System integrators play a critical role in implementing manufacturers' process automation and digitalization goals. As vendor-agnostic experts with proficiency across multiple hardware and software platforms, they are uniquely qualified to integrate the diverse technologies common in industrial manufacturing facilities.
There are many advantages to utilizing system integrators for complex multi-platform control system integration and digitalization projects. Several project examples include integrating programmable logic controllers (PLCs) into a larger distributed control system (DCS), linking Industrial Internet of Things (IIoT) sensors with DCS, implementing cloud storage solutions and connecting advanced data analysis platforms for predictive maintenance and advanced process control.
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With a majority of manufacturers highlighting smart manufacturing as an important contributor to competitive advantage within the next five years, it is clear that the adoption of advanced integration technologies and Industry 4.0 tools is a widespread priority. Smart manufacturing requires the integration of wide-ranging facility data sources into a consolidated system. Integration goals include safer operations, increased operational visibility and improvements in process and personnel efficiency, as well as increased uptime.
Process data is available from every PLC, IIoT device, human-machine interface (HMI) and various other monitoring systems. This data drives the smart-manufacturing tools that generate key insights into a facility’s operation. However, due to the current state of most manufacturing facilities, which typically include legacy systems, equipment from multiple vendors and other incompatibility issues, obtaining data in a usable way can be challenging. This can leave a large percentage of available process data stranded in the field, invisible to the control room operator.
Because system integrators specialize in bringing together disparate hardware and software systems, they are particularly well-suited to guiding manufacturers through the process of connecting and implementing smart manufacturing solutions.
Benefits of a fully integrated facility
System integration for digitalization involves making facility data available and usable across the organization. By pulling together data from wide-ranging sources, high-level insights can be more readily drawn that may otherwise go unnoticed. At the operation level, real-time process data provides visibility into the current state of an operation. This data can also be used to adjust process parameters to improve product quality.
Troubleshooting is simplified because the underlying problem is easier to find and address. Collected over a longer period of time, process data can be analyzed to identify long-term trends and patterns, shedding light on specific areas for improvement and informing strategic planning. Likewise, equipment data provides insight into the condition and performance of machinery, allowing a manufacturer to tailor the maintenance program based on the actual state of the equipment, rather than based on a rigid schedule.
System support
Most system integrators are vendor-agnostic. They have a broad range of expertise with multiple hardware and software platforms and can help industrial operators bridge gaps between disparate, incompatible systems and technologies. Integrators specialize in assessing existing infrastructure and identifying the best pathway to digitalization while taking full responsibility for the project scope. Although they often have particular system platform specialties and experience, system integrators are generally not owned by control-system suppliers. This allows them to remain vendor-neutral. Lastly, most system integrators are not geographically restricted, enabling them to support projects across diverse locations.
System integrators in action
Automation integration and Industry 4.0 initiatives are commonly performed by system integrators. These integration projects require a holistic understanding of the systems involved and a strong grasp of cybersecurity concerns to ensure effective implementation.
The wide breadth of knowledge possessed by system integrators can facilitate the integration of diverse types of equipment and platforms, most often from multiple vendors.
Example 1: Connecting a PLC to a larger DCS
Connecting a PLC to a larger DCS most often involves integrating a primary DCS with one or more PLCs that manage auxiliary systems, often found within skid-mounted equipment. Historically, it was common for the communication between the DCS and PLC to have been limited to hardwired status signals, but this means control-room operators, engineers looking at history trends and artificial-intelligence (AI)/machine-learning (ML) applications only have a partial view into the plant’s processes. This can significantly hinder speed and accuracy in decision-making at all levels of an organization.
In many facilities, much of the process data may be derived from these auxiliary PLC platforms. Depending on the age of the PLCs involved, the communication protocol may use newer Ethernet-based protocols like Modbus TCP, EtherNet/IP, Profinet or OPC or use older serial Modbus or Profibus.
System integrators are prepared to execute this type of integration due to their cross-platform expertise and understanding of the operational interdependencies between these control systems. They readily take the necessary holistic approach to blend different platforms and technologies for optimized system functionality successfully.
For example, a refinery integrated both a PLC and safety instrumented system (SIS) into its main DCS. The refinery wanted the DCS to have comprehensive visibility and control of these systems so that both process control and operational data from the PLC and safety system data from the SIS were available within the higher-level DCS.
This work was accomplished in a staged environment, allowing engineers to integrate and fully test the control systems to ensure proper communication and coordination. A factory acceptance test (FAT) verified the functionality of the systems before being shipped to the facility for installation and startup.
Example 2: Cloud and external applications
Integration projects involving cloud and external applications allow manufacturers to take advantage of cloud server architectures and specialty cloud-based applications. They also allow manufacturers to transfer IT-related responsibilities to the cloud service provider, reducing their own IT burden. Cloud applications in the process control domain are often hybrid, with most control and first-level monitoring and data collection remaining on-premise (Figure 1).
Cloud server architectures, accessible over the internet, provide users with customizable and scalable processing capabilities and storage. Businesses can transition to the cloud using a “lift and shift” methodology, where existing on-site server images are transferred to the cloud-hosted environment, allowing quick access to the benefits of cloud computing.
Specialty cloud services often provide powerful processing capabilities using AI and ML algorithms. These tools are designed to analyze large volumes of operational and business data to offer novel insights that would otherwise be unavailable to the manufacturer, primarily due to limitations in local computing resources. However, for these applications to be effective, they require access to relevant, high-quality data.
Implementing these tools involves not only understanding what data is needed, but also how to collect it from various sources across the operation and securely connect it to the cloud service, while also addressing cybersecurity concerns.
An increasing number of process historians now support native cloud deployment, allowing them to operate directly within a cloud environment rather than from on-site servers. Again, this structure not only improves enterprise-wide data accessibility and reduces onsite hardware requirements, but also simplifies data management.
A chemicals company recently installed a hybrid private cloud solution where a small site became a remote data collection source for a historian server located at a larger site. A data buffering and connectivity application was installed at the smaller site, which fed data via the corporate wide area network (WAN) to the historian server. This reduced overall installation costs—hardware and services—and the simplified architecture will reduce long-term maintenance requirements.
A specialty manufacturer used a third-party cloud AI service provider to pull data from the site-based process historian through a secure portal. The AI provider was then able to provide process analysis using both data scientists and AI to offer enhanced insights into process irregularities and inefficiencies.
Example 3: DCS and IIoT smart devices
The integration of DCS with IIoT smart devices is increasingly common, driven by the growing prevalence of smart devices and advanced IIoT platforms. Integration projects may incorporate stranded data from existing unconnected devices or capture data from new instrument devices operating outside of the DCS environment.
This work may involve connecting dozens or even hundreds of diverse devices: sensors, actuators, control boards. Many of them are battery-powered and utilize various wired or wireless communication technologies including message queuing telemetry transport (MQTT), Bluetooth, Wi-Fi, WirelessHART, 5G, OPC or Modbus TCP. Each device typically has low data rates and volumes, presenting challenges in data aggregation and interpretation.
The integration of DCS with IIoT smart devices and platforms presents several challenges that are best addressed using the broad expertise of system integrators. For example, differences in communication protocols between the DCS and IIoT platforms may require gateway cards for communication. Middleware or application programming interfaces (APIs) may be required for data flow between these systems. Although there is complexity involved in the process, the benefits of increased data visibility and usability make the effort worthwhile.
A facility installed a wireless vibration monitoring system to monitor motors (Figure 2). The system used wireless sensors set up through a smartphone app and connected to a local gateway device. The gateway then retransmitted the sensor readings through the existing wireless infrastructure to the cloud-hosted environment for data analysis, trends, and alerts.
The system was particularly useful for motors that were otherwise hard to access for routine inspection because of their mounting locations. While this particular setting may seem unique, the practicality and usefulness are widely applicable.
System integration for digitalization
While the goal of system integration for digitalization within industrial manufacturing facilities may seem daunting, it is attainable. Because of wide-ranging, holistic knowledge and expertise in many diverse technologies, system integrators are positioned to connect disparate systems within a facility.
