ARC report confirms ABB continuing DCS market dominance

ARC Advisory Group is one of those typically American consultancy organisations that produces reports describing technology trends and competitive analyses that are then sold to the suppliers in the industry. Undoubtedly they are also employed to produce specific reports at the request of single specific clients, but the main reports publicised for public sale are the overall market surveys. Without paying a lot of money, the general public don’t get to see these.

All the data from the reports is generalised, and as ever, subject to interpretation, so hopefully each client can find something that reinforces his optimism about his company’s place in the market. So they are essential sources of backup data for Board presentations and the like.

The ARC DCS market study

The recent ARC report on the “Distributed Control Systems Global Market 2016-2021” report provided ABB with sufficient confidence to issue a Press Release stating that the ARC had confirmed ABB to be the ‘#1 supplier of Distributed Control Systems Globally’, with a 20% market share ‘across industries’, making ABB the leader of ‘digitally enabled control and automation’. This is a continuation of the position they have held according to ARC since 1999.

Peter Terwiesch, President of the ABB Industrial Automation division echoed these findings: “With our installed base of over 70 million connected devices and 70,000 control systems, and an annual investment of $1.5 billion in research and development, ABB is leading the digital transformation of industry.”

Such reports and statistics were the bread and butter, and even the honey, for the reports written for the Industrial Automation Insider newsletter that your editor produced from 2010 to 2015. The focus for such a report would have been that with at most seven major suppliers competing for the top slot, a 20% market share would imply the dominance margin is (still) fairly slim!

The ARC report provides a competitive analysis of the market shares of leading suppliers by geographical region, and broken down into eleven major industry groups, as well as equipment type, project size and style. The ABB release specifically mentions the ABB activity as delivering sustainable progress for power, water and process industries.

The ABB Profile

More interesting in many ways were the specific project examples picked out by ABB as the prime examples of their expertise in several sectors, viz:

“ABB’s leadership in DCS stems from countless ground-breaking projects around the globe. ABB Ability System 800xA plays a key role in securing the success for Sadara, the world’s largest chemicals complex built in a single phase. The monitoring and automating of the entire production process is fully integrated with System 800xA, all coming together in 18 control systems and 260 operator work stations. The integration capabilities also helped the Garpenberg mine to become one of the world’s most cost-effective and modern mines in the world. Hoists, mill drives, ventilation, dewatering, substations, conveyors, crushers, ore storage, and maintenance, as well as document management and communications are seamlessly integrated to the automation system. Very recently Emami Cement has chosen System 800xA to automate its new production plant which will help boost infrastructure growth in India.

“ABB Ability Symphony Plus is, for example, the core solution for integrating new emission control technology at a power plant in Wisconsin, US; for protecting the UNESCO World Heritage site of Venice, Italy from high water by controlling the city’s MOSE flood barrier system; for providing the automation and electrification solution for Adani, the world’s largest solar power plant in a single location, in Kamuthi India; and for enabling the Vietnamese utility Saigon Water Corporation (SAWACO) to control and operate its infrastructure in real time, significantly reducing the amount of non-revenue water.”

Walt Boyes has expanded on this report in the December issue of the Industrial Automation INSIDER, which was published on 11 January 2018.

 

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Diabetes plant for Novo Nordisk chooses Emerson

Another Novo Nordisk greenfield pharmaceutical project has chosen Emerson Automation Solutions to achieve a fast project start-up: this Emerson release gives the following information.

Emerson advises: “Global healthcare company Novo Nordisk has awarded Emerson a $40 million automation systems and services contract for a new US-based drug manufacturing facility to help battle the global diabetes epidemic. The largest project in its history, Novo Nordisk’s new $2 billion plant in Clayton, North Carolina, will leverage Emerson Project Certainty methodologies and automation technologies to help ensure the plant achieves a tight project construction schedule to meet a construction target of 2020.

The new 825,000-square-foot production facility will help the Danish drug company increase manufacturing capacity and meet its goal of doubling production of diabetes drugs over the next decade. According to the Centres for Disease Control and Prevention, more than 29 million Americans are living with diabetes, with another 86 million living with prediabetes.

“Our extensive experience in the life sciences industry and integrated offering for capital projects and automation perfectly positions us to help Novo Nordisk deliver its largest project in history,” said Mike Train, executive president, Emerson Automation Solutions. “Together we can design and deliver this world-class manufacturing facility to be ready on time, and to quickly deliver these important diabetes medicines.”

Novo Nordisk will implement elements of the Emerson Project Certainty approach to help reduce project complexity and achieve the tight project schedule. This transformational approach leverages automation technology, which serves as a central nervous system in a plant, and new methodologies, to reduce costs and complexity and accommodate late-stage project changes.

Novo Nordisk selected Emerson’s integrated portfolio of automation technologies and services, including its DeltaV distributed control system (DCS) and Syncade manufacturing execution system (MES). Emerson will also provide smart automation technologies including valves and measurement instrumentation.”

ABB automation increases capacity 10x for Tate & Lyle food additive plant

When Tate & Lyle acquired Biovelop, a Swedish manufacturer of oat based food ingredients in 2013, the factory in Kimstad, Sweden was modernized and expanded by installing automation systems, variable speed drives, motors, motor control cabinets  and valve positioners from ABB Automation. In 2016 the remodeled plant celebrated the first anniversary of operations with the new systems and significantly increased production capacity.

The global market for specialty food ingredients, including health and wellness products, is growing, with annual sales of $51 billion and annual growth rate of 4-5%. Oat ingredients have been actively involved with this trend as they offer some key nutritional and functional benefits. In particular, oat contains beta glucan, a soluble fiber that has been shown to lower cholesterol and reduce post prandial glycaemic response – claims that have been approved by the European Food Safety Authority (EFSA). In fact, it was these properties of the grain that made the sector an attractive one to Tate & Lyle, and triggered the decision to diversify its portfolio into this sector.

“We have seen a more than tenfold increase in capacity with the same number of shift operators compared to four years ago,” said Annika Werneman, Tate & Lyle plant manager. “It’s a huge change in such a short time, and it means that we’ve gone from a low-level facility to one that can deliver high quality product to our customers globally.”

Advanced automation technologies in the plant run critical food processing equipment -including pumps and decanters: material handling machinery is also used to transport the dry food products. ABB delivered automation equipment that included 85 variable speed drives (VSDs), with power ratings ranging from 0.37 kW to 55 kW, as well as ABB MNS 3.0 motor control cabinets and low voltage motors. ABB also delivered 44 Digital Electro pneumatic positioners (TZID-C) , which use the Hart protocol to communicate with the control valves.

“We needed a process that was highly automated and could run 24 hours, seven days a week, all year long,” Werneman continued. This meant building a system that enabled Tate & Lyle engineers to digitally interact with the system, commission (start) devices, and diagnose performance deviations or failures from anywhere in the world. This not only helps ensure operational consistency, but also reduce the total cost of ownership by enabling staff to manage the processes without being physically present at each site.

Such interactivity was enabled by the ABB fieldbus automation for the drive controls, providing flexibility as well as remote monitoring of the plant performance. “I like that ABB designed the system so that the fieldbus responsible for device control is split from the fieldbus used for asset management,” explained Leo Dijkstra, power & controls team leader Europe at Tate & Lyle. “This ensures that I can make any changes to the configuration of the devices without the risk of the whole network going down.”

At Tate & Lyle, they place great importance not just on what they do, but how they do it. “We are working continuously wherever we can to reduce the environmental footprint of our operations,” said Dijkstra. ABB was well placed to help as it has developed a portfolio of products and solutions that improve industrial energy efficiency.

“In our pump applications alone, we are using up to 50 percent less energy thanks to the variable speed drives, and these have been running non-stop for the last two years without a single failure,” Dijkstra continued. “What’s more, ABB was so quick to deliver products that we even had the first VSD delivered in just a few days.”

Although the nearest ABB support is only a ten-minute drive away from the Kimstad factory, the fieldbus flexibilities in the drives enable Tate & Lyle to rely on its own staff to handle the ABB equipment remotely. “Our work with Tate & Lyle illustrates the benefits of digitization, which can yield immense productivity and output gains from existing facilities,” said Petter Hollertz, area sales manager at ABB. “The improvements at this plant also show what great teamwork between the equipment supplier and the user can accomplish, as we worked together as true partners on this project.”

600,000 flowmeters measure beer and lager flow

Titan Enterprises has established a long-standing working relationship with Vianet plc (formerly Brulines) for the supply of beer flowmeters for pub and bar automation projects. Over the last 20 year period Titan have delivered, and Vianet has installed, over 600,000 of these meters for beer and other bar flow measurement and automation applications.

Brulines, was formed in 1993 with the intention of providing pub chain owners with data on their bar activity via an electronic point of sale (EPOS) system. After trialling several other flowmeters, the company sought a solution to resolve flowmeter bearing lifespan problems and to overcome the unreliability of the optical detection method in beer.

beer-meter

The beer flowmeter

Following a collaborative approach to developing the solutions needed for the Vianet customer base, Titan Enterprises proposed an adapted version of its 800-series turbine flowmeter as the design included durable sapphire bearings proven reliable for many thousand hours operation, and a Hall effect detector which was not subject to problems with discolouration inside the pipe. After successful tests, a trial order for 400 units was placed in 1997, which after the subsequent field trials, was followed by an order for >5000 meters which were all delivered to the clients required timescales.

To ensure the flowmeter was ‘fit for purpose’, Titan additionally adapted the cable type as well as the body and increased the length to 10 metres. These adaptions enabled Brulines installations to be maintained in beer cellars with differing wire runs to the control panel without any junction boxes.

Twenty Years of Collaboration

With the widespread reliability of this product, Vianet turned again to Titan Enterprises in 1999 to develop for them an “intelligent” flowmeter (IFM) for their enhanced iDraught retail product. The specification for the IFM required that it should additionally measure temperature as well as determining the type of fluid in the line to detect line cleaning cycles which are essential for the dispensing of a good pint.

At the time, Titan did not have the technology to provide sensing electronics at a reasonable price so we produced a revised version of the beer flowmeter with the capability of being matched to a PCB designed, manufactured and installed by a third party.

After trialling and testing, this new IFM was introduced in June 2000 and supplied to Vianet at the rate of up to 3500 units a week. Mark Fewster, product manager at Vianet commented “Titan’s supply chain has always delivered to our quality and timescale needs”.

IoT Developments

ifm latest

An intelligent flowmeter design

Since this first IFM introduction, close collaboration between the two parties has resulted in 5 iterations of the product with revised features as end user requirements have developed and evolved with the growth of the IOT (Internet of Things). Drawing upon this close working relationship, over a long period of time, Titan continue to work with Vianet on new solutions and offerings as the Vianet customer offering further develops.

This Titan Enterprises application story is based on a report in the Autumn issue of Flowdown, the regular news bulletin published by Trevor Forster, MD of Titan, from their Dorset, UK base.

Yokogawa EPMS and SCADA for the UK’s BPAL pipeline system

Yokogawa has received an order from the British Pipeline Agency Limited (BPAL) to supply a management and control system for one of the UK’s major multi-product fuel pipeline systems, to replace the current BPAL pipeline management and SCADA systems.

The BPAL UK pipeline system consists of three integrated multi-product fuel pipelines that link two, refineries, one at Ellesmere port on the Mersey near Liverpool and the other on the Thames in Essex, to inland distribution terminals. These pipelines, operational since 1969, meet over 50% of the jet fuel needs at London’s Heathrow and Gatwick airports, and are altogether some 650 km in length. BPAL, jointly owned by Shell and BP, are the operators of these pipeline systems (known as UKOP and WLWG), which are owned by a consortium of partners.

This order is for Yokogawa’s Enterprise Pipeline Management Solution (EPMS), which will manage functions such as delivery scheduling and oil storage, and their Fast-Tools SCADA software, to monitor and control the oil pipelines and related equipment such as compressors. The EPMS uses specific gas and liquid applications that enable a pipeline operator to manage delivery contracts in a time and energy efficient manner. With the SCADA system covering monitoring and control, the EPMS will integrate the management of the SCADA data. Delivery of these systems will be completed by March 2018.

Further order for UAE Power and Desalination Station

Yokogawa also recently received its first ever DCS order for a power and desalination plant in the UAE. The company is to supply the Sharjah Electricity & Water Authority (SEWA) with control and safety systems, plus field equipment, for Units 7 and 8 at the Layyah Power and Desalination Station.

Each unit comprises a 75 MW oil and gas-fired thermal power plant and a 27,000 m3 per day multi-stage flash (MSF) desalination plant: a technology that involves the heating and evaporation of seawater in multiple vacuum distillation tanks to produce steam, which is then condensed to produce fresh water. Such systems are energy-efficient because they use the heat from the steam that is created in the vacuum distillation tanks.

Yokogawa Middle East & Africa will deliver the CentumVP integrated production control system for the boiler, turbine governor, turbine protection system and the desalination plant at each of these units, as well as the ProSafe-RS safety instrumented system for burner management and boiler protection. The field instruments will include Yokogawa products such as the DPharp EJA series differential pressure and pressure transmitters, continuous emission monitoring systems (CEMS), and steam and water analysis systems (SWAS). In addition to being responsible for engineering, the company will provide support for the installation and commissioning of these systems, with all work scheduled for completion by September 2017.

Demand for electricity and water is soaring throughout the Middle East due to their rapid economic growth. Power and desalination plants that rely on the region’s abundant oil and gas resources make up an important part of this region’s infrastructure.

Yokogawa invests in IIOT cybersecurity

Yokogawa has made some significant investments in the resources needed to develop future techniques for IIOT cybersecurity, first with a new engineering centre to be established in California, and second, by investing US$900,000 into Bayshore Networks, as a partner in a current round of venture capital funding.

New IIOT Division

The new Yokogawa Architecture Development Division in California will pursue the development of the core technologies needed to establish the robust and flexible architecture required to improve operational efficiency and productivity when using the IIoT. The new division will function as a unit of the Yokogawa Marketing Headquarters Business Development Centre, and will keep up with the new technologies being developed every day in the IIoT sector – as well as facilitate close co-ordination with partner companies. The West Coast of the USA is therefore the correct location for this work. The division will be staffed by engineers from Yokogawa who have an extensive knowledge of Yokogawa systems and services, and locally recruited engineers who are conversant in a range of IT fields. The first employees of the division have been located at the local engineering office of a partner company since November 2016, but their own offices are scheduled to open in April 2017. Subsequently, the division will add functions for planning services that use the IIoT and cloud computing, and it is expected that the number of staff will be increased to around 50 over the next five years.

Investment in Bayshore

A parallel press release from Yokogawa explains that there has also been a $900k strategic equity investment into Bayshore Networks, a company established in 2012 that has gained rapid recognition for its expertise in cybersecurity.

Mike Dager, CEO of Bayshore, commented “Yokogawa shares our vision for a secure industrial internet of things enabling new applications that will increase safety, optimize processes, and drive efficiencies. We are proud and excited to partner with such a renowned global leader in industrial controls.”

This Yokogawa investment is part of the recent US$6.6M Series A funding for Bayshore, arranged by Trident Capital Cybersecurity, and its existing angel investors.

Trident Capital

Trident Capital Cybersecurity is a venture capital firm that invests in early-stage companies leveraging emerging technologies in cybersecurity. The firm is a spinout of (or maybe the successor to) Trident Capital, which in 1998 became one of the pioneers of cybersecurity venture capital investing. Renowned as the venture capital firm with the most valuable network of cybersecurity relationships, Trident Capital Cybersecurity also relies on input from a 40–person Cybersecurity Advisory Council, consisting of industry CEOs, customers and former top-level government leaders.

“We led the Series A Investment because Bayshore has been recognized as an innovator and early leader in an emerging cybersecurity segment that is largely untapped to date,” said J. Alberto Yépez, managing director of Trident Capital Cybersecurity. “We are honoured to have Yokogawa join us in supporting the development of the cutting-edge Bayshore technology and business.”

The Trident Capital Cybersecurity website claims 28 cybersecurity investments and 16 successful exits. These have included the Solera acquisition by BlueCoat in 2013, the Qualys IPO in 2012, the acquisition of Accertify by American Express in 2010, the Sygate acquisition by Symantec in 2006 and the Signio acquisition by VeriSign in 2000.

The Bayshore technology

The Bayshore cloud-based software, called the Bayshore IT/OT Gateway, provides IT departments with visibility into OT (Operational Technology) infrastructure, networks, applications, machines and workers.  These OT networks are undergoing transformation and require services traditionally available for IT networks, such as secure remote access and analytics. Bayshore provides immediate value by preventing OT process disruptions and enhancing operational efficiency and business continuity.   The software is distinguished by extremely granular inspection and filtering of network flows – all the way down to machine sensor values – and the ability to provide security enforcement and application segmentation and isolation via flexible, rapidly deployed policies.  The Bayshore policy engine is capable of supporting common industrial protocols and quickly adapting to new and proprietary protocols.

These capabilities are built from the ground up for Industrial Internet and provide Bayshore customers with future-proof, cloud-based solutions that are complementary to legacy hardware-based industrial firewalls. Designed for IT perimeter security, firewalls look for IP addresses and ports, which means they block attacks according to standard Internet parameters.  Because industrial cyber-attacks are typically based on granular machine instructions that alter sensor values, the unique Bayshore technology is well positioned to detect industrial attacks that are often overlooked by other security technologies.

Bayshore has strategic alliances with leading technology companies including AT&T, BAE Systems, Cisco Systems, and VMware. It is currently based in New York, but intends to relocate the HQ to Bethesda, Maryland. No engineering base is quoted as existing in California.

2017 Business plan comes together

satoru-kurosu-med

Earlier, Yokogawa had announced the completion of the acquisition of Soteica Visual Mesa (SVM), the leading energy management technology provider, which will be integrated into KBC Advanced Technologies (acquired in April 2016) alongside “Data as a Service” (DaaS) provider Industrial Knowledge (acquired December 2015). Satoru Kurosu, executive vice president and head of Yokogawa’s Solutions Service Business Headquarters, commented that these moves delivered on a number of the key objectives of the Yokogawa Transformation 2017 mid-term business plan: “Key strategic objectives of Yokogawa’s Transformation 2017 plan are to expand the solution service business, focus on customers, and co-create new value with customers through innovative technologies and services.”

(c) ProcessingTalk

The latest Robots are Friendly

We all know what a robot is. But then it really does depend on whether you immediately think of them in ‘sci-fi’ films, or paint spray booths, or welding on automotive production lines, or stacking in automated warehouses. These have been the big applications, in big automated factories, with around 240,000 robots sold last year. The article below was for a column published in the November issue of South African Instrumentation & Control, see a digital copy on http://www.instrumentation.co.za/archives.aspx

The emergence of the cobot supplier

However, there is a new breed of robot now: collaborative robots, or cobots, have only really emerged as practical devices in the current decade. A cobot is a robot that is intended physically to interact with humans in a shared workspace, so the special pens and protective light curtains around the robot operating area are gone. The cobot is designed to work alongside a human operator, typically maybe lifting the heavier items involved in electronic device assembly operations: it has smooth surfaces with no sharp edges, and protected joints, so a human working alongside cannot trap their fingers, plus it stops at the slightest external touch.

Additionally, the cobot is flexible, it can be trained (taught) by the assembly operator, by guiding its arms and grippers to show it what to do. Currently the cobot market is around 5% of the total, $100 m last year. These robots are lower in cost, say $24,000 each, but are aimed at the small to medium sized companies that account for 70% of global manufacturing, where flexibility is essential. New international standards for their safe design and use are emerging, and there are many suppliers, as the market is forecast to be $1Bn by 2020.

ABB’s YuMi

yumi-robot

One such product is the ABB YuMi (‘you-me’) desk-top robot: a dual-arm small parts assembly robot that has flexible hands, incorporates parts feeding systems, camera-based part location and automated control: yet it has twice the reach and more strength than an operator. It can collaborate, side-by-side (or across the bench), with humans in a normal manufacturing environment, enabling companies to get the best of both humans and robots, working together.

In April, the ABB YuMi was recognised for outstanding achievements in commercialising innovative robot technology with the prestigious Invention and Entrepreneurship Award at the Automatica trade fair in Munich. There followed a Golden Finger award as ‘one of the best industrial robots of 2016’ at the China International Robot Show in Shanghai. One out of every four robots sold today is sold in China, which is the world’s leading robotics growth market: 68 000 units were sold there in 2015, 17% up on 2014.

YuMi was specifically designed to help consumer electronics meet the challenges produced by the need for customised personal electronics products, by enabling operators and cobots to share tasks, with easy training when the task changes. The YuMi appears to be targeted at the assembly operations common with electronic equipment, significantly in Southeast Asia.

Universal Robots – another successful start-up.

Universal Robots (UR) was formed in Odense, Denmark in 2005, with the goal of making robot technology accessible to small and medium-sized enterprises. It introduced its first cobot in 2008, and particularly focused on food industry applications, with 3,5 and 10 kg payload cobots. Their average payback period of 195 days for customers is claimed as the fastest in the industry.

Recently its cobot arms have been awarded certification for use in clean room applications, so UR robots can now be used in areas where purity and hygiene – such as particle emission, easy-to-clean surfaces and extreme reliability – are decisive criteria for precise automation processes. This opens up more applications in the food industry, in the production of microchips and semiconductors, and in the electrical and optoelectronic industries.

At the end of 2014, more than 3500 UR robots were installed worldwide: currently they claim the figure is 6000 – annual sales maybe growing x2,5 in just over a year. Mercedes-Benz has replaced old robots with humans on some lines, to better manage customised products. They are moving to having production workers guiding a part automatic robot. Scientists at MIT, working with BMW, have found that robot-human teams can be about 85% more productive than either of them, alone. Subsequently Universal Robots were rated #25 on the MIT Technology Review’s list of the world’s 50 smartest companies: Teradyne Inc then acquired UR for $285 m in 2015.