Industrial Internet Big data
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1 Industrial Internet Big data Presenter: Mika Karaila Research manager Content: Johan Pensar Head of Industrial Internet Sakari Ruotsalainen President of Valmet Automation
2 Contents Concept and evolution to Industrial Internet Valmet as a frontrunner Big data in Industrial Internet Food for thought case examples 5 Summary
3 Concept and evolution to Industrial Internet
4 The concept of Industrial Internet By industrial internet we mean the integration of physical machinery with networked sensors and software. This enables gathering and analyzing data from machines and processes, and utilizing it to adjust operations and plan predictive maintenance to positively affect the value chain. The topic has many names: Industrial Internet Internet of Things Industry 4.0 Internet of Services Big Data 4 April 28, 2016 Valmet
5 Evolution to Industrial Internet Cross system impact Remote control and operations Cross-system optimization System of systems Data sharing and analytics between systems Network of systems Internet wide, deep analytics and business processes Monitoring and Control Product systems Plant-wide data collection and control Smart components Connectivity and intelligence Industrial Internet Components Mechanical function Impact on work Impact on industry Impact on society 5 April 28, 2016 Valmet
6 Valmet as a frontrunner
7 Valmet has a long history in the digitalization of process industries 1960 The Airmatic a pneumatic measurement and control system 1970 Elmatic-100 system, electronic instrumentation 1980 s Damatic, the first Distributed Control System (DCS) Sensodec Condition Monitoring System Damatic XD, modular second generation DCS 1990 s PaperIQ, QCS metsodna, Dynamic Network of Applications 2000 s Multivariable Model Predictive Controls (MPC) 24/7 ProCenter for DCS/QCS PaperIQ Select 2010 s Metso PQV web inspection system 2015 Valmet DNA 2015 Valmet IQ Advantages to customer industries: Distributing controls & gathering performance data Embedded intelligence & advanced information Increasing availability Increasing productivity through information services Benchmarking and best practice sharing capability 7 April 28, 2016 Valmet
8 Today, customers are extensively utilizing our Industrial Internet capabilities Valmet s competence network Customer s process Valmet s remote center Ongoing Valmet-supplied lines with Valmet DCS Condition Monitoring (CM) references with over I/O tags Advanced process control installations Online connections Performance agreements with remote connections Co-creation of advanced analytics with customers 8 April 28, 2016 Valmet
9 We have moved our customers performance forward with Industrial Internet Case examples Reduced energy consumption 8% Metsä Board Joutseno Mill, Finland Raw material savings (0.45%) USD 1.55 million Celulose Nipo-Brasileira AB Cenibra, Brazil Chemical savings 8.7% Burgo Ardennes, Belgium Production increase of 2.8% Zellstoff- und Papierfabrik Rosenthal, Germany 9 April 28, 2016 Valmet
10 16% energy savings with data analysis Case: Siam Kraft Industry PM16, Thailand Recycled fluting machine Basis weight g/m 2 Design speed m/min Trim width mm Start-up April, 2016 Valmet
11 Energy efficiency improvement right from start-up Case: Siam Kraft Industry PM16, Thailand Electricity consumption reduction from 230 kwh/t to 200 kwh/t Steam consumption reduction from 1,55 t/t to 1,25 t/t Oct 2014 Feb 2015 Corrugating medium grade A105g/m 2 Oct 2014 Feb 2015 Total Saving (eur/a) 3 M April, 2016 Valmet
12 Big data in Industrial Internet
13 Big Local factory site: Over measurements Many thousands of motors Typical execution ms Big Data Paper quality vision: Video stream 40GB/s All data stored local databases. 13 April 28, 2016 Valmet
14 Big Cloud storage: Aggregated min/max & average Compressed transfer ~ 1GB/day/factory site Data needed in analytics collected & stored. Big Data 14 April 28, 2016 Valmet
15 Some practical numbers Small, standalone devices: Few hundred bytes of data/min 100 MB/month Big Data Paper machine analytics: 1.3 GB/day 40 GB/month 15 April 28, 2016 Valmet
16 Today, we serve our customers with intelligent technology, automation and services locally and remotely Fully automated, intelligent machines with connectivity for Industrial Internet The Valmet DNA automation platform connects instruments, analyzers, vision systems and process controls Advanced Process Control enables real time optimization of core processes Customer Expert support locally and through remote services Performance optimization and support agreements 16 April 28, 2016 Valmet
17 we enhance mobility and introduce even more advanced automation technologies and embedded diagnostics Growing fleet of intelligent machines and mills leveraged More diagnostics embedded into processes Next generation analytics introduced to selected processes Customer Valmet DNA evolves to include virtual and cloud-based applications and services Integrated customer portal and mobility enable secure access to all information and expertise anytime and anywhere Advanced benchmarking and best practice sharing tools 17 April 28, 2016 Valmet
18 Food for thought - case examples
19 Path analysis of paper machine events Problem fingerprint Using tree-event paths (sequence of three events) Top 200 three-event-paths leading to unplanned shutdown First time occurrence Event A, Event B, Event C Second time occurrence Event A, Event B, Event C And 200 predicting no-shutdown (normal operation) 5:35 AM Guide roll 4 torque from low to normal 5:35 AM Guide roll 5 torque from low to normal 5:40 AM Nip 2 edge temp DS from normal to high Triplet reoccurance 5 times ~6:15 AM ~7:00 AM Triplet reoccurance 15 times 3 h 20 min 9:35 AM Unplanned shut down April, 2016 Valmet
20 Valmet s on-call services relating to Valmet DNA automation system Calls routed through call center 24/7 Remote connection utilized for troubleshooting 92% of the calls are solved without site visit April, 2016 Valmet
21 Valmet s predictive roll-cover analysis Roll cover lifetime modelled using big data and predicting future behaviour Operational parameters can be optimized to minimize roll-cover costs How many running days remaining? Can lifetime be extended? Critical Vibration Level 10 days Lifetime with alternative component? 5 days 5 days Critical part lifetime (days) April, 2016 Valmet
22 Valmet s remote diagnostic, reporting and alarming of analyzers Challenge Geographically distributed in large area One person is responsible of a large fleet Our Solution Analyzer data replicated in a central location. Remote diagnostics on demand Software updates and configuration remotely. Fleet performance can be compared and analyzed with one set of tools Results Helps maintenance personnel prioritize work Faster reaction time on unexpected disturbance cases Improves the service level and availability April, 2016 Valmet
23 Summary
24 Summary Valmet is a frontrunner in Industrial Internet Our intelligent production technologies, long experience in the digitalization of the process industry through our automation business and services expertise create a solid foundation for the industrial internet. Today, our customers are extensively utilizing our industrial internet capabilities and achieved significant performance improvements We are further strengthening the utilization of industrial internet by: Providing expertise globally using remote technologies Utilizing and developing our unique automation technology and innovations Developing the next generation of analytics and services 24 April 28, 2016 Valmet Some images designed by freepic.com
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