IOT- Insight into Industry Trends - The Path to Top Quartile Performance

1. IOT- Insight into Industry Trends- The Path to Top Quartile Performance Jagdish Pranami – DGM & HOD Electrical Instrumentation, SRF Limited, Dahej

2. Introduction Speaker • Name : Jagdish Pranami Designation : Dy. General Manager (Electrical & Instrumentation) SRF Limited – Gujarat • Industrial Experience : Projects , Operation & Maintenance of Heavy chemical , Fine chemical , Fluoro-chemical, Specialty chemical , Power • Key responsibilities: • Innovative projects • Designing concepts • Project Management • Maintenance

4. Early Adopter's Experience: SRF Limited • Company Profile • A legacy of more than 100 years – lineage of Sir Shri Ram & Dr. Bharat Ram • Established in 1973, SRF is a leading Indian multi-product industrial group • Corporate office at Gurgaon, near New Delhi • Company Turnover of INR 6000 Cr • 11 manufacturing locations • 9 in India • One each in Thailand and South Africa • Selected TQM in 1991 as the methodology to drive quality • Technical Textiles Business successfully challenged the Deming Prize in 2004 • Bhiwadi unit of Chemical Business successfully challenged the Deming Prize in 2012.

5. What is IoT and IIoT? The internet of things, or IoT, is a system of interrelated computing devices, mechanical and digital machines, objects, animals or people that are provided with unique identifiers (UIDs) and the ability to transfer data over a network without requiring human-to-human or human-to-computer interaction. A thing in the internet of things can be any natural or man-made object that can be assigned an IP address and is able to transfer data over a network such as, • A person with a heart monitor implant • A farm animal with a biochip transponder • An automobile that has built-in sensors to alert the driver when tire pressure is low

6. What is IoT and IIoT? • The internet of things is also a natural extension of SCADA (supervisory control and data acquisition), a category of software application program for process control, the gathering of data in real time from remote locations to control equipment and conditions. • The hardware gathers and feeds data into a computer that has SCADA software installed, where it is then processed and presented it in a timely manner.

7. IoT Applications

8. IIoT - History • Kevin Ashton, co-founder of the Auto-ID Center at MIT, first mentioned the internet of things in a presentation he made to Procter & Gamble (P&G) in 1999. • Wanting to bring radio frequency ID (RFID) to the attention of P&G's senior management, Ashton called his presentation "Internet of Things" to incorporate the cool new trend of 1999: the internet. • MIT professor Neil Gershenfeld's book, When Things Start to Think, also appearing in 1999, didn't use the exact term but provided a clear vision of where IoT was headed.

9. Industry 4.0 - Evolution 2nd Revolution 3rd Revolution 1st Revolution 4th Revolution

10. SCADA – An Overview HSSE (Health, Security, Safety, Environmental) Reliability Manager Machines Manager SCADA Operator Console Cloud Process Engineer Network LAN Server Controller Wireless Gateway Wireless Input Analog Input Digital Input / Output Analog Output

11. Connected Services are based on See, Decide, Act Data Monitoring Expert Analysis Data Collection Analytics and Action On-Premise Sensing and Data Collection Repair Recommendations, Collaboration, or Services

12. Application for Safety Data Display from Remote Area (1.5 Km) Entire wireless infrastructure/Network CO & ETHYLENE GAS STORAGE 4-20mA Analog Signal to Wireless Transmission DCS Graphics • ANTENNA FOR SIGNAL TRANSFER WIRELESS GATEWAY

13. Wireless Implementation in Tank Farm • Challenge: • Tight schedule for green field specialty chemical project • Space constraints with variety of product manufacturing in the same location • Diversified Manufacturing processes • Elevated process units with multiple recipe production • Applications: • Process measurements Utilities and Tank Farm area • Remote Data measurement in the Hazardous Chemical storage area Installation in Utilities & remote monitoring area • Solution: • Wireless networks were deployed for Pressure, Level , Temp and Remote measurements in process plant WirelessHART mesh network architecture

14. Benefits of IIoT • Overall Benefits • Monitor their overall business processes • Improve the customer experience • Save time and money • Enhance employee productivity • Integrate and adapt business models • Make better business decisions • Generate more revenue 2018: Implemented Wireless Pressure Gauges that Improved Worker safety 2017: Implemented Wireless Analog Multiplexer that Enhanced Productivity of employees Adoption & Replication 2016: Implemented Wireless Pressure and Temperature Transmitters on remote equipment that Improved Process Reliability • Results - SRF • Worker tracking improved • Improved safety • Productivity improvement 30 % • Cost saving 11 % • Quicker startup saving @ 70% 14 2015: Implemented Wireless HART Technology that resulted in Cost saving & Quicker startup of plant

15. Chiller Condition Monitoring – IIoT Implementation SCADA Operator Console Cloud PLC Real Time Condition Monitoring Real Time Data Analytics Chiller

16. Challenges & Opportunities in Mobility, IT infrastructure & network security in chemical process industries • Maintenance challenge • Pump failures lead to severe downtime • Maintenance team gets to know only after the occurrence of the failure • Condition Monitoring lets maintenance team get notified of situation prior to failure by continuously monitoring the process parameters • All kind of mechanical equipment can be monitored and uptime of assets can be increased IoT Gateway Pump Parameters Maintenance Engineer

17. Challenges & Opportunities in Mobility, IT infrastructure & network security in chemical process industries • Infrastructure challenge • Outdated/Obsolete systems (DCS/PLC) have to be upgraded as and when necessary in order to prevent the loss of data • If the existing system is not compatible for digital transformation, migrating to a new system might be the best option to stay in race • Network must be capable of transferring such a humongous data and secure enough to thwart cyber assaults MOD Migration Compatible System Outdated System

18. Challenges & Opportunities in Mobility, IT infrastructure & network security in chemical process industries • Mobility • Maintenance team uses FLP android based smartphones • An integrated HMI fetching data from SCADA, PLC, DCS and other systems can be handy for the operator

19. IIoT Liability • Possible Threats: • System Malfunction • Cyber Assault • Access to Control System • Information Theft

20. System Malfunction • Possible Threat • A deeper level of automation based on IIoT systems are done, for instance, automatic ordering of inventories based on IIoT data on cloud, then malfunction of instruments / glitches in networking/programming may lead to financial loss • Prevention • A manual check has to be made mandatory in case of taking actions upon IIoT data 20

21. Cyber Assault • Possible Threat • The other applications in the device in which the IIoT application is accessed might be prone to cyber attacks • Prevention • Built-in protection • Encryption • Risk Analysis • Authorization 21

22. Access to Control System • Possible Threat • Intruder can gain the access to process control network • Intruder can alter the opening of critical valves that may lead to disaster • Prevention • Since the flow of data is unidirectional, i.e. only process data are fetched from control system through OPC channel and the communication with cloud is through remote system, this threat can be eliminated for our case 22

23. Information Threat • Possible Threat • Since the data points are from the critical processes, a breach can expose the history of parameters of the critical processes to the competitors • A diligent work around of this data combined with our purchase data(which products are bought, which equipment are purchased), other non critical data can give a great all-round idea of the patented processes • Prevention • Built-in protection • Encryption • Risk Analysis • Authorization