Customer Stories Archives | AVEVA

Linn Energy

Dragomir Emiloff — Sun, 17 Dec 2023 15:19:53 +0000

Linn Energy

Thanks to the remote performance monitoring of the system
that is unmanned overnight, it is now possible to assess
quickly whether or not an intervention on-site is needed.

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Background

US-based Linn Energy is a household name worldwide when it comes to hydrocarbon exploration. What Michael Linn started in 2003 has meanwhile grown into a billion-dollar company. This rapid growth also created a need, with a view to safety and efficiency, to monitor all systems remotely and turn the available data into useful management information. Linn Energy chose AVAVA Select!
Within a time span of only a few days, Linn Energy has managed to increase its operational effectiveness by optimising data accessibility and visibility for the various teams.

Goals

Unlock essential management information that used to be available only at the central control room.
Enable remote system performance monitoring – especially at night, when the system is unmanned – to be able to determine whether or not an intervention is required.

Challenges

Linn Energy was after a safe and secure system that gives operators any-time and anywhere access – including remote access – to all the available system performance information.
The solution had to be straightforward to implement and use, so that operators can focus fully on managing the system and do not have to spend time on software maintenance or training (new) employees.

Results

Within a time span of only a few days, Linn Energy was able to measurably improve its operational decision-making by optimising access to and visibility of information for the various teams, while also enabling teams to share information with each other.
Critical operating network information has been unlocked and is now available to all operators.
Improved visibility of critical data for еngineers, calibrators and third parties.
Information is now shared all the time, anywhere and on any device, producing enormous time savings as operators can now assess alerts and events remotely.

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Hill’s Pet Nutrition

Dragomir Emiloff — Sun, 17 Dec 2023 15:19:53 +0000

Hill’s Pet Nutrition

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Background

Hill’s Pet Nutrition (a subsidiary of Colgate-Palmolive) is an A-brand producer of dog and cat food. The production location in Etten-Leur, in the south of Holland, makes use of Wonderware Manufacturing Analytics to gain clear insights in the production processes and that is the starting point for continuous improvement.

Balancing between costs and quality

Data-analysing helps Hill’s to get more grip on the desired balance between quality and costs of the products. A variety of dashboards show the (production) staff the moisture levels of the products at any time in the production process. It can be monitored per product, production run, job order, period etcetera and this information can be translated into a saving
potential.

Detailed Analysis

The dashboards show what was and is, but intelligent analytics also show what the quality-effect on the end-product will be if the process variables (extra water, higher temperature, steam, production rate etc.) will be changed. These very relevant process parameters are correlated with other quality measurement results and the outcome of these studies is the basis for continuous improvement.

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Elbe tunnel Hamburg Germany

Dragomir Emiloff — Sun, 17 Dec 2023 15:19:53 +0000

Elbe tunnel Hamburg Germany

An open, highly scalable AVEVA software solution enables the Elbe
Tunnel in Hamburg, Germany to continually modernize its facilities
management system quickly and cost effectively.

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Background

Hamburg, Germany – A harbor city nicknamed ‘The Gateway to the World’, Hamburg is home to one of the most amazing underwater tunnels ever built. First opened in 1975, the Elbe Tunnel has grown along with the city and provides an invaluable link between northern Germany and Denmark for residents, tourists and business people. Now, eight lanes of traffic carry an average of 142,000 vehicles through the 3.1 kilometer (1.9 mile) tunnel daily. An extensive traffic control and safety system is in place, including signals, message signs and barriers that provide guidance. Planning for Multiple Goals Given the changes in technology since the Elbe Tunnel was built, it is evident that city planners have been forward-looking from the very beginning. In 1995, work began to enlarge the then-20-year-old structure. In 2002, a fourth bore with two additional traffic lanes and three emergency exit tunnels became available. Hamburg officials knew that increasing capacity was only part of the solution. An updated control system to ensure the tunnel’s efficient operation and safety was also critical.

Goals

Monitor and control traffic through the underwater tunnel, which averages 142,000 vehicles per day
Regulate tunnel ventilation, lighting, safety and emergency systems

Challenges

The four-tunnel system includes
approximately 850 control points
The tunnel is over 34 years old, and continual updates are required to keep the project modernized

Results

An open, highly scalable system featuring AVEVA Select software has enabled easy integration of technology additions and upgrades
Expansion of the facilities management system has become more cost effective and time efficient

Find out what AVEVA Select can do
for infrastructure organisations

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Implementing a Modular and Open System

Their goal was to future-proof the Elbe Tunnel by implementing a modular and open system. With it, further expansions could build upon the existing facilities management and control deployment and increase the return on investment for the project. With a modular and open system, further expansions could build upon the existing FMS deployment and increase the return on investment for the project. State-of-the-Art Monitoring and Control The new AVEVA Select software solution was chosen by the city and developed in conjunction with Cegelec AT GmbH. AVEVA Select’s proven ability to provide the latest capabilities within an open environment complemented Cegelec’s system integration expertise and experience in developing custom functionality. The new, open system would be anchored by the AVEVA Select InTouch® Human Machine Interface (HMI) and would monitor and manage multiple components of the tunnel’s operations, including:

Ventilation
High-voltage electrical power
Low- and medium-voltage switching
Emergency management and call facilities
Fire safety and hydrants
Pump plants and drainage
Lighting
Temperature
Load monitoring
Control of recess doors

Upon completion, the new facilities management system (FMS) for the Elbe Tunnel incorporated a total of 850 control points and 72 visual monitors as well as innovations to aid tunnel operators in their around-the-clock responsibilities:

The AVEVA Select InTouch software provides a consistent screen design that enables all operators to view and control tunnel operations. Operators can see the entire system diagram, or may choose to click on any one of 40 specific areas for more information.
The AVEVA Select solution also supports the important safety functions that are built into the tunnel. Alarms and their response status can be seen at a glance on all operator screens.
Various peripherals that support the system are connected via AVEVA Select InTouch. For example, specific events and faults trigger the video cameras in the tunnel, which immediately swivel into position and activate the corresponding monitor to help the operator diagnose the situation.
For security and redundancy, the computers in the central control unit are linked to others throughout the facility. And while each computer is independent and has its own database, if one fails, the system can be accessed and controlled by another computer on the network. And when the failed computer returns to service, its database automatically updates through the network connection. Expansion and Scalability The new facilities management system has met the requirements of the City of Hamburg and the many people who depend on the tunnel each day. But just as importantly, it will meet the needs of the future. As the modernization and expansion of the tunnel continues, the standardization that is built in to the AVEVA Select software will contribute in key ways. When adding new components and subsystems, the AVEVA Select Graphics Library provides easy-to-use, pre-built images that help engineers design quickly and save costs. And because learning the software is so intuitive, training is efficient as well. Additionally, AVEVA Select software is developed to ensure upward compatibility. Applications that were first implemented in 1995 when the Elbe Tunnel’s expansion project began are still supported to the current version release, since the AVEVA Select software is kept updated through an easy migration process. Connecting to the Future Because the AVEVA Select software is based on industry standards and provides maximum repeatability, the FMS can be expanded at any time, quickly and at the most reasonable cost. The solution is an important part of how Hamburg is fulfilling its reputation as an international travel destination. And with AVEVA Select software, the Elbe Tunnel is one of the most highly used, modern – and safest – underwater tunnels in the world.

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Damen Shipyards

Dragomir Emiloff — Sun, 17 Dec 2023 15:19:52 +0000

Damen Shipyards

Logging data feeds the engineers on shore and challenges the
development department to come with advanced ship
designs; continuous improvement based on collected data.

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Background

Damen Shipyards is a renowned shipbuilding group consisting of over 30 shipyards across all continents. Dutch maritime tradition with more than 10.000 employees worldwide that design and build all kind of ship types.

Data is the Basis for Improvement

Logging data feeds the engineers on shore and challenges the development department to come with advanced ship designs; continuous improvement based on collected data. Collecting data is just the start, analysing the data and making it useful information gives Damen Shipyards the proper understanding of the exact usage of the sailing ships.

Deployment of the Ships

The dashboard shows exactly where the vessel has sailed last week and what kind of work the ship did; the percentages display the time sailing and waiting and the corresponding locations. This – combined with the weather conditions and other relevant information – offers the required detail information of the deployment of every individual ship. The gathered data is used by Damen Shipyards to come to better ship designs.

Damen Shipyards at the AVEVA Select KnowledgeXchange

View the stage presentation of Toine Cleophas of Damen Shipyards; the realistic story of Manufacturing Intelligence in practice.

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Bluewater

Dragomir Emiloff — Sun, 17 Dec 2023 15:19:52 +0000

Bluewater

Bluewater and its customer can now monitor the control and safety systems,
both on and offshore, in real time. After replacing the Emerson ProVox
and Delta V DCS with an integrated AVEVA control and safety system,
Bluewater was able to successfully meet ‘First Oil’ date on time.

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Background

The core business of Bluewater is to design, engineer, construct, install, lease, and operate Floating Production, Storage and Offloading (FPSO) systems, Floating Storage and Offloading (FSO) systems, and the turnkey supply of Single Point Mooring (SPM) systems. Ever since its cooperation in 1978, Bluewater has been a technological front- runner in its industry. The company has designed, manufactured, supplied and installed many innovative FPSO, FSO and SPM systems for oil companies worldwide through time charter and turnkey supply contracts.

Goals

To replace and upgrade the existing integrated control and safety systems
To achieve ‘First Oil’ on time in order to avoid contract penalties and lost production
To maximize the availability/uptime of the control and safety systems and to minimize the total cost of ownership

Challenges

The Project teams are located in multiple locations, that is, the Netherlands, Slovakia, Germany
and Singapore
Process data from the new ICSS,
including serial interfaces, safety systems and new I/Os, were
available only in the very late stages before the planned FAT
The original DCS had to be kept ‘alive’ as long as possible and the existing safety systems had to remain operational with just a few hours available to upgrade

Results

After replacing the Emerson ProVox and Delta V DCS systems and
implementing a new integrated
control and safety systems on the Glas Dowr, Bluewater was able to
successfully meet ‘First Oil’ date on time
Bluewater and its customer can now monitor the control and safety systems, both on and offshore, in real time

“The Glas Dowr Kitan project has been a tremendous success. We were
impressed with the AVEVA attitude throughout the project and their ‘
change the game’ approach. It is one thing to have a good project plan
in place, but another to actually execute and deliver.”

Ernest Hofstee, Senior Project Manager, Bluewater

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Beaulieu International Group

Dragomir Emiloff — Sun, 17 Dec 2023 15:19:52 +0000

Beaulieu International Group

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Background

Beaulieu International Group (B.I.G.) is a global specialist in raw chemical materials (polymers), semi-finished engineered products (yarns, fibres, technical textiles and technical sheets) and is a leader in a broad range of floor coverings for the residential and commercial markets (vinyl rolls, vinyl planks, laminate, parquet, carpet, needle felt, artificial grass and mats) as well as upholstery fabrics. Headquartered in Belgium, B.I.G. employs more than 5,000 people across 29 plants with a major presence in 17 countries all over Eurasia, the Americas and Oceania. For more info see the website.

Find Out How to Determine the Added Value
of Manufacturing Analytics

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A Proof of Concept to determine the added value of Manufacturing Analytics

Beaulieu initiated a Proof of Concept on one of the plants to see if AVEVA Select Intelligence could help them gaining insight in the performance differences between the lines for the products that are produced on multiple lines. The performance score of a product on a line is determined by a combination of 3 factors: Quality, Energy Consumption and Meltpump Deviation.
Because data for each of the 3 factors was stored in different source systems, their challenge was to merge all data (automatically) into a single data store, suitable for analysis.

Choosing the Best Production Line for Each Product

The AVEVA Select Intelligence software was used to build to create a contextualized data set that refreshes automatically. On top of that data set a performance dashboard has been built. This dashboard gives insight in the best line(s) to produce a specific product on looking at each factor, or all factors combined. Thanks to AVEVA Select Intelligence, Beaulieu was not only be able to detect optimizing possibilities, improve quality results and reduce energy costs, they could also spare a lot of time because process engineers will not have to collect, clean and prepare data manually anymore.

Data Made Visual to Gain Insights

The image below shows one of the dashboards that was delivered during the Proof of Concept. Each KPI is calculated by comparing several process parameter actuals with their given targets. With the software we managed to create relationships between different types of data coming from different source systems. This resulted in a single contextualized data set that made it possible to build a set dashboards.

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Ballard

Dragomir Emiloff — Sun, 17 Dec 2023 15:19:51 +0000

Ballard

AVEVA Insight has empowered Ballard to quickly and securely implement a cloud-
based approach to monitoring operational fuel cell products. The real-time
data and insights that Ballard obtains, in combination with the analytics
capabilities, help them make the right decisions.

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Background

At Canada’s Ballard, a groundbreaking developer and manufacturer of fuel cell technology, it’s all about sustainability. Clean energy is the future and Ballard keeps pushing boundaries. Every new generation of fuel cells delivers yet more energy, and this is the result of consistently measuring everything, learning from the resulting metrics, and further developing the technology based on advancing science. AVEVA Insight is the tool that Ballard uses to measure the performance of fuel cells
in use across the globe.

Goals

Develop a replicable model that makes it possible to monitor and optimise Ballard fuel cells worldwide.
Enable remote diagnostics for fuel cell problems.
Implement a transparent solution to be able to meet contractual fuel cell efficiency obligations.

Challenges

Finding a user-friendly IIoT solution for secure data collection and storage.
Enabling monitoring and analysis of both online and offline sources.
The system needs to be scalable and flexible, so that it can grow in step with Ballard’s current and new fuel cell operations.

Results

A closed-loop system has been implemented that allows Ballard to monitor and analyse fuel cell performance of its entire
operational fleet.
Data is now stored at a speed of 500MB/s.
Engineers can run problem diagnostics for units anywhere in the world and it is now possible to implement a global OEM model.

“A transparent cloud-based solution to be able to meet
contractual obligations with respect to the efficiency
of our fuel cells anywhere in the world”

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Ascend Performance Materials

Dragomir Emiloff — Sun, 17 Dec 2023 15:19:51 +0000

Ascend Performance Materials

Ascend Performance Materials is the global leader in the production of Nylon 6-6.
The company implements IntelaTrac combined with AVEVA Select Intelligence
and AVEVA Select Workflow to create ‘Visual Factory’ to improve its
manufacturing operations.

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Background

Pensacola, Florida – What does carpet, tennis balls and radiators have in common? They are all manufactured using Nylon 6-6, a type of nylon which is used in the production of textiles, carpet and molded plastics, with worldwide production of this material growing every year. With four integrated manufacturing facilities located throughout the southeast region of the U.S., Ascend Performance materials is the global leader in the production of Nylon 6-6.

Goals

Eliminate manual input of data
Visualize the overall manufacturing process
Accurately record all manufacturing data

Challenges

The business was not tracking data to ensure production efficiency and product quality
There was a lack of process
consistency throughout the plants

Results

The company achieved a savings of $500,000 in utilities and materials costs
More than $1 million in savings was achieved in maintenance costs
Avoided potential plant shutdowns which equates to a savings of $2 million

“We’ve managed to meet and beat our expectations
and have achieved a number of unintended benefits
no one could have expected when we began”

S. Melissa Scheppele, CIO and Vice President of IT / Ascend Performance Materials

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Visual Factory and AVEVA Select

While maintaining its leadership position in production, Ascend was behind the times in the implementation and use of modern technology to optimize its operations. “I was brought on board to help Ascend transform from a ‘1950s’ era plant, into a modern manufacturing facility with the implementation of advanced technology to more effectively run the business,” said S. Melissa Scheppele, CIO and vice president of IT at Ascend. “We looked at a number of companies and solution from both
hardware and software perspectives, and found the AVEVA Select solution was the best match for our operation.” “Visual
Factory keeps tabs on the ‘big picture,’” said John Johannemann, Ascend plant manager for the Pensacola facility. “It basically tells us whether or not were straying from the middle of the road and getting close to a ditch. We are able to see the warning signs.”

Turning Operations Data into Actionable Information

Ascend operations must access multiple software systems to manage day-to-day operations in an effective and secure manner. These systems generate large sets of data which contain critical information pertaining to management systems, planning and cost information in business systems and energy consumption. As a result, Ascend management was challenged with creating relevant reports reflecting performance measures in overall context of their operational process. The company’s previous process entailed collecting and analyzing data manually which was not effective, since the information collected was generated after the fact, and was too complex for collaborative use across the organization.

Leverage the Hidden Insights in Industrial Data

The software automates the transformation of time series and transactional data across multiple sources and turns large amounts of Industrial “Big Data” into actionable metrics and Key Performance Indicator (KPI) information. Metrics and context data is kept in an open information model, providing a single version of the current data. This is stored in data warehouses and enterprise business intelligence tools enabling Ascend management to make strategic sense out of the production data. “Prior to implementing AVEVA Select software, the data was collected manually on pieces of paper that stayed on a clipboard until the clipboard was full,” said Bert Penegar, maintenance coordinator at Ascend. “Now that data is recorded and we can see who did the round and track down what they posted in the system.”

Organizational collaboration

“Previously, someone had to constantly monitor the data to make sure we were able to see the trigger points we wanted during the production process,” said H. Walt Woodfin, Maintenance Reliability at Ascend. “Prior to AVEVA Select, we didn’t have the proper tools to enable our teams to be successful in the overall management of the manufacturing facilities.”

Ascend has achieved this through the use of AVEVA Select IntelaTrac, a mobile workforce and decision support system that features configurable software and ruggedized mobile hardware solutions. IntelaTrac enables workflow, data collection and general task management for plant operations, maintenance management, production tracking and compliance applications. “We went from having no servers and no technology set up, to having connected operators in the field in just 90 days,” Unruh said. Ascend field workers can now transmit field data collected using IntelaTrac handheld hardware back to the automation system so it can be viewed by operator on their displays in the control room, or by engineers and managers utilizing plant information portals. “We found that the overall AVEVA Select solution was the best match for our requirement of handheld technology scanners,” Scheppelle said. “IntelaTrac brings our field operators into the automation loop by giving them a powerful tool to successfully complete their job.” The combination of AVEVA Select IntelaTrac’s workforce management software, mobile handheld computers, monitoring devices, and Radio Frequency Identification (RFID) equipment tags or bar codes, results in a significantly improved decision support system for Ascend mobile workers to manage plant assets. Not only has AVEVA Select solutions automated the Ascend overall process, but they have improved the job satisfaction of its employees. The combination of the AVEVA Select technologies has helped the company both from an employee retention perspective, as well as from a business growth and development perspective. “The business case itself is great,” Scheppelle said. We’ve successfully met as well as beat expectations. The company has managed to collect a number of unintended benefits that are paying off in ways no one could have calculated when we started the technology implementation process.

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9REN

Dragomir Emiloff — Sun, 17 Dec 2023 15:19:50 +0000

9REN

The 9REN Group designs, develops, builds and operates renewable turnkey power
plants using photovoltaics, solar thermal energy and wind. AVEVA Select helps
9REN Group monitor its extensive network of renewable energy generation
plants with the help of System Platform, InTouch, Historian and Historian Client.

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Background

Madrid, Spain – Eventually the world will shift its energy dependency from fossil fuels to renewable sources of power. As the price of crude oil and natural gas continues to rise with global demand, geopolitical instability and the approach of peak oil, new ventures are leveraging inexhaustible sun and wind power to offer clean and renewable energy alternatives for lighting our homes and powering business.
To manage and monitor its photovoltaic plant facilities, 9REN created EOSystem, a solution built on AVEVA Select System Platform. EOSystem is a real-time monitoring technology that provides instantaneous information from all photovoltaic installations operated by 9REN throughout Europe and the Middle East. As a result, 9REN has considerably reduced the cost of its field operations.

Goals

The company needed to increase the production levels of its
renewable energy generation
installations in Europe and the
Mideast
9REN wanted to reduce its field
operations maintenance costs by minimizing manual supervision of plant operations

Challenges

Geographic dispersion of the
company’s power generation sites throughout Spain, Italy and the
Mideast demanded a centralized approach to system monitoring across differing time zones and weather patterns.
9REN required a solution that could easily scale with the projected installation of new renewable energy facilities in new regions

Results

AVEVA Select software enabled 9REN to increase event recognition by 50% and boost the solar tracking capabilities of the photovoltaic
systems by 5%.
AVEVA Select also helped improve the monitoring report performance, reducing the time it takes to produce the reports from one month to two days.

“AVEVA Select software lets us access all our installations in
real time. Because of this, we only require one person
to control the operation of all of the 568 plants,
regardless of location”

-Antonio Palacios Higueras, Technical Services Manager

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Total Picture of Power Production

AVEVA Select System Platform is the delivery mechanism for enterprise control, and consists of the components necessary to provide a true aggregated view of information across an organization, enabling a robust foundation for collaboration between people, processes and systems. System Platform provides a single, scalable software solution for all the SCADA, supervisory HMI and MES needs for monitoring 9REN’s renewable power-generating installations. System Platform also provides a simple upgrade path for easily adding new software and hardware to the system from any third-party vendor. By including an industrialized application server, a powerful historian server and an easy-to-use information server, System Platform easily tackles demanding, precision-driven real-time power generation activities.

A side benefit of System Platform was its ability to help power plant managers achieve higher levels of consistency and quality across its entire “grid” of photovoltaic and wind installations. Employing five servers, System Platform controls all of 9REN’s installations. Two servers act as redundant object servers with one controlling the plants in Spain and the other controlling operations in Italy. A third server is for historic information and operates the historian database. The historian is a high-performance real-time database for power generation information and is designed to collect a wide variety of plant data, at full resolution and very high data rates. Delivery of this vital information ensures that decision-makers at all levels have the information needed to take steps needed to ensure maximum operational efficiency. Another server provides visualization via AVEVA Select InTouch HMI. InTouch empowers 9REN to quickly and easily develop custom graphical views of its real-time power generation processes. As an open and extensible HMI with high-end graphical capabilities, the software provides the power and flexibility needed for advanced application design with connectivity to a broad range of systems and devices.

With the help of AVEVA Select, the EOSystem has delivered tangible benefits for 9REN. For example, while the 6-megawatt photovoltaic plant in Bella, Italy generates electrical power, the EOSystem transmits valuable information via satellite to 9REN’s Madrid office. The plant, located in southern Italy near Rome, consists of an extensive array of 30,000 solar panels with 12 inverters to convert the DC-generated solar panel electricity into the AC power required to run homes and businesses. The solar power facility has extensive monitoring tools to measure generated energy in real time and stations to record local weather conditions, enabling managers to anticipate reduced power generation due to cloudy or inclement weather.

The System Platform enables EOSystem to provide effective collaboration tools that enable standardization, reduced engineering time and cost savings.

“The System Platform lets us access all our installations in real time,” said Antonio Palacios Higueras, services technical manager for 9REN. “Because of this, we only require one person to control the operation of all of the 568 plants, regardless of location. We also have achieved a significant cost reduction in time per designer and project.”

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Suiker Unie at the Spotlight

Dragomir Emiloff — Sun, 17 Dec 2023 15:19:49 +0000

Suiker Unie at the Spotlight

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Suiker Unie

Suiker Unie – part of Royal Cosun – produces a large variety of sugar products like Van Gilse granulated sugar and syrup.
Approximately 750 people work in the three sugar refineries in The Netherlands and in Germany.

Less losses, higher output

The crucial issue in the cutting mill process is the need to reduce losses and to increase the output. More uptime leads to higher production. Therefor it is necessary to find the right balance between energy usage, sugar production numbers, equipment costs and deterioration of the assets. The collected data makes it possible to optimise the processes and in this situation especially timely maintenance positively influences the process.

Intelligent cutting mills

Monitoring and analysing the process parameters – like for instance the rotational speed, the torque and the energy consumption – and correlate the data with all the other information makes it possible to predict what the best time is to exchange the blades in the cutting mills. This is a powerful tool for operators that can now make well-founded decisions.
Manufacturing Analytics helps Suiker Unie to reduce the losses and increase the output, but it also leads to less energy and excipients usage so it cuts two ways.

Suiker Unie in the spotlights

Read the complete article in response to the presentation of Peter van Dam (Manager Technical Service – Suiker Unie Vierverlaten) at the Wonderware KnowledgeXchange.

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