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2019-10-20 10:19:00

Digital Transformation. Plantweb. Easy.

Digital Operational Infrastructure

Plantweb Digital Ecosystem
The Case for Change
Regardless of the industry, each plant, or mill, site, factory, field, offshore installation, station, vessel,
terminal, complex, rig, facility, or whatever you call it is aiming for operational excellence and top quartile
performance; to be ranked among the top 25% in the industry. To move from average or below average
performance to top quartile performance to gain or retain a competitive advantage a plant must change the
way it operates. Because the industry average performance is constantly improving, plants which are already
ranked top quartile in performance must continue to innovate to stay on top.

Operational Challenges
Operational departments globally and across industries face very similar challenges throughout the lifecycle;
improve reliability, reduce maintenance and energy cost, reduce emissions, increase safety and ensure
compliance, and improve various aspects of production. And the workforce may already be stretched and an
ageing plant may have difficulties in attracting and retaining talent.

How many days of lost How much did How many incidents How much out-of-spec
production last year energy cost increase or near misses were product was produced
due to unscheduled last year? there in the plant last last year?
downtime? year?

Reliability, Maintenance, and Integrity Challenges

The site may struggle with unscheduled downtime due to unexpected equipment failures as personnel
struggle with reactive maintenance and to keep up with the preventive maintenance schedule, or too long
and too frequent scheduled downtime for shutdown/turnaround/outage losing several days of production
every year. Personnel may not be able to complete required tasks within turnaround window. The plant may
be faced with escalating maintenance cost due to repair, as well as opportunity cost for lost production.
Some process equipment may see premature end of life. This may be due to a reactive maintenance culture.
Loss of containment due to aging piping and vessels is another challenge. Moreover, plants are expected to
improve without increasing headcount.

Energy and Emissions Challenges

Plants see energy consumption going up, but not knowing where or why, compounded by increasing or
unstable energy price. Flaring may be on the rise. New regulatory requirements to reduce CO2 emissions
and carbon tax are coming into play. The plant may be fined for emissions from time to time. Greater public
demands on climate change accountability and sustainability; consumption and emissions. The energy
intensity must be reduced. Again, plants can’t hire more people to help energy conservation.

Safety and Compliance Challenges

Plant Health, Safety and Environmental record has improved year by year but incidents still occur, there are
near misses, and the response time is sometimes too long. It is hard to keep up with inspection and
verification requirements in new HS&E directives and mandates. There may be fines or risk of losing license
to operate. Once again, manpower cannot be added to perform these tasks.

Production Challenges
Manual product transfer cross contamination or uneven temperature profile may cause off-spec product.
Manual operation and underutilization of storage tanks and batch reactors may be causing production
bottlenecks. The plant must deal with variance in feedstock from different markets to maintain margin, such
as opportunity crudes in the case of refineries. Plants must tackle changing customer demands. Operating
cost may be escalating for a variety of reasons. Customers demanding ever shorter lead-times. As ageing
staff are retiring the remaining personnel are left with more to do.

Operational Certainty Programme

Many of these challenges stem from manual and paper-based work practices, and in some cases because
important tasks are not done at all. Emerson has the technology and subject matter experts to tackle these
tough challenges. We call this programme Operational Certainty. This programme helps plants achieve
operational excellence and top quartile performance. Digital transformation is an important part of this
programme.

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Plantweb Digital Ecosystem
Digital Transformation – The New Digital Ways of Working
Many tasks around the plant are still manual. Plants are now tackling their challenges though digital
transformation; or call it digitization, digitalization, Industry 4.0, or Industrie 4.0 - it is about changing from
traditional manual paper-based tasks to new automatic, digital, software-based, and data-driven ways of
working. The new operations can be supported by experts in the plant itself, at the company’s own fleet
management center, or by third-party subject matter experts as a connected service.

Transformation

Automatic
Digital
Manual Software-based
Paper-based Data-driven

The Digital Plant

In a digital plant the personnel can carry out their daily duties more effectively. A digital plant also enables
digital shutdown/turnaround/outage thanks to these digital transformations.

Predict equipment Pinpoint inefficient Identify risks and Identify potential

failure equipment and incidents causes and process
points of losses upsets early

Digital inspection
Less routine manual collection of maintenance, reliability, and integrity data from equipment like pumps with
portable testers or time-consuming interpretation. Instead vibration, acoustic, corrosion, and other equipment
data is collected automatically to detect early signs of problems ahead, transmitted digitally, and analyzed by
software to predict and distinguish between various equipment failure modes. This prediction drives
maintenance, reliability, integrity, and asset management along the ISO 55000, API 691, API 570, and
similar guidelines. Personnel are freed-up to act on information rather than collecting data. Notifications of
developing issues sent to your phone or tablet wherever you are. Any remaining manual inspection rounds
are not by clipboard and paper forms, but instead a tablet and software. A central pool of domain experts, at
company’s own fleet management center or external, tap the information to support plant personnel.

Digital collaboration
No delays waiting for an expert to mobilize to site or trying to explain a problem in the field from the phone in
the office or via email. Instead two-way digital video and audio between field technician with wearable
camera at site, such as offshore, and subject matter expert seeing the problem up close and live in software
from onshore or another country.

Digital document box

No carrying of papers or returning to the office to pick up additional documents. Instead open any
procedures, drawings, and manuals etc. in software on a tablet or browse information from the company
Intranet or the Internet on-the-go in the plant.

Digital distress calls

No walkie-talkie required for distress calls. Instead automatic detection, digital transmission, and alarm on
safety shower activation, man-down not moving, or distress call button, in operator software and locating
software.

Digital safety checks

No ad-hoc visits to the plant to check if a manual valve was closed, dipping to see if tank is nearly full, or
inspect for leaks and spills etc. Instead automatic detection, digital transmission, and indication in control
room software, as well as use in interlocks. This drives safety along the ISO 45001, ISO 14001, and OHSAS
18001 standards.

Digital mustering and rescue

No mustering cards, visitor logbook, and walkie-talkie for headcount during emergency evacuation mustering
and no search parties required to return back into the plant to find missing personnel. Instead the
geolocation of every person is sensed digitally in real-time and automatically tallied in software. Contractors
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Plantweb Digital Ecosystem
are managed and with geofencing alarm issued if personnel wander beyond permitted work areas or into a
high-risk area.

Digital field operator rounds

No routine manual collection of operations data on clipboard and paper forms. Instead data for production
and quality is collected automatically and transmitted digitally to historian and operator software etc. Any
remaining manual rounds are instead by tablet with software. This drives quality management along the ISO
9001 and ISO 29001 standards. This is particularly important for unmanned sites like oil fields, offshore
platforms, pipelines, and reservoirs etc. Move work from offshore to onshore, de-manning platforms, putting
workers on land.

Digital notebook
No paper notebooks for jotting down near misses, incidents, hazards, and maintenance needs etc. Instead
notes and digital photos of incidents, hazards, leaks, and damaged equipment is captured digitally on tablets
or phones and shared with relevant parties.

Digital field operator learning

Tagging along experienced staff is not the only way to teach newcomers how to perform manual tasks. Field
operators can also learn and practice new tasks in a very immersive virtual plant environment with virtual
reality also ideal for emergency escape route practice.

Digital energy management

No manual collection of flow meter readings or tallying of consumption report. Instead consumption data is
collected automatically, not just for electricity, but for all utilities flows, transmitted digitally, and
overconsumption alarmed by software also generating the ISO 50001 reports. Further supported by
equipment performance monitoring including heat exchangers, steam trap, and relief valve health
monitoring.

Connecting Data to Experts

Process equipment data may require an expert opinion. Multiple options exist for bringing data to the
experts. Most plants use a combination of these approaches as best suited for the piece of equipment. The
underlying technology and tools are the same. Most plants do not want to connect to the Internet or cloud in
the beginning, so not Industrial Internet of Things (IIoT), they want to start digital transformation and Industrie
4.0 initiatives on-premises.

On-premises Enterprise Fleet Emerson Connected

Using experts within the plant. Management Center Services
Using experts in your own center Emerson experts. IIoT
or integrated operations. IIoT.
Cloud

No internet. No cloud Analytics

Analytics

Analytics
Diagnosis
or Work
Instructions
Edge

Data

Data

Data Site Personnel

On-Prem Management
When experts on vibration, control valves, steam traps, analyzers, pumps, compressors, or flow meters etc.
are available locally at site, the monitoring of that type of equipment can be done on the premises, without
IIoT so no internet or cloud is required. The job of the personnel is made easier by automatic data collection
by sensors and data interpretation by predictive analytics apps. The control of these equipment is already
taken care of by the existing control system.

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Plantweb Digital Ecosystem
Fleet Management Center
When an equipment expert is not available at site, the equipment data can be transmitted to a private cloud
to be monitored by experts at a enterprise-wide fleet management center. These experts monitor equipment
at all the company’s sites across the globe. This is an Industrial Internet of Things (IIoT) solution. IIoT-based
equipment management can be combined with process operations in an integrated operations (iOps) center.
Some power companies have multiple plants throughout a country they manage from a fleet management
center; remote operations center. Some companies in the hydrocarbon industries have production sites,
pipelines, refineries, and petrochemical complexes they monitor from a global fleet management center.
Less people offshore, instead moved onshore. Some equipment manufacturers sell their machines like
pumps, compressors, and air-cooled heat exchangers etc. to plants around the world, but can monitor these
equipment at their customer’s sites from a central location providing a better service for these plants. The
real-time control of these equipment is already taken care of by the existing control system in the plant.

Outsourced Connected Services

Alternatively, when an equipment expert is not available in the company, the equipment data can be
transmitted to the cloud to instead be monitored by subject matter experts at a service provider’s monitoring
center. These domain experts monitor equipment at many sites across the globe for many companies. This
is also an IIoT solution. It is different from the steam trap surveys and vibration checks outsourced to third-
parties today, in that with IIoT the data collection is automatic, more frequent, and therefore more predictive.
This connected service business model is already disrupting traditional service providers. The service
provider does not run the process, just help to ensure the equipment are in good condition. The process is
still run by the operators in the plant and the real-time control of these equipment is done by the existing
control system.

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Plantweb Digital Ecosystem
Digital Operational Infrastructure – The Architecture Building Blocks

• A complete digital ecosystem

• Using existing historian platform
• Standards-based, platform independent
• Purpose-built, readymade apps and solutions
• Engineered analytics or data science
• Embedded process and equipment domain expertise
• On-premises or cloud deployment (IIoT)
• NAMUR open architecture
• Building blocks designed to work with each other and your system
• Modular for phased implementation
Digital Ecosystem
Before there can be a digital transformation of how the plant is run and maintained additional automation
must be deployed in the plant making it a digital plant and connected plant infused with digital technology
such as digital networks, digital sensors, predictive analytics, other software. and optionally cloud computing.
A DCS and historian is no longer enough. All the building blocks of the Plantweb digital ecosystem, from
mobility and dashboards, underlying analytics, connectivity, Connected Services, and security down to the
solid foundation of sensors have been designed to work together to provide the greatest capabilities with
less integration effort and minimal risk. Not just shipped together, but designed together. Plantweb
deployment is very flexible to fit in at each Purdue / ISA95 / IEC62264 model level of the existing automation
architecture, the automation architecture does not need to be changed to accommodate Plantweb. An
award-winning concept. The Plantweb digital ecosystem is not a general-purpose solution, it was created
specifically for the process industries, not a compromise to accommodate other domains.

NAMUR Open Architecture

The Plantweb digital ecosystem is a Digital Operational Infrastructure (DOI), a second layer of automation
beyond the P&ID, for digital transformation of the many manual tasks around the plant along the lines of the
NAMUR Open Architecture. This second layer of automation sits side-by-side and is integrated with existing
plant operational infrastructure and the global enterprise IT Infrastructure.

IT Infrastructure Open
BI ERP
L3.5 Integration Architecture
Higher
Operational Analytics MES
Infrastructure Reliability Historian Process Historian

Detail
Analytics DCS
Pervasive
Networking IO & Control
Pervasive
Sensing Sensors & Actuators
Digital Operational Core Process Control
Infrastructure (DOI)

Digital Operational Infrastructure (DOI) – A Second Layer of Automation

The Plantweb digital ecosystem was developed for making digital transformation of plant operations easy
with built-for-purpose readymade building blocks for rapid deployment, and without affecting the safety and
robustness of the core process control system. The Plantweb digital ecosystem is not just a software
‘platform’, it is the complete solution for digital transformation; a technology stack with mobility and
dashboards, underlying analytics software, network connectivity, optional Connected Services, security, all
resting on a solid foundation of add-in sensors. The modular architecture allows you to think big, start small,
and scale fast. You need not do it all at once. The I&C engineers take care of the sensors, networking, and
operational analytics technology so the users of the information need not worry about the technical details.

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Plantweb Digital Ecosystem
Digital transformation, optionally including IIoT, is a new era in automation. Moreover, cloud and internet
connection are not required by Plantweb, indeed most plants start digital transformation on-prem without
cloud or internet connection. Cloud and internet are only required for IIoT-based Connected Services and
some mobility solutions.

Digital Foundation – Core Process Control

The Plantweb digital ecosystem works hand in hand with the DeltaV and Ovation control systems, as well as
with the AMS suite including the Device Manager and Machinery Manager, and the Syncade MES. But
Plantweb is platform-independent, an open system built on open standards, so it interoperates with other
control systems, Plant Information Management System (PIMS) historians / enterprise historian, safety
systems, machinery protection system, and vibration monitoring systems using international standard data
formats like OPC-UA providing the ability to share information between software applications. Sensors from
other manufacturers integrate through international standard data formats such as WirelessHART or
FOUNDATION fieldbus. That is, data from a wide variety of sources is aggregated and used.

• Asset Performance Management

• Equipment Health Analytics • OPC-UA • DCS
• Equipment Performance Analytics • OPC Classic • MES
• Energy Management • Modbus/TCP • PIMS / Historians
• Operational Notifications • FF-HSE • SIS
• Operational Dashboards • HART-IP • Machinery Protection System
• Intelligent Device Management • Etc. • Etc.
• Etc.
Digital Operational Infrastructure (DOI) Digital Foundation – Core Process Control

Plantweb gets the data to the experts in the company, or externally. Plantweb also integrates with other
Manufacturing Execution System (MES) level 3 applications. Other systems may include alarm
management, digital logbook, reservoir management system, and production management system.
Plantweb also integrates up to Computerized Maintenance Management System (CMMS) and global
Enterprise Resource Planning (ERP) system like SAP or Oracle including modules such as Planning &
Scheduling and Supply Chain Management (SCM) to complete the digital workflow chain.

Digital Operational Infrastructure (DOI) Core Process Control (CPC)

BI Reports ERP/CMMS

Historian Cloud Physically

Data Diode DMZ
Connection Independent

Operational Operational Equipment Historian,

Asset Platform App Platform OPC-UA
Notifications Dashboards Analytics MES
Vibration Corrosion DCS
Valve Analytics OPC-UA
Analytics Analytics Software
Industrial Wi-Fi Fieldbus WirelessHART 2nd DCS
Access Point Linking Device Gateway Channel Hardware
Position Vibration Acoustics Corrosion Location Sensors &
Sensor Sensor Sensor Sensor Sensing Actuators

Platform Independent
Plantweb can use your existing historian as the single software platform for data aggregation it was originally
meant to be when you first bought it years ago. Plantweb Optics extends the platform for reliability data.
Thus there is no need to duplicate the function of the plant historian software and data already in it, or the
costs associated with doing so. Plantweb analytics apps get data from the combined platform. That is,
analytics and presentation has access to data from across the control system, machinery protection system,
and various other data sources.

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Plantweb Digital Ecosystem

Operational Operational
Presentation Dashboards Notifications

Cooling Heat Air Cooled

App Steam Trap Relief Valve Pump
Platform
… Analytics Analytics Analytics
Tower
Analytics
Exchanger
Analytics
HX
Analytics
…

Data Asset Performance Platform Historian Platform

Platform (Reliability Data) (Process Data)

Other Vibration Intelligent Machinery Other

Data Wireless Sensor Network
Data Monitoring Device RTU PLC SIS DCS Protection Data
Sources (Pervasive Sensing)
Sources System Management System Sources

Always Aware: Mobility Software

Mobility is not about controlling the plant, it is about knowing what’s going on at site. A lot of time is spent
away from your desktop, some carrying out tasks in the field, meeting in the admin building, offsite, even in
the boardroom etc. Access to information from a tablet or phone is now the expectation. You can access
high-level plant situational overview from your phone or tablet any time, and zoom all the way down into a
piece of equipment if you have to. Within the plant you just need Wi-Fi, no need for an Internet connection.
When you are in an offsite meeting or on your way to or from work, you just need an Internet connection
through Wi-Fi or the mobile network. The system can also send you a notification when something happens
in your area of responsibility so you are always aware what’s going on, for instance on high vibration or a
critical pump issue, allowing personnel and experts to collaborate wherever they are. The mobility
applications in the Always Aware building block are readymade software, no custom programming or
ongoing code maintenance required.

iSolutions Operational Dashboards

In a digitally transformed plant, work by everyone from the plant manager down is data-driven. Personalized
information must go to the desk and pocket of the person responsible. Each person needs data relevant to
their responsibility to do their job better; role-based. A personalized dashboard provides an on-the-go at-a-
glance overview of the domain of responsibility for each role. For instance, the reliability manager’s phone
and tablet has a dashboard very different from the safety manager. Dashboards are generated in the web
interface part of the plant historian using information from underlying analytics apps like equipment condition
monitoring which in turn get data from multiple underlying data sources such as the control system and
machinery protection system etc. Operational dashboards contain real-time operational indexes; real-time
information that impact manager’s KPIs, specific to the person's responsibilities displayed on tablets or
phones, making information immediately available wherever you are, be it in a meeting, in the canteen, or on
your way to or from work. Enterprise-level reports are again different. Tablets and phones are available in
industrially hardened and intrinsically safe models for use also in the plant including in hazardous areas.
Some tablets include push-to-talk walkie-talkie functionality.

Production Manager Maintenance Manager HS&E Manager

Plant Manager

Quality Manager Energy Manager Reliability Manager

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Plantweb Digital Ecosystem
DeltaV Mobile
Because work at every level including technicians in a digitally transformed plant is data-driven, personalized
notifications must also go to the desk and pocket of the person responsible. Each person needs notifications
when something in their area of responsibility happens so they can work more effectively. Personalized
notifications enable situational awareness for each role; role-based. For instance, the maintenance
manager’s phone and tablet get notifications different from the quality manager. Notifications include alarms
related to the person's responsibilities displayed on tablets or phones, making you aware immediately
wherever you are, be it in a meeting, in the canteen, or on your way to or from work. DeltaV Mobile is
mobility software used regardless of control system. DeltaV mobile delivers personalized notifications to your
phone or tablet. DeltaV Mobile gets alarms from multiple underlying data sources such as the control system
and machinery protection system etc. You receive these alarms as notifications on-premise or through Azure
cloud, SMS/text message, or email on-the-go. Filtering capabilities ensure only relevant alarms are received.
Alarms can be throttled, frequency selected, and nuisance alarms disabled. This allows personnel to receive
notifications in the plant, in the office, or offsite in a timely manner enabling the personnel responsible for the
production, equipment, energy efficiency, safety, and integrity etc. to stay aware of the situation. The
notifications are distributed based on roles and responsibilities ensuring personnel only receive notifications
relevant to their needs and expertise. These notifications are engineered to be easily understood, help
identify the problem, and guides towards a resolution with an emphasis on the important aspects.

Catalytic Pump pre- Boiler fuel Isolation Quality Catalytic Motor Pipe wall
cracker unit cavitation gas over- valve left going off- cracker unit bearing thickness
trip consumption open spec trip wearing out thinning
fast

Plant Maintenance Energy HS&E Production Reliability Integrity

Manager Manager Manager Manager Manager Manager Manager Manager

DeltaV aggregates and display alarms and data from control systems, historian, machinery protection
system, and other data sources.

DeltaV Mobile also gives selected personnel login access to operations data away from the control room or
office, and even offsite. Personalized watch lists include trend including recent past for selected tags and
alarm list. Watch real-time process values, setpoints, and outputs etc. All data is read-only preventing users
from inadvertently affecting operations. Native notifications routed through Azure cloud include
recommended action. A large screen device can display operator graphics from a web browser. Links can be
shared with other users directly to the details for the alarm for collaboration including subject matter experts,
wherever they may be located.

Plantweb Optics Mobile App

Plantweb Optics works together with AMS Machinery Manager for vibration analytics, AMS Device Manager
already in use in many plants for device diagnostics, and Plantweb Insight for equipment analytics, plus AMS
Machine Works the new software for vibration analytics. Plantweb Optics mobile app on a tablet or phone
receives reliability-related notifications from equipment and instruments to through Wi-Fi or the Azure cloud
wherever you are. These notifications are personalized, so you only get notifications for equipment in your
area of responsibility. If you are responsible for multiple plants, you get notifications from all of them, neatly
organized. Unhealthy assets can be seen at a glance.

Mobile

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Plantweb Digital Ecosystem
As plant personnel encounter maintenance and reliability issues, safety risks including near misses, or
energy losses in the field they can trigger work requests in the ERP/CMMS from the Plantweb Optics mobile
app. Even without a CMMS, personnel can send messages from their mobile device to the team and attach
photos to drive remedial action. That is, digitally document events, observations, incidents, near misses, and
make notes in daily operations instead of using paper and notebooks. Since it is digital it can be shared with
all, not just stay in one person's notebook. This drives collaboration, sharing of ideas, and continuous
improvement. Moreover, history can be searched to find prior occurrence, resolution, and frequency etc.

AMS Device View

AMS Device View is used with AMS Device Manager and is a web-based mobile-friendly user interface
suitable for phone or tablets for on-the-go at-a-glance overview of the health of the device population in the
plant and their calibration status. The instrumentation dashboard includes instrument diagnostic alarm
summary listing and calibration listing. Technicians can zoom into a detailed device page for description of
the problem and recommended action.

EDS Mobile
EDS Mobile is an extension of the Enterprise Data Server historian used with Ovation Control System, which
provides users on the go a display on a mobile device such as phone or tablet. EDS Mobile also has the
capability to connect with 3rd party systems. This mobile application gives executives, managers,
supervisors and engineers flexibility in managing operations when they are away from their offices. It
provides access to key performance indicators and archived plant data. It is ideal for managing multiple
plants, such as a fleet of power stations.

Higher Analytics Software

The Plantweb software suite for higher analytics focuses on operational analytics for operational intelligence
and includes tools based on both engineered analytics and data science. Engineered analytics includes well-
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Plantweb Digital Ecosystem
known physics first principles (1P) and equipment Failure Mode and Effect Analysis (FMEA) which are easily
verifiable. Domain expertise is built-in so historical data is not required. Data science includes Artificial
Intelligence (AI) based on various Machine Learning (ML) algorithms used to uncover knowledge from
historical data where there are no documented FMEA or first principle models. The key to successful
analytics in the plant is to use the right tool for the right job because one size does not fit all. FMEA models
are used for equipment condition monitoring and first principles models are used for equipment performance
monitoring. Various ML algorithms are used mainly for process analytics, by analyzing historical process
data to uncover dependencies and correlations to understand the process better to enable a predictive
model to be built. A predictive model is then configured using fault trees based on FMEA and calculations
based on 1P. That is, a plant is managed using a combination of analytics tools.

Plants that use the OSIsoft PI-system historian can use analytics with PI AssetFramework integration and
native PI data integration for data access. That is, not just interface with PI through intermediate protocol, but
direct integration into PI. This allows plants to maximize the use of their PI system. Platform independent
analytics is also available for use in plants with other historian or no historian at all, but is also used in plants
with PI historian.

Ready-made analytics pre-engineered for specific well-known problems using FMEA-based or first principle
models cover perhaps 80% of the plant’s analytics needs. This includes equipment condition monitoring of
steam traps, relief valves, pumps, cooling towers, and air-cooled heat exchangers etc. Since it is readymade,
these are very easy to deploy. These predictive analytics apps already encode subject matter expertise are
used for performance and condition monitoring of process equipment. Equipment analytics synthesizes
multiple measurements to predict problems, allowing failures to be averted. Raw data from sensors is
distilled into actionable information. When problem starts to develop the technician already knows what to do
and what to bring before going to the field. This is predictive maintenance; specifically condition-based
maintenance. The equipment analytics software can be installed on L2 and L3 servers on-premises, or L1
embedded device at the ‘edge’, or on virtual machines in the cloud. Equipment analytics results can feed into
L4 global enterprise KPI reports, Business Intelligence (BI) software, CMMS, and ERP workorder
management.

Process analytics uncovers correlation and dependencies from historical process data and can be used to
codify knowledge of experienced operators to predict developing process upsets and abnormal conditions to
help other operators assess the situation correctly and take correct action to reduce off-spec products and
risk etc.

Plantweb KNet Plantweb Plantweb Plantweb

Insight Health Performance Energy
Advisor Advisor Advisor
FMEA ● ● ●
First Principles ● ● ● ●
Machine Learning ●
OPC-UA ● ● ●
Native PI integration ● ●
PI AssetFramework ● ●
Ready-made ● ● ●
Equipment analytics ● ● ● ●
Process analytics ●
Energy management ●

Plants may use either one of these analytics, and there are plants many of these. Sites using the OSIsoft PI-
system historian will tend to use Plantweb Advisor, while sites having other historian or no historian at all
tend to use Plantweb Insight. That is, Plantweb can be used regardless of the historian platform the plant is
using. For any of these analytics, the plant’s existing historian remains in place for Big Data storage, it need
not be replaced by another middleware data storage platform, and there is no need to add another data
storage platform on top of the historian thus protecting the plant’s investment and keeping the administration
cost low. The predictive analytics uses data aggregated from multiple sources; the new wireless sensors,
existing wired sensors, package unit PLCs, SCADA system RTUs, control systems, safety system,
machinery protection systems, intelligent device management (IDM) software, etc. The historian is the single
software platform for operational data storage, available for data mining. Conversely, analytics from
equipment apps can feed into dashboards for the unit or whole plant. Similarly, information can be integrated
into the augmented reality (AR) visualization solution.

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Plantweb Digital Ecosystem
Plantweb Insight and Plantweb Health Advisor use the same algorithm to predict failure and distinguish
between various failure modes for each type of equipment, not just “correlation” or “anomaly”; descriptive
analytics so personnel know what action to take; prescriptive analytics. Detail pages has a trend displaying
how quickly the piece of equipment is deteriorating. Using this information maintenance can be scheduled for
the same day, the next turnaround, or somewhere in between.

Plantweb has a layered open architecture where real-time analytics is done at the sensor level, edge
analytics is done in higher level devices and servers, feeding up to global enterprise business intelligence at
level 4.

Data Science (Machine Learning)

MULTIPLE Predictive
PLANTS
Complex Problems, Analytics
PLANT To-Be-Discovered Solutions

PROCESS UNITS &

COMPLEX ASSETS

EQUIPMENT

Known Problems,
Known Solutions
COMPONENTS

Engineered Analytics: First Principles (1P) and FMEA

Plantweb Insight and Plantweb Health Advisor are not general-purpose data analytics. These apps are
purpose-built for real-time equipment monitoring; specifically for each type of equipment, easy for
maintenance and reliability professionals including managers, engineers, and technicians to use with
overview equipment dashboards, alarm summary with simple health index, priority, plain text problem
description, and ability to zoom into detail and history trend to see accelerated degradation and estimate
remaining useful life. Years of process equipment experience and domain knowledge is built into the apps
which helps drive maintenance management. The predictive analytics detect signs of developing equipment
issues, predicting failure and providing an early warning on these leading indicators so breakdown can be
prevented. And it is not just vibration, the FMEA fault models also uncover early signs of other kinds of
trouble and distinguish between many types of equipment specific failures to provide more actionable
information. These apps are pre-engineered based on years of experience so no algorithm training periods
associated with AI are required, just capture the baseline. These are readymade apps, no expensive custom
programming or costly ongoing code maintenance required. Digital transformation need not cost many
millions of dollars.

The plant may already have sensors and software for the large turbomachinery. Digital transformation brings
similar condition monitoring to other smaller equipment as well.

Plantweb Insight
The Plantweb Insight predictive analytics apps are platform independent, not depending on any particular
historian or control system, aggregating data using OPC-UA regardless of vendor. OPC-UA also enables
migration to other open platform in the future if need be.

Plantweb Insight includes an ever-growing set of apps for steam trap analytics, pressure relief valves,
corrosion, pump, and heat exchanger analytics etc. The apps display in a common framework for ease of
use.

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The ease of use of the built-for-purpose analytics apps has won Plantweb Insight several awards
2017 Vaaler Award 2017 Oil and Gas 2017 Processing Control Engineering
Engineering Product of Breakthrough Award 2018 Engineers’ Choice
the Year Award

Chemical Processing Oil and Gas Engineering Processing Magazine Control Engineering

Plantweb Advisor Suite

The Plantweb Health Advisor and Plantweb Performance Advisor analytics software are created specifically
for the OSIsoft PI-system historian already in use as the platform in many plants.

The real-time equipment analytics software plugs into the historian just like Advanced Process Control
(APC), Real Time Optimization (RTO), process simulation, process analytics, batch analytics, and loop
tuning often already deployed in plants. These software applications are tightly integrated with the PI
AssetFramework (AF) ensuring a familiar and easy to navigate user interface. The OSI PI platform enables
web access to the analytics as well as text/SMS and email notifications for alarms.

Plantweb Health Advisor

Plantweb Health Advisor includes an ever-growing suite of modules for pumps, heat exchangers, blowers,
air cooled heat exchangers, compressors, cooling towers etc.

Plantweb Performance Advisor

The Plantweb Performance Advisor modules are not general-purpose data analytics. These modules are
purpose built for equipment performance monitoring. The modules are easy for maintenance and operations
staff to use with overview equipment dashboards, alarm summary with simple performance index, plain text
performance improvement opportunity description, and ability to zoom into detail and history to see
accelerated performance degradation. Plantweb Performance Advisor has modules for centrifugal
compressors, reciprocating compressors, gas turbines, steam turbines, boilers, fired heaters, furnaces,
HRSGs, condensers, pumps, cooling towers, fans, and many others which helps drive performance
management. The performance analytics uses verifiable ASME-PTC thermodynamic first principle models to
detect performance degradation early. This knowledge drives operations and remedial action. You can tell
which of pump A and B in a standby arrangement is more efficient, and operate it while the other is
overhauled. Once inefficiency is detected, the cause can be investigated. These modules are pre-
engineered based on years of experience and domain knowledge so no long algorithm learning periods are

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Plantweb Digital Ecosystem
required. Turbomachinery comes with a protection system, Plantweb Performance Advisor adds
performance monitoring.

Plantweb Energy Advisor

The Plantweb Energy Advisor is an Energy Management Information System (EMIS) purpose built for
process plants, managing multiple energy streams such as water, air, gas, electricity, steam, and others,
easy for energy managers and loss control engineers to use to generate automatic reports for the plant,
areas, units, and down to equipment level. The overconsumption alarm summary helps drive energy
management to reduce energy intensity and emissions. Plantweb Energy Advisor has verifiable models, a
digital twin of the process, based on first principles (1P) or empirical data to dynamically predict target energy
consumption based on production rate.

Digital
Twin

That is, Plantweb Insight and Plantweb Performance advisor identify root cause for losses such as steam
trap failure, relief valve passing, or heat exchanger fouling etc., Plantweb Energy Advisor complement these
by indicating there may be other losses as well.

KnowledgeNet (KNet)
KNet is used to anticipate abnormal conditions and to recommend operator action (prescriptive analytics),
dynamic performance targets (e.g. throughput, feedstock and energy consumption), and to dynamically
predict process properties faster than lab analysis etc.

KNet has analytics tools used to for analyzing historical data for better understanding of abnormal conditions,
the cause and effects of events, etc. This way KNet unravels complex unit processes or the whole plant for
which first principle models and FMEA have not been documented. Historical process data including alarms
are analyzed using Machine Learning (ML) algorithms such as regression, Principal Component Analysis
(PCA), clustering, and Artificial Neural Networks (ANN) etc. Next, predictive models of the process or plant
are built based on the correlations uncovered including expert rules with recommended action. The models
are then used in the online mode on real-time process data to help the operator see upsets coming and
guide the operator to the correct action to reduce the impact.

KNet also allows you to visualize data with various kinds of plots and charts to understand what is going on
in complex processes. Pattern recognition allows you to identify clusters of related data or discover recurrent
sequences in alarm & event data. KNet alarm analytics find alarm chattering and standing alarms, correlate
alarms to remove redundant alarms and reduce alarm floods, and correlate alarm and process data for
troubleshooting and root cause analysis.

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Plantweb Digital Ecosystem

Data
Science

Artificial
Intelligence

Machine
Learning

Asset Performance Platform

The predictive, descriptive, and prescriptive analytics information is meaningless unless it reaches the
persons that can act on it. The information must reach the workstation but also their mobile device like phone
or tablet, and it much reach the ERP/CMMS so maintenance can be scheduled.

Plantweb Optics
Plantweb Optics is an asset performance platform that marshals alarms from assets like process equipment
including pumps and heat exchangers, turbomachinery like compressors and turbines, and instrumentation
like valves and analyzers etc. into notifications to the experts and persons responsible and the CMMS/ERP
for more effective Asset Performance Management (APM). Mobile notifications are received in the Plantweb
Optics mobile app explained above.

Asset
Performance Platform
Management

ERP/CMMS Integration
Plantweb Optics integrates with the ERP / CMMS for a completely digital workflow eliminating the manual
step of work request entry. Currently SAP and IBM Maximo interfaces are supported, with other CMMS in the
works. When underlying analytics predicts or detects a problem in process equipment, machines, or
instrumentation a ticket is triggered to the CMMS for that asset ID. This in turn drives corrective action. When
issues are spotted in the field, work requests can also be triggered from the Plantweb Optics mobile app.

Asset Explorer
All equipment and instrumentation are organized in the asset database. Asset Explorer is the hierarchy in
which assets including process equipment like pumps, heat exchangers, and cooling towers as well as
instrumentation like transmitters, analyzers, and valves are organized according to their location in the plant
as per the ISA88 model. Data for each asset is grouped together; contextualization. These assets are also
prioritized. Plant personnel are assigned user accounts in the Plantweb Optics system according to their
roles and responsibilities, per asset class and by site location. This allows the system to automatically
forward equipment notifications to the right person to act, without flooding others with nuisance notifications.

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Plantweb Digital Ecosystem

Asset View
Unhealthy assets can be seen at a glance from Asset View and you can launch detail analytics and
diagnostics for these equipment. That is, all the asset in a particular unit in the plant are grouped together,
and when you click on one of the equipment the analytics app opens up for more information.

Reliability Historian
Plantweb Optics historizes reliability data from rotating machinery, instrumentation, and wireless add-on
sensors on process equipment to visualize trends over time. This complements the process historian most
plants already have which historizes process data (process variables and process alarms). Plantweb Optics
does not duplicate that function.

Detail Analytics Software

In addition to the easy-to-use Plantweb Insight and Plantweb Advisor analytics software, there are also
specialized expert tools for detail investigation like AMS Machinery Manager for vibration experts, Data
Manager for corrosion experts, and ValveLink capable of distinguishing between many failure modes for
control valve experts. It is possible to zoom all the way down to analytics of an individual sensor; diagnostics
of sensor health.

Vibration Expert Corrosion Expert Control Valve Expert

If in-house experts are not available, then use the higher-level equipment diagnostics tools like Plantweb
Insight and Plantweb Advisor or Connected Services can instead be subscribed to.

AMS Machinery Manager

AMS Machine Manager is a vibration analysis tool for diagnosis of rotating machinery from turbomachinery
to small pumps. It organizes vibration Big Data acquired through the wireless vibration transmitters, AMS
6500 ATG machinery protection system, AMS 6500 machinery health monitor, or portable vibration
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Plantweb Digital Ecosystem
analyzers in the asset database, and includes tools to make it easy to view spectrums, waveform, trends,
and plots plus other analytics tools. Documents and images can be added. Collaborate and share with other
users. A dashboard gives at-a-glance overview of rotating machinery. Routes are setup for portable testers.

Turbomachinery are supplied with a protection system, AMS Machinery Manager adds prediction and
analysis.
Online Watch
Online Watch predictive vibration analytics automatically identifies and describes problems like imbalance,
misalignment, looseness, bearing wear, fault, and oil whirl, rotor stiffness and rub, etc. in real-time. With this,
the maintenance personnel have batter information to act on, earlier.

Nspectr
Nspectr automatically analyses offline data collected with portable vibration testers. It automatically identifies
and describes problems like alignment, imbalance, belt issues, shaft issues, improper lubrication, looseness,
roller defects, bearing issues, foundation, gear issues, cavitation, and surging etc. This greatly reduces the
workload for vibration analysts.

Permasense Data Manager

The Permasense Data Manager software corrosion and erosion software monitors wall thickness and
predicts when “retirement thickness” will be reached - when the pipe section needs to be replaced. Corrosion
rate is computed to optimize corrosion inhibitor injection or opportunity crude mix. Surface roughness
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Plantweb Digital Ecosystem
analytics indicates how the inside surface is changing. Metal loss “heat map” indicates where metal loss
happens at the same time; localized or general across the unit.

Mobile Worker
Wireless technology allows plant personnel to work in the plant itself, as needed, outside the control room
and away from the office desk; a digital workforce with connected workers.

AMS Trex
AMS Trex is a new generation field device communicator with large backlit touchscreen screen for a full
tablet-like device experience and with ability to power the field device eliminating the need for separate
device power supply. The communicator is rugged, industrial grade, and intrinsically safe, yet compact and
light enough to hold in one hand ideal for work in the field.

AMS Trex automatically synchronizes changes made in the field with the AMS Device Manager database via
Wi-Fi, Bluetooth, or USB connection – thereby automating otherwise manual configuration management by
using digital technology.

AMS Inspection Rounds

Some manual inspection and field operator rounds for data collection will remain. AMS Inspection Rounds is
an app that runs AMS Trex handhelds to easily record data digitally on ‘soft’ forms instead of paper forms.
The data collected automatically synchs to a server over Wi-Fi in the plant or office. Data is user-, date-, and
time-stamped. Alarm is triggered if limits are violated. Because it is in digital form, notes are legible and
complete.

The inspection routes and scheduling are freely configurable. The ‘soft’ data entry forms are also freely
configurable with fields for numeric, freeform text, choice, multiple choice, data or simple acknowledgement
etc.

Emerson Asset Connect: RFID

Valves and actuators can be fitted/retrofitted with Emerson passive RFID tags that have on-chip data storage
that holds valve and actuator data. On-chip data storage means a network connection is not required. An
ISO 18000 RFID reader and the Emerson Asset Connect software accesses this data. Tags and reader are
intrinsically safe suitable for hazardous areas. Tags can be read at a distance reducing the need to climb or
work at height. RFID is also used to quickly locate valves by scanning the process unit, warehouse, or
laydown yard instead of spending hours searching. RFID have many other advantages of QR code in
industrial environments.

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Plantweb Digital Ecosystem

RFID

The RFID tags support the unique Electronic Product Code (EPC) for integration with ERP, CMMS, and
other software.

Augmented Reality (AR)

Plantweb Optics and DeltaV Mobile support Augmented Reality (AR) a solution which is in its final phase of
development. The AR back-end software runs in the Azure cloud aggregating data from multiple sources
such as control system, package units, and equipment condition monitoring software etc. to the AR units
such as industrial grade phone or tablet. Data is communicated to the AR units using Wi-Fi or mobile
network. The person in the plant gets instrument and equipment identification, process and equipment data,
and work instructions superimposed on the display of a tablet or phone pointing to the equipment making
equipment easy to find and check. That is, when you look at a tank “through” the tablet you see the level, at
a valve you see opening, or at a pump you see status and condition etc., you don’t have to radio the control
room or others.

Pervasive Networking
Digital networks are the central nervous system of a digital plant transferring data with digital integrity. All
plants deploy a plant-wide wireless sensor network and optionally also an industrial wireless LAN (WLAN)
infrastructure depending on which operations tasks will be digitally transformed. The wireless network
infrastructure consists of wireless gateways for the wireless sensor networks, and in some plants also
wireless access points for the industrial Wi-Fi. The wireless sensor network and Wi-Fi can be deployed
separately or the wireless gateways can optionally piggyback on the wireless access points. Since these
networks are used for operational functions, both wireless networks integrate with the control system,
historian, machinery protection system, and other operations systems.

Wireless Sensor Network

Sensor data is transmitted digitally using pervasive networking infrastructure. Plants instrumented and
interconnected with fieldbus can use those networks to integrate more sensors simply by connecting them to
the existing junction boxes. A standard wireless sensor network infrastructure like WirelessHART supports
not only one type of sensor for one application, but many kinds of sensors from multiple vendors enabling
the network to be shared for multiple applications solving problems for multiple departments.

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Plantweb Digital Ecosystem
Wireless Plant Network
Appropriately certified wearable video cameras, industrial phones, and tablet can be used in the field to
assist in various tasks. Industrial tablet use-cases include web interface for CMMS, MES, and ERP systems
such as for digital permit to work (PTW), retrieving maintenance history, workorder management, as well as
warehouse requisition without returning to the office. Access to documents like standard operating
procedures (SOP), checklists, work instructions, guidelines, drawings, and instruction manuals etc. As well
as data collection and reporting, and video expert collaboration are other examples of functionality which
make use of industrial Wi-Fi at level 1 (L1).

Wearable

Pervasive Sensing
Data-driven work practices starts with the raw data from sensors. Sensors bridge the gap between the
physical and digital world. Without sensors there can be no analytics and no Big Data. You can’t predict
equipment problems with only process data. You need equipment data. Process equipment like pumps,
compressors, heat exchangers, blowers, cooling towers, air cooled heat exchangers, manual valves, and
tanks etc. even steam traps usually have no sensors for condition monitoring; missing measurements. This
equipment is now instrumented, retrofitted with additional permanent sensors to cover these missing
measurements to make them connected and intelligent. The automatic data collection is much faster,
providing early detection of “markers” of developing problems, thereby making the asset management more
predictive, and far more productive. The Pervasive Sensing building block includes both wired and wireless
sensors, but in an existing plant, wireless sensors are easier to deploy.

Wireless Sensors
Wireless sensors often take the place of mechanical instruments, portable testers, and clipboards. Sensors
are installed on equipment around the plant. Instrumenting equipment like pumps is the essence of smart
connected devices. Wireless sensors include pressure, flow, level, position, on-off contact, vibration,
temperature, corrosion, erosion, acoustic noise, electric power, H2S, CO, O2 depletion, and sand as well as
level switch which can be deployed without having to lay more cable and installing more I/O for 4-20 mA and
on-off signals. Control valves and flow meters not already digitally integrated are fitted with wireless
adapters. Many of these sensors are non-intrusive or reuse existing process connections meaning they can
be installed while the plant is running without shutting down the process. Wireless sensors can be deployed
without opening cable trays or junction boxes avoiding the risk of damaging existing cable. Some
transmitters such as for vibration include edge analytics pre-processing the raw data.

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Plantweb Digital Ecosystem

Wireless
Sensors

Flint Hills Pine Bend Petrochemical BP Geel got tank An American oil & gas
had had no pump fires Company in India overfill prevention company in Thailand
in 5 years, have immediately detect and demonstrated has eliminated data
avoided shut downs, at hydrogen passing in compliance thanks to collection trips to
1/10th the cost of PRVs thanks to Pervasive Sensing offshore installations
manual inspection Pervasive Sensing thanks to Pervasive
thanks to Pervasive Sensing
Sensing

All sensors are intelligent and can be integrated with intelligent device management software like AMS
Device Manager to monitor the condition of the sensors themselves including batteries in wireless devices.

Location Awareness
Employees, visitors, and contractors wear a personnel tag for geolocation of people and assets within the
plant for live monitoring, digital mustering headcount, emergency rescue locating, and geofencing for alarm
when personnel stray into restricted or high-risk areas or during high-risk activities like startup to keep people
out of harm’s way. The personnel tags include an emergency distress call button and sensor for no
movement (man-down). The tag is rechargeable on a standard Qi charger, intrinsically safe, suitable for
zone 0 hazardous areas. Location awareness is also used for contractor workforce management, particularly
notification on activity outside the assigned work area during turnarounds, and to manage fatigue.

Location
Awareness

Intrinsically safe wireless location anchors are installed in a grid pattern across the plant areas covered, no
network or power cabling required. The personnel tags communicate with the anchors. The anchors in turn
communicate to a WirelessHART gateway. The Plantweb Insight Location software is the location engine
and user interface.

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Plantweb Digital Ecosystem
Secure First Mile
Security is always required, but when monitoring is done from a central location away from the plant across
the Internet using IIoT, an additional security function is required for the cloud connection. Similarly, when
automation is integrated with the ERP/CMMS system (L4), additional security is required.

Pervasive Security
Security is implemented at every level of the digital ecosystem architecture; in the wireless sensor networks,
the Wi-Fi networks (L1), wireless gateways, wireless access points, analytics and other software: defence-in-
depth.

IT/OT Integration - Secure Enterprise Integration and Cloud Connection

For those plants using IIoT-based Connected Services to get additional support from a central pool of
experts, either their own at a fleet management center, or outsourced to a third-party service provider, the
cloud connection also has its security to prevent unauthorized access to the manufacturing systems (control
system and plant historian etc.). The Emerson Connected Services uses the Microsoft Azure cloud which
meets standards like ISO 27001 and many others.

These same security solutions can also be used for data access from the global enterprise level IT network
for world-wide enterprise integration such as for workflow integration with the ERP and CMMS.

Figure 1 Department of Homeland Security (DHS) Industrial Control Systems Cyber Emergency Response Team (ICS-
CERT) Recommended Practice: Improving Industrial Control System Cybersecurity with Defense-in-Depth Strategies

There are several enterprise integration and cloud connection options (IT/OT integration) in the Secure First
Mile building block (at L3.5):
De-Militarized Zone (DMZ)
If the plant already has an existing De-Militarized Zone (DMZ) for enterprise integration between the
manufacturing systems and the enterprise systems (ERP etc.) using back-to-back firewalls. This DMZ can be
used for IIoT-based service data as well.
Historian Cloud Connect
If the plant is using the OSIsoft PI-system, the associated Cloud Connect solution can be used to mirror
selected data to a PI-system in the fleet management center, at a connected service provider, or to an
enterprise historian for global enterprise integration.
Physically Private Network (PPN)
If IIoT-based service data is collected by dedicated sensors and gateways as a standalone system not
connected to the manufacturing systems, a physically separate backhaul network can be used. 3G/4G
mobile or broadband networking can be used.
Industrial Data Diode (IDD)
If IIoT-based service data is collected through the control system, another option is a unidirectional
hardware-based data diode. Use of data diode is standard for power plants in some countries. The data
diode can be used for enterprise integration as well.

Connected Services
Often there is not enough experts at site to interpret data such as vibration spectrums, valve signatures, and
chromatograms etc. Some plants therefore opt for an IIoT-based solution for digital services with subject
matter experts in a central location monitoring equipment across multiple sites. This is a new digital approach
to lifecycle management. It can be the company’s own fleet management center to manage process
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Plantweb Digital Ecosystem
equipment in the company’s fleet of plants around the world, or it can be a third-party service provider
monitoring process equipment in multiple companies’ sites globally. For the Connected Services building
block Emerson’s global IIoT center of excellence in Singapore has a pool of experts in the areas of rotating
machinery vibration, control valves, analyzers, static process equipment, and steam traps etc. to guide the
personnel at site with expert advice. These are established monitoring services, proven and refined over the
past few years with customers around the world across a broad spectrum of industries. New services are
constantly being added. Emerson is well established in the process industries with more than 125 years of
process automation and equipment know-how. The Emerson cloud is hosted in Microsoft Azure and is
available to plants globally.

Emerson

Site

Currently offered Emerson Connected Services include:

• Steam traps
• Rotating machinery (vibration)
• Static equipment
• Control valves
• DeltaV system
• Gas chromatographs
• Ultrasonic flow meters

In the cloud, predictive analytics software monitors the equipment in the plant. Emerson staff extracts reports
listing equipment condition, predicted problems, and what actions are required. The reports are reviewed by
Emerson domain experts before sending to plant personnel. The report format has been created specifically
for each kind of equipment including the relevant information allowing plant personnel to act immediately.
The reporting frequency depends on the type of equipment. Automatic exception reporting through SMS/text
or email is optionally available for critical equipment.

In an optional business model for Connected Services, instrumentation such as acoustic and vibration
sensors are included as part of the subscription fee. That, is little or no upfront investment for the plant.

Equipment-Level Services
For process equipment like pumps, compressors, heat exchangers, cooling towers, air cooled heat
exchangers, fans, and blowers etc., sensors installed on the equipment in the plant send data into the
Emerson cloud using one of the Secure First Mile solutions. If the equipment already has instrumentation,

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Plantweb Digital Ecosystem
this data is used. Often there is insufficient data for condition monitoring in which case wireless sensors are
added for the missing measurements.

Turbomachinery comes with a protection system; Connected Services adds prediction and expertise.

Denka Chemicals
in Singapore
reduced their
steam consumption
by 7% using
Connected
Services

Device-Level Services
For digitally connected devices like gas chromatographs, control valves, flow meters, level transmitters,
wireless network management, as well as the DeltaV control system additional sensors are not required.
These devices are digitally networked through to the Emerson cloud. As the manufacturer, we are the factory
experts on these instruments and valves.

Training & Simulation Software

Software enables digital transformation of operator upskill and learning of new competencies, and for
process optimization

Mimic
The Mimic process simulation and Operator Training Simulator (OTS) software is tightly integrated with the
DeltaV control system but can work with any control system. The process model is a digital twin of the actual
physical plant. This virtual plant process model is easy to setup and very easy to maintain, to keep true to
actual process as changes are made. It can be done by the process engineers or system engineers in the
plant, it does not require data scientists. Mimic is connected to an off-line control system using the same
operator graphics and controls as the real process to train operators to take appropriate action in various
scenarios like process upsets or batch switching etc., all without disturbing the actual plant.

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Figure 2 OTS Instructor View Figure 3 OTS Student View

Mimic is also used to try out new control strategies and logic improvements, tuning, and setpoints etc. for
process optimization, especially for batch recipe optimization.

At FAT, Mimic is used for configuration validation and logic test to speed up the process.

Mimic is available as a purchased license that runs on a server in a plant or as a cloud-hosted subscription-
based model where a server is not required in the plant.

Mimic Field 3D
With 3D Virtual Reality (VR) simulation software and goggles, field operator tasks like unit startup, shutdown,
loading, and offloading etc. can be practiced and learnt in a classroom environment yet with a very realistic
and immersive experience for accelerated learning and better retention as compared to traditional training.
There may not be enough opportunity to practice manual tasks like startup in the actual plant. Incorrect task
actions are uncovered and the operator can continue to practice getting competent before going to the field
for hands-on training and actual operation. Learn onshore before going offshore. VR is also another way to
practice emergency evacuation path from various parts of the site.

Digital
Twin

Virtual
Reality
(VR)

The plant model is a digital twin created from the actual plant 3D design drawings or by other means. The
process values can optionally be dynamically simulated from the process model. Plant work processes for
tasks are also built.

Consulting Services
The technology in the Plantweb digital ecosystem is complemented by Plantweb consultants, subject matter
experts supporting the digital transformation of how a plant is run and maintained.

Operational & IIoT Strategy

The operational certainty programme helps uncover latent needs and opportunities of each department in
the plant, set their goal and vision to change operating model to digital, how to justify the project, bringing the
project through the gate process, identify the business cases, and where to start, change management for
incorporating the digital technology in the daily work practices, upskill workforce competency, improve worker
productivity, and to train quicker etc.
• Safety consulting
• Reliability consulting: criticality ranking, maintenance record review
• Production consulting
• Energy consulting
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Plantweb Digital Ecosystem
• Justification
• Change management: rewriting work process, learning modules and completion, employee
communication, HR, establishing a digital culture – check the software first mindset of a digital
worker

Analytics & Architecture

Plantweb consultants help with the system design for the Digital Operational Infrastructure (DOI), developing
the digital roadmap master plan, implementing the initiatives in that roadmap, maintain a common
infrastructure across plants and departments:
• Wireless infrastructure: network architecture, network technology selection, gateway/access point
placement, backbone network, backhaul network
• Equipment scope: rank criticality, select assets and process units to be monitored
• Instrumenting: select sensors based on equipment failure or process upsets to predict
• Analytics solution: analytics technology selection
• Mobility solution: hardware selection, network technology selection, internet access, dashboard
design, notification alarm management strategy
• Security solution: network security for each network level, end-point security, software security,
cloud, security policies
• Connected services: selecting which asset classes will be monitored on-prem, from fleet
management center, or by third-party
• IT integration and cloud: historian integration, CMMS integration, ERP integration, internet access,
and workflow

Industry Expertise
Emerson automation solutions runs the foundational process control in plants across all industries around
the world. The subject matter expertise of Emerson engineers and industry consultants is unparalleled. Each
possess deep knowledge, in their specific industry which helps with digital transformation of business-critical
functions:
• Upstream oil & gas production • Marine
• Refining • Water & Wastewater
• Petrochemicals • Glass & Cement
• Chemicals • Textile & Fiber
• Mining & Metals • Pipelines
• Pulp & Paper • Waste & Remediation
• Pharmaceuticals / Life Sciences / Biotech • Semiconductors
• Power generation • Tobacco
• Food & Beverage

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Operational Excellence: Top Quartile Performance
As a result of digital transformation of how their plant is operated, built on the Plantweb digital ecosystem,
plants move from average or below average performance to top quartile performance. All the operational
departments benefit from digital transformation; meeting their KPIs and saving people’s time. As another
outcome, modern digital technology makes the plant a more attractive place to work for the new digital
generation of engineers.

Reliability and Maintenance

Digital transformation sets the stage for a data-driven, condition-based, more predictive maintenance culture
across the company, acting ahead of time for maintenance excellence. Condition-based maintenance results
in reduced scheduled downtime as turnarounds are shorter and further apart, and reduced unscheduled
downtime meaning greater availability; more days of production for greater revenue and faster deliveries.
Reduced repairs meaning lower maintenance cost. Extended equipment life meaning reduced replacement
expenditure. Improved maintainability. Greater integrity. A top quartile plant has lower maintenance cost than
an average plant. Automatic data collection and more effective maintenance and turnaround planning saves
people’s time.

Energy and Emissions

Lower energy consumption and flare reduction meaning lower energy cost and reduced CO2 emissions
(carbon footprint) towards greater sustainability and lower energy intensity. Automatic data collection and
reporting saves people’s time.

Safety and Compliance

Digital transformation drives safety excellence. Reduced man-hours in the field means fewer incidents.
Increased situational awareness for operators. Faster response time to incidents means faster attention by
medical care for speedy recovery. Reduced regulatory non-compliance with government directives and
mandates means fines are also avoided. More effective mustering. Automatic test recording saves people’s
time.

Production
Temperature profiles, batch analytics, and other improvements translate into less off-spec product (greater
yield) and higher product quality meaning more revenue. Automation of data collection, interpretation, and
other manual tasks means greater productivity allowing personnel to instead spend time acting on
information. Condition monitoring such as knowing the state of corrosion in your pipes or fouling of your heat
exchangers results in greater flexibility to accommodate new feedstocks such as opportunity crudes for
reduced cost. Better utilization of storage tanks and batch reactors etc. Greater operability. Access to
experts through Connected Services and telepresence means reduced travel and mobilization costs.
Automatic data collection saves people’s time and shrink the costs associated with fly-in, fly-out workers.

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Plantweb Digital Ecosystem
Digital Transformation Project Certainty Programme
Just like you want certainty of outcome when building a new plant, you also want confidence of success
when adding Digital Operational Infrastructure (DOI) to an existing plant for digital transformation.

Eliminate Cost
With Plantweb you don’t need to deploy a new or additional platform on top of the historian and ERP.
Instead, use the existing historian or control system as data platform – these systems are already
aggregating data from multiple underlying sources, or access the data direct from these sources through
OPC-UA. Since an additional platform is not required, deployment is much lower cost and it protects the
plant’s investment in these systems. Moreover, the high cost of maintaining such a platform with software
upgrades, security updates, and user management etc. is eliminated. Similarly, for Plantweb the predictive
analytics apps are readymade, no custom programming required. This again makes deployment very much
lower cost. Moreover, the ongoing cost of maintaining custom apps for new Windows versions, security fixes,
and other technology updates is dramatically reduced. Digital transformation us much less disruptive and
lower cost than mechanical and civil modifications. Digital transformation thus provides a fast Return On
Investment (ROI).

Reduce Complexity – Reducing Risk

By using the plant’s existing historian or control system as the platform instead of adding another middleware
platform the system becomes less complex, more elegant, and easier to deploy and maintain. This reduces
the risk of unforeseen challenges such as compatibility issues. Similarly, readymade software tested and
proven in many sites around the world across many industries eliminates the risk of unproven custom-made
software. Most hardware and software components were designed by Emerson to work together seamlessly
further reducing risk of compatibility issues.

Accommodate Change – Saving Time

Making changes to custom software requires custom programming and iterative testing which is costly and
time-consuming causing delays. Moreover, another challenge is that defining requirements for custom
software is notoriously difficult so there will always be a lot of changes. By instead using readymade software
these challenges are avoided. Moreover, since inputs from many other users are already incorporated, the
need for changes are much smaller. By using digital networking such as fieldbus and wireless instead of
hardwiring like 4-20 mA and on-off signals, changes and additions to sensors are easily accommodated.
Emerson make most of these components assuring deep in-house expertise that independent system
integrators cannot match. It is supported by permanent staff, not temporary project teams. Ready-made
software accommodate the specific plant through configuration settings; “parameterization”.

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Plantweb Digital Ecosystem
Digital Plant
Get your plant on the fast track to digital transformation with readymade software packages compatible with
your existing systems and platforms. By using readymade applications instead of custom software
programming, you are not paying for the costly software development process and long implementation
period associated with other analytics platforms, similar to ERP systems. Similarly, costly software
maintenance just for you is also avoided.

With a History of Digital Transformation

The original PlantWeb digital plant architecture was launched in 1996. It was the beginning of digital
transformation of how the plant is run and maintained, starting with introduction of digital fieldbus
instrumentation in place of analog 4-20 mA as well as software for Intelligent Device Management (IDM) for
instrument diagnostics, configuration, and calibration management. Users, independent of Emerson, on their
own accord, started to monitor the health of control valves on offshore platforms in Asia from their
headquarters in Europe across the Internet. This is an early instance of Industrial Internet of Things (IIoT)
although the term was not yet coined.

Over the years digital wireless instrumentation was added, as well as early essential asset monitoring
software applications.

Through the incorporation of solution partners and additional enabling technologies the new Plantweb digital
ecosystem was introduced in 2016, 20 years later, almost to the day.

Solution Partners
Emerson is collaborating with multiple partners to complete the Plantweb digital ecosystem

Major Partners

Microsoft Azure for cloud service, OSIsoft for PI-system integration, Cisco as preferred supplier for Wi-Fi
infrastructure, and Dell as preferred supplier for edge gateway computers.

Several other partners contribute to the Plantweb digital ecosystem making it suitable for a broad spectrum
of industries regardless of the control system or platform in the plant.

Enabling Technologies
The Plantweb digital ecosystem is built upon many digital technologies to enable digital transformation of the
many tasks involved in running and maintaining a plant. These technologies include HTML5, WirelessHART,
Wi-Fi, OPC-UA, FOUNDATION fieldbus, and Bluetooth etc. which are open standards enabling integration
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and interoperability with existing control systems and platforms and use of partner and third-party products
as part of the solutions. Future integration and changes also become much easier.

Expert Partnering
The future is digital. But don’t try to transform everything at once. Work out a phased approach to digital
transformation. An Emerson facilitator can conduct a digital transformation discovery session at your site to
uncover which departments and tasks in the plant have challenges and can benefit from digital
transformation. Emerson experts in the domains of reliability and maintenance, energy efficiency and loss
control, HS&E, integrity, regulatory compliance, and production etc. can advise the corresponding
departments in the plant.

Digital Transformation Strategy

Many companies have many sites globally and therefore need a corporate digital transformation strategy and
a corporate standard for Digital Operational Infrastructure (DOI) driven by the I&C team (“OT”) to prevent
departments from working silos and to ensure thoughtful implementations across sites and globally. IT
support comes in for L4 connection to ERP and CMMS for workflow etc. as well as for internet connection
(IT/OT collaboration). This includes corporate standards for digital sensor network infrastructure, wireless
plant network, OPC-UA software API, and location awareness etc.

Digital Transformation Journey

The steps to get started on digital transformation are already well established, used successfully by many
plants.

Operation
Visioning Establish Project Management
Design of Change and
Workshop Roadmap Execution
Evaluation

Visioning
Start with an operational certainty discovery session, brainstorming/ideation to identify operational
challenges, manual and paper-based practices, new opportunities, reviewing current performance to uncover
needs and envision the new digital plant and the new digital ways of working there, using design thinking and
agile methodologies to innovate. This visioning session is conducted in a meeting room environment, often
offsite such as at an Emerson solutions center, with operational departments including maintenance,
reliability, integrity, production, HS&E, process (energy), as well as the I&C department which owns the
digital operational infrastructure (DOI). The IT is department also involved for integration with ERP/CMMS
and cloud-based solutions.

Roadmap
Next establish a roadmap for the digital transformation. Think big, start small, scale fast. You can’t implement
all digital technologies at one go. Define the scope of the project. It would be too taxing on capital and
resources. Begin with a few applications in one area of the plant. Prioritize and target those that matter most,
bringing the greatest value. Each phase of the project is taken through the ‘gate’ approval process most
companies typically must justify investments with a business case and value proposition. Use readymade
solutions to challenges wherever available; solution mapping. New untested solutions can be co-created and
tested in a Proof of Concept. This may be unit by unit, and application by application. It may start with pump
vibration or steam trap monitoring. Over time the first pilot scales to other units and more applications
covering the entire plant. From a single site expand across multiple sites across a country or the globe. That
is, there may be multiple small concurrent projects ongoing in various stages driven by various departments
in various areas, but with a common goal.

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Office Wi-Fi Business Intelligence

Voice Recognition
Cloud Connection Video Conferencing
Social Media Analytics
Mobility Connection ERP Integration
IT Track CMMS integration
Video Analytics

Pervasive Networking Plant Wi-Fi

Pervasive Sensing Process Analytics 3D Scanning and Modelling
Location Awareness Augmented Reality Fleet Monitoring Center
I&C Historian Integration Virtual Reality Robotics
Equipment Analytics RFID Drones
Connected Services Wearable video

Phase 1 Phase 2 Phase 3

Rev D

Design
The design phase includes technology selection for network infrastructure, type of analytics, software
integration interfaces, and sensors etc. as well as establishing the overarching architecture including
cybersecurity, which all go into a Functional Design Specification (FDS). Design dashboards with real-time
indexes, KPI reports, and notifications. Site walk-down, with review of existing systems and sensors. Detail
design includes asset criticality ranking, asset selection, software, instrumentation requirements for the
equipment, and network infrastructure.

Project Execution
The deployment phase includes installation of wireless network infrastructure, installation and commissioning
of sensors on equipment, install the servers and software apps, configuration and baselining of apps,
integration with DCS and historian, building of dashboards, reports, and notifications, as well as integration
with ERP and CMMS where applicable.

Change Management
Changing workflows is the objective of digital transformation; to rewrite the work processes associated with
each role and duties, as automated manual tasks can now be eliminated. Along with this comes the change
management process changing the way people work to “check the software first” mindset. People
development through training for the new digital competencies required such as new best practices using
software and other digital tools is provided to let people experience and learn the new tools before they are
deployed for use. But most importantly, analytics and other software is purpose-built and therefore intuitive
and easy to use – there is no need to hire data scientists or acquire dramatically new skills.

Operation and Evaluation

Once the system is put into operation it is possible to measure the results of digital transformation. Certain
improvements such as reduced energy consumption and flaring is visible almost instantly. Other
improvements such as reduced equipment failures, incidents, and product defects become visible over time.
System administration shall be in place to maintain the software, network infrastructure, and sensors
throughout the life of the system.

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