PTQ Q4 2022 Issue

Demystifying digital transformation

How to automate and optimise operational processes using technology

Jason Maderic and Mike Howells Emerson

I n process manufacturing, high volumes of oil, gas or chemicals are moved every day. Maintaining the actua- tion of process valves that control fluids and gases is at the centre of a plant’s performance. Unmeasured param- eters or unknown anomalies can compromise the valve package, resulting in catastrophic failure. If critical process valves and actuators fail, refineries will suffer unplanned shutdowns with millions of dollars lost each day. To pro- tect the area and maintain uptime, knowing the condition of assets, systems, and equipment is highly critical. Yet, many plants do not have ways to monitor and mea- sure asset health, or, if they do, they are often ineffective and subject workers to hazardous environments. Without a clear picture of asset health, plants often have one of two ineffi - cient approaches to maintenance. For some, service is time- based and performed in a fixed cycle or at a periodic interval. Others are reactive, running machines until components fail, then making repairs. Both have high operations and mainte- nance costs and a high frequency of unplanned downtime. There is also a third, proactive option. Technology is available that enables operators to see the real-time health and condition of their assets remotely so they can make informed, proactive decisions that maintain the valve pack- age and minimise unplanned downtime. Through digital transformation, refineries can use this technology to auto - mate and optimise operational processes to keep processes running as long as possible and personnel safe ( Figure 1 ). Benefits of digital transformation To some, the term ‘digital transformation’ may sound abstract, mysterious or complex. In reality, digital trans - formation is anything but. Rather than cryptic and compli- cated, it is about taking practical steps to make operations clearer, easier, and more concrete. By definition, digital transformation is a process that a facility, system or piece of equipment undergoes that allows end users to see real- time data, make decisions based on it, and act based on those decisions. Basically, digital transformation puts the right information in the hands of the right expert, no matter where they sit, which improves the speed and accuracy of decision-making and action. Some facilities manually measure and record their critical data, such as valve cycling and position. The very nature of this scorecard-and-stopwatch process means that people must climb ladders and take catwalks to get data that is already outdated when used for decision-making. And there are still some measurements that cannot be taken, so even stale data cannot be accessed.

Digital transformation, on the other hand, allows opera- tors to easily record and see data that reflects the current state of their assets from a handheld device or control room workstation. The digital transformation of a machine can be as simple as adding a sensor that captures data about its current performance and health. Through this process, real-time information can be collected and converted into useful analytics and insights that can be used to automate a task, like moving from clipboards to digital record keeping or optimising an area around safety, production, energy use or reliability. In this way, digital transformation gives operators access to a previously hidden level of asset health and condition, affording them a deeper understanding of assets in their present state as well as their past — for comparison — and possible future. The expertise this access grants will empower operators to make confident, informed decisions that significantly improve their operations, resulting in greater reliability, cost savings, and safety. Setting the see-decide-act cycle in motion Digital transformation, or automating and optimising operational processes using technology, puts into motion an unending cycle. This cycle includes three stages: see, decide, and act. In process applications, different fluid con - trol devices automate each stage. The ‘see stage’ starts the cycle at the sensor. Sensors and switches collect vital data about process valves that allow operators to see measurable input, such as cycles, Figure 1 The digital transformation of process manufacturing enables personnel to see the real-time health of refinery assets, providing the insight needed to make decisions that can improve safety and increase productivity

PTQ Q4 2022