending breakdowns. Solutions can now utilise machine learning, a field of computer science that does not require explicit programming. “Unlike traditional programs that use rules, statistical models, and engineering equations, machine-learning based systems learn patterns in data and use them to predict future outcomes. State-of-the-art machine learning systems automate these learning, adapting, and predicting activities,” states Peter.
 
Other than AI there are the various ‘immersive realities’ that are bringing interesting applications to the process industries spread across vast areas. How can AR/VR technologies improve Productivity, Safety, and Quality for process plants located remotely?
 
“Augmented reality is one of the most exciting and impactful experiences making its way into today’s manufacturing industries. Just a few years back, the best examples of AR could be found in gaming development. Assistive technology such as augmented reality (AR) and virtual reality (VR) has enabled technicians to provide remote assistance by sending customers’ AR- and VR-enabled devices and walking them through advanced troubleshooting and repairs,”says Sachin Vaidya. According to him, by creating digital constructs directly in a person’s field of vision, AR makes it possible to organize, structure, and perform many tasks remotely, significantly improving productivity, consistency, and mobilisation costs. “ABB recently deployed its augmented reality solution, encompassing audio, video, document sharing, and live annotations for remote factory acceptance testing (FAT) during tight Covid-19 travel restrictions. The cyclo converter upgrade at a steel mill in Spain was successfully completed without ABB engineering visits to the site,” he explains.

Ashish Gaikwad says Honeywell offers remote operations solutions for large facilities and helps in monitoring and execution of process operations, utilising the power of Honeywell Forge AI. Honeywell's remote operations specialists employ AI-based algorithms for peak prediction, value stack optimisation, and asset maintenance strategies. This proactive approach detects issues and involves both customers and Honeywell experts through wearables, video assistance training, and access to on-call experts. “Through remote collaboration, optimisation, and operations solutions, operators can access data, deliver information when needed, make informed decisions, and enforce consistent operational and business processes. The operators can also be trained better on field jobs using AR/VR technologies that would help them better prepare for unforeseen situations. The Honeywell Immersive Field Simulator (IFS) offering is a virtual reality (VR) and mixed-reality-based training tool that incorporates a digital twin of physical plant operations to provide targeted, on-demand, skill-based training for workers,” Ashih Gaikwad elaborates.
 
“The landscape of work is being reshaped by technological advancements, and one area experiencing a notable transformation is factory automation, where Augmented Reality (AR) and Virtual Reality (VR) are playing a pivotal role,” says Hemal Desai. “The integration of automation technologies not only streamlines and optimises production processes but also paves the way for the utilisation of augmented reality. This combination introduces a game-changing dynamic, revolutionising the way tasks are performed and enabling workers to benefit from AR & VR-enhanced capabilities. By overlaying digital information onto the physical world, AR & VR empowers factory workers with real-time guidance, interactive instructions, and access to critical data, thereby enhancing their efficiency, accuracy, and overall performance,” he adds.
 
“Regarding AR/VR, these technologies are helping users move to a more visual way of working. AR uses displays, cameras, various types of sensors, and software to augment the user’s real-world environment with artificial perceptual experience. Most AR applications use smart devices such as smartphones, tablets, and smart glasses to overlay digital information and graphics onto the user’s real-world view. Pokemon Go and Snapchat filters are some of the most popular AR applications in the consumer world,” says Peter Reynolds. “The oil & gas industry is faced with an impending crisis related to the rapidly approaching mass exodus of skills from the industry with few young people wanting to take up the gauntlet. AR is proving to be an effective tool to help the industrial workforce. With remote augmented communication, and augmented operations, AR can help the industry better address the impending skills gap challenge,” he suggests.
 
While Cloud Computing with remote data centres has long been the norm, today more and more industries – discrete or process – are also relying on Edge Computing where data resides closer to the end-users in terms of geographical and network proximity. So what benefit does edge computing bring to process industries vis-à-vis the traditional model?
 
During the previous decades, an increasing number of industries benefited from bringing their IT applications into the cloud, leveraging its scalability as well as its power for big data processing. However, in many cases, more local solutions also have benefits, e.g., in terms of end-to-end latency or data privacy. This is why edge computing is seen as a promising technology in many areas. Both edge computing and cloud computing have their benefits, and there are always trade-offs when deciding between these deployment alternatives for a specific application,” says Sachin Vaidya. “Edge computing is not to be understood as an alternative to cloud computing but as a complement. Industry investment in edge computing has grown a lot within recent years, including efforts for industrial edge computing reference architectures and standardisation; accordingly, edge computing is well on its way to becoming a leading digital technology,” he clarifies.
 
“In edge computing, data processing and analysis takes place directly at the data source. Since the edge device is able to act autonomously, data can be processed continuously even in the event of a network failure, which increases system availability. Instead of sending all data to a central location, the data is pre-selected, sorted and processed to filter the process data so that only the truly relevant data remain. This is particularly important as the data streams are growing continuously, and this process reduces the load on the networks,” explains Franziska Rostan. According to her, the decentralised architecture consists of several control systems that are each individually assigned to a specific plant section and take over its process control. With the C60xx ultra-compact Industrial PCs, Beckhoff offers maximum computing power that takes up next to no space. Alternatively, the embedded PCs or fieldbus couplers with a modular I/O level allow terminals from the Beckhoff I/O range to be directly connected, so that sensors and actuators can be linked to the edge device with ease. “However, edge computing is not just a solution for greenfield scenarios as a completely new system concept. Edge devices can also be integrated into existing plants in brownfield scenarios. With the help of a retrofitted edge device, for example, IoT functions can be introduced into the existing application without any software or hardware changes to the existing control unit. The openness of the Beckhoff control architecture also enables communication with all common process control systems by configuring the industrial PC interface or selecting the appropriate fieldbus coupler,” she elaborates further.
 
“The edge device is the bridge between your field devices and your cloud services, collecting relevant data that can provide great insights for daily operation in your plant. Depending on the service, edge devices can deliver measurement data, health statuses, or any other information that can augment your work. For instance, services such as Netilion Health from Endress+Hauser monitor the health of your devices, collecting data through an edge device to show users how things are running at any time,” says Hemal Desai. “NAMUR recommends using edge devices, creating a secondary channel to send data to the cloud without affecting control systems. Edge devices also work as diodes, moving information in only one direction, so you can read the data without interfering with your processes. Best of all, it’s a turnkey solution, meaning configuration is straightforward and quick,” he adds.
 
Summing up, Peter Reynolds says the term “Industrial IoT edge” recognises that cloud-based digital transformation strategies require data from and access to the physical devices, assets, machines, processes, and applications that reside on the factory or plant floor.  The “edge” was initially viewed as the place where industrial network infrastructure devices like switches, gateways or routers, as well as endpoint devices, connected to the Internet. Internet connectivity and automation protocol conversion were the main tasks. Since then, the role of the Industrial IoT edge has developed rapidly. “Today, edge functionality ranging from data preprocessing to artificial intelligence (AI) is being integrated into a broadening variety of systems and intelligent devices. These include traditional automation devices like PLCs as well as edge servers hosting a local cloud,” he concludes.
 
Note: The responses of various experts featured in this story are their personal views and not necessarily of the companies or organisations they represent. The full interviews are hosted online at https://www.iedcommunications.com/interviews