Why One Weekly Comprehensive Insights Publication Rather than Many
The industrial Internet of Things (IIoT) and Industrial Internet of Wisdom IIoW)
are increasingly empowering operators to make holistic rather than independent
decisions. By the same token the supplier must take into account the broader
process implications of his product offering. McIlvaine believes that IIoW is
the key to successful IIoT. All the McIlvaine publications are being written
with the goal of furthering the use of IIoW.
Automation suppliers and consultants acknowledge the need for subject matter
expertise but do not give it the highest priority. The recipe for Tiger soup can
be more easily obtained than the tiger. Subject matter expertise is a “very
tough” tiger.
The IIoT Pyramid
It can be argued that the rate of progress depends more on new ways to develop
and utilize subject matter expertise than IIoT. McIlvaine coined the term IIoW
(Industrial Internet of Wisdom) to cover the systematic leveraging of subject
matter expertise.
Rate of Progress = 1 x IIoT + 2 x IIoW
IIoT IIoW
Data Physical parameters and status of each component Google, blogs, news
Information Historian, Edge Computing, SCADA Papers, presentations, Valve World
magazines, and conferences
Knowledge PLC, Data Analytics
Remote monitoring with alarm system Association white papers, structured
LinkedIn discussion groups
Wisdom Digitally powered process management Leveraging subject matter expertise
by plant, industry, product, process, and niche expert
Plant specific information: In the beta site for BHE the background data such as
air and water permits, white papers, and articles all are displayed and linked
to specific plants and processes. Every week hundreds of useful bits of BHE
information become available.
Industry specific information: The BHE site also has links to Coal-fired Power
Generation, and Gas Turbine Combined Cycle Decisions which also include valve
decision guides for individual processes, e.g. HRSG. Input gained from coffee
breaks at a PowerGen convention can be categorized as “data”. Papers presented
at the conference can be grouped under “information”. EPRI studies can be
grouped under “knowledge”. But it takes a cloud type integration to create
wisdom.
Product specific information: One of the Amgen pillars of procurement includes
not only supplier access but innovation. Conferences and magazines on valves
such as published by KCI are extremely valuable. However, this data needs to be
organized and analyzed. McIlvaine Decision Guides on molecular sieve and choke
valves are examples. There are innovations which change the options in both
applications. The decisive classification of valve types and the numerical
identification of Chinese suppliers are further examples.
Process specific information: There is little communication among industries.
BHE now is testing a NOx control process in a coal-fired plant based on
revelations in a McIlvaine webinar relative to success in the refining industry.
The hard coating innovations which are improving valve performance in one
process in one industry need to be considered by operators of similar processes
in other industries.
This new Insights format includes multiple processes in one issue. The
opportunity to extract information from other industries is therefore provided.
Water Treatment Chemicals Market will be shaped by IIoT
Water treatment chemicals suppliers can anticipate business as usual industry
revenue expansion to $39 billion in 2025 up from $26 billion in 2017. But the
penetration of IIoT and remote O&M will transform the industry. The opportunity
will be much larger but the industry structure will change.
Water treatment chemicals companies have traditionally been selling a
combination of knowledge and product. Sales engineers have fulfilled a service
and advisory role. The value added has been process knowledge and the ability to
provide the right mix of chemicals.
Treatment chemical companies are already providing remote monitoring services.
Nalco has installed more than 1000 3D TRASAR boiler automation systems supported
by Nalco 360™ Service, to provide 24/7 monitoring for boiler systems.
Solenis has its OnGuard controller system also supported by 24/7 remote
monitoring.
GE TrueSense directly measures all three primary chemistries used in cooling
water treatment and interfaces with InSight, GE’s cloud-based knowledge
management solution.
IIoT and Remote O&M is much more than just optimization of treatment chemical
use. It is optimization of the entire process. Top management is recognizing
this opportunity. Danaher has embraced IIoT with the strategy of embedding its
equipment with sensors with the expectation of increased consumables sales
opportunities.
Danaher now owns Pall, Hach and Chemtreat. In the future Hach sensors can be
sending data to remote control centers operated by Pall, Hach, and Chemtreat.
This will supplement data on the plant which will be supplied by other vendors.
The plant and third party O&M providers will be viewing all the remote input.
The cloud based system will provide the details which will allow decisions on
whether to replace a Pall filter element or just change the Chemtreat chemical
dosage to reduce the scale.
The enthusiastic proponents of IIoT tend to downplay the importance of what they
call “subject matter expertise”. Mcilvaine thinks that IIoW (Industrial Internet
of Wisdom) is even more important than IIoT. In fact, the potential should be
viewed in terms of IIoW empowered IIoT. The decision to change chemicals or
replace a filter element must be made somewhere. If the filter is purifying
condensate in a gas turbine combined cycle plant, one needs to know how often
the unit is cycling and also the condition of the boiler tubes. Many plants are
upgrading filters due to contamination from ambient air through air cooled
condensers.
At Danaher filters are in a different division than instruments and chemicals.
How do you insure that the highest level of subject matter expertise can be
applied for an event at 2:00AM in Indonesia? The answer is that you need the
same quality of structural effort in your IIoW system as is applied to the IIoT
system.
It can be argued that the water treatment chemicals division has the process
knowledge base to take the lead. In any case those companies with niche experts
who understand the processes and the relationship of the product to the process
efficiency will be the ones in demand.
This process knowledge must be cultivated. Buckman Laboratories led the way in
the 1990s with the bestselling book “Building a Knowledge Driven Organization”.
Sales people posted questions into a company intranet system. The priority of
personnel from top management down was to provide answers. Twenty years later
this effort can be made much easier and better with IIoW.
Water Treatment Chemical IIoW Empowered IIoT Opportunity
Category 2025 Revenue
$ billions Percent
Conventional Treatment Chemical Revenue 39 2.8
IIoT Supplemental Opportunity 30 2.2
Sub Total 69 5
Total IIoT and Remote O&M 1400 100
Water treatment companies have the potential to capture a big chunk of the $30
billion supplementary opportunity in 2025. But why not think larger? The $69
billion is only 5% of the total IIoT and remote O&M opportunity.
On the other hand, the treatment chemical companies are potentially facing some
pretty stiff competition. Let’s says Accenture or Genpact supplies complete
digital process management and strategic sourcing systems for all the BHE
facilities comprising 7% of U.S power generation and gas transmission. Basic
chemicals could be purchased and mixed for all the plants. Genpact is already
supplying process management for several Duke wind facilities. If Genpact was
contracted with AEP, Duke and BHE it would be purchasing 25% of the U.S. power
plant water treatment chemicals.
The large strategic procurement firms are making a practice of hiring experts
from industry. Seven percent of the knowledge workers retire or change jobs each
year. However, their expertise is higher than average. As a result, fifteen
percent of the industry knowledge is in play each year. A treatment chemicals
company can have a knowledge advantage today but lose it tomorrow. On the other
hand, a company which adopts a robust IIoW program is not dependent on the
knowledge of the few and makes superior decisions with the niche expertise of
the many.
The system suppliers are either customers or competitors. MHPS has remote
control centers in the Philippines and Orlando providing support for power plant
rotating equipment. A sister company, Mitsubishi Electric is in water treatment.
The transition to becoming a strategic procurement source is a goal that many
system companies have selected. IIoT and Remote O&M is a springboard to this
goal.
GE is well positioned to be the leader in this market. However, they have
offered the GE Water group for sale. Earlier they sold their BHA filter group to
Clarcor. So, they will apparently want to play the role of integrator rather
than supplier. The earlier spinoff of Genpact also testifies to this strategy.
There are a number of less ambitious collaboration strategies which could be
attractive. Chemtreat and World Water Works have a partnership to provide the
ASSURED COMPLIANCE PROGRAM™, a solution that uses advanced wastewater automation
and control technology to deliver low lifecycle treatment costs while ensuring
sustainable environmental compliance. There are system suppliers in food, pulp
and paper, power, refining and other areas who will be attractive partners for
treatment companies.
The general wisdom is that IIoT will add many trillions of dollars to world GDP
in the coming years. The IIoT and Remote O&M opportunity for treatment chemicals
suppliers is too large to ignore and the threats too real to underestimate.
Continuous analysis of the situation is provided in two publications
N026 Water and Wastewater Treatment Chemicals: World Market
http://home.mcilvainecompany.com/index.php/markets/27-water/449-n026-water-and-wastewater-treatment-chemicals
and
N031 Industrial IOT and Remote O&M
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/106-n031
$18.7 Billion Market for Sedimentation and Centrifugation Solutions by 2026
The market for sedimentation and centrifugation equipment will expand from $7.5
billion in 2016 to $9.8 billion in 2026. On-site service will expand from $1.45
billion to $1.94 billion in the same period. The biggest growth potential is in
remote service and monitoring which will increase from $200 million/yr. to $3
billion. If the potential for related remote monitoring is included, remote
monitoring and service will generate revenues of $7 billion by 2026. These are
the new predictions in N005 Sedimentation and Centrifugation World Markets.
Sedimentation and Centrifugation Revenues ($ Millions)
Segment 2016 2021 2026
Centrifuge Equipment 3,000 3,500 4,000
Service On-Site 750 875 1,000
Remote Service and Monitoring 100 700 1,800
Sedimentation Equipment 4,500 5,100 5,800
Service On-Site 700 810 940
Remote Service and Monitoring 100 600 1,200
Related Remote Monitoring and Service 50 1,000 4,000
Suppliers of sedimentation and centrifugation equipment have the opportunity to
take advantage of the rapid growth in automation and remote monitoring and
service. Companies such as Alfa Laval and Evoqua can take a leading or secondary
role. Alternatively, the lion’s share of the revenue can be garnered by third
party O&M operators such as Veolia and Suez. Software developers such as
Emerson, ABB, Siemens and GE could also take a leading role. However, GE is
exiting the water treatment chemicals and equipment business, so this does not
seem to be in their game plan.
Centrifuge manufacturers are well positioned to take a leading role due to the
challenging maintenance requirements for this high-speed equipment. Many
centrifuge manufacturers already have remote monitoring programs. Centrysis
wireless remote monitoring is web based and tracks 32 key parameters. It
includes alerts, reports and service.
Alfa Laval has a number of remote monitoring initiatives including decanter
centrifuge condition monitoring at the Metropolitan Wastewater Reclamation
District of Chicago. Vibration is monitored and controlled through an X20 PLC
from B&R Industrial Automation. A custom I/O module has reduced costs and made
remote monitoring attractive.
Alfa Laval has expanded the concept to related remote monitoring and service.
The Octopus biosolids dewatering centrifuge autopilot monitors and controls all
aspects of the dewatering process. This includes material feed, polymer dosing
and internal decanter settings. Infrared sensors analyze performance and
automatically make necessary adjustments. Alfa Laval also manufactures pumps,
valves, heat exchangers and belt filters used ahead of centrifuges. This
knowledge can be leveraged to provide O&M for the complete process.
GEA Westfalia is well positioned to take advantage of this opportunity. Their
various businesses have been combined into just two. One is equipment and the
other is solutions. Engineering has also been centralized. Several years ago,
GEA would have bid only portions of a starch plant and now it can bid for the
entire plant. Taking the next step to offering remote O&M for that plant is now
an option.
Sedimentation and centrifugation suppliers should also position themselves to
take advantage of the opportunity to provide remote monitoring and service in
collaboration with other suppliers or as sub-contractors to an integrator.
GEA has the opportunity to be one of the participants in remote O&M of gas
turbine plants. Plant suppliers such as MHPS have set up remote control centers
to monitor turbines. They are now expanding into the balance of the plant. This
includes treatment of the oil which is often a secondary fuel for gas turbines.
GEA supplies centrifuges to purify the oil. The gas turbine manufacturers
specify limits for the trace elements to ensure safe and economical operation.
For sodium and potassium these limits are between 1 ppm and 0.1 ppm. The harmful
water-soluble trace elements are reduced to the required levels by separation
only or by a combination of washing and separation. Contaminants such as sand,
rust and cat fines are removed from the fuel oil under high centrifugal force.
The measurement of some fuel parameters can be continuous. PECO Facet uses light
scattering techniques to monitor particles in the gases. However, measurement of
the contaminants in the fuel oil requires periodic laboratory analyses.
The integrated system would incorporate the centrifuge condition monitoring with
both laboratory and online fuel sampling. If the end user, system supplier, oil
quality monitoring supplier and centrifuge supplier all have access to the
online data then better decisions can be made.
For more information click on N005 Sedimentation and Centrifugation World
Markets
NOx Control Market Opportunity is $38 Billion per Year
Suppliers of NOx reduction products and services have an opportunity to generate
sales of more than $38 billion per year. No one technology provides a complete
solution. Minimizing the generation of NOx needs to be combined in a series of
reduction steps. New technologies are providing opportunities for greater NOx
reduction at modest cost. McIlvaine recently conducted 9 hours of webinars for
one utility which resulted in a NOx control path which was more cost effective
than the conventional approach.
The knowledge regarding marrying these technologies for optimum NOx control is
particularly well suited to India where a big NOx control program has been
initiated. Operators of the existing 187,000 MW of plants will have to spend $8
billion to meet standards for existing units. Small units built prior to 2003
are tasked with reductions as low as 15 percent. Units larger than 500 MW will
have to make NOx reductions of 50 percent or more. New units built after 2015
will need to remove 85 percent of the NOx at an annual investment of $1.5
billion. Full scale SCR (or catalytic filtration) will be needed for the new
units but unique combinations of technologies will be the best option for the
older units.
The world market opportunity combines the revenues for existing NOx control
systems as well as for new plants.
Annual NOx Control Market for Utilities and Industrial Plants (2017- 2022)
Segment $ Millions/yr.
Coal-fired power
New SCR systems 8,000
Balance of plant investments (e.g.) fan upgrades 5,000
Replacement catalyst and reagents 4,800
Subtotal 17,800
Potential O&M with remote monitoring 12,000
Coal-fired power total 29,800
Gas turbine and industrial total 9,000
Total all industries 38,800
Important factors shaping the market are:
• Continuing concern over smog in large cities around the world
• Retrofit of coal-fired boilers in Asia
• Large inventory of SCR systems in developed countries
• CHP and distributed generation
• Technology developments:
o Combustion optimization software
o Improved instrumentation for in furnace measurements
o Remote monitoring
o Third party O&M capability
o New chemicals for reduction and oxidation
o Catalytic filtration
o Greenhouse CO2 fertilization with gas engines
Since NOx control requires application of multiple technologies working together
it is desirable to utilize monitoring systems which measure parameters starting
with the amount of fuel being consumed, the performance of each burner, the
quantities of chemicals and the measurement of NOx, O2, CO, and CO2 at various
process points. Remote monitoring allows access and advice by experts. This then
leads to the opportunity for third party O&M. Presently, this services is very
common for rotating parts such as turbines. It is being used for electrostatic
precipitator operations. NOx control offers another segment where third party
O&M will be cost effective. It is a $12 billion /yr. opportunity.
For more information click on N035 NOx Control World Market
Remote Support is a $1.6 Billion Potential Business for Precipitator Product and
Service Companies
The supply of services and parts is a potential $1.6 billion/yr. business for
suppliers of electrostatic precipitator systems, components, remote monitoring
software, advisory and maintenance services. This is the recent finding in N018
Electrostatic Precipitator World Market published by the McIlvaine Company.
Metric 2017 2021
Utility Precipitators Installed
GW
2200
2440
Utility Air Flow cfm (m3/h) millions 6600 (11,000) 7320 (12,200)
Industrial Precip Air Flow
cfm (m3/h) millions
660 (1,100)
732 (1,220)
Total Air Flow cfm (m3/h) millions 7260 (12,100) 8052 (13,220)
O&M Cost ($0.60/cfm) $ millions 4,356 4,931
Third Party Potential Revenues ($0.20/cfm)
$ millions
1,452
1,610
Third party potential revenues are 20 cents/cfm. This creates a potential market
next year of $1.4 billion rising by $200 million in 2021 to $1.6 billion.
Included in this total are the following:
• Remote monitoring 24/7 of precipitator performance
• Advisory or direct intervention to adjust operating parameters
• Training of operators
• Expert advice monthly or more often if warranted
• Supply of parts for the precipitators, dust conveying and energy management
• Other service
•
This opportunity is already being pursued by several types of organizations:
• Boiler system companies (Alstom, Doosan, Mitsubishi)
• Precipitator suppliers (FLSmidth, Longking, Feida)
• Parts suppliers (B&W has both the boilers and parts)
• Integral Component suppliers (NWL has remote systems focused on the energy
management)
• Auxiliary component suppliers (valves, fans)
• Service companies (Neuendorfer)
• Specialized consulting (TRK provides 24/7 monitoring and emergency advice
along with monthly reports and meetings)
• General consulting companies (Sargent & Lundy, Burns & McDonnell)
• Continuous emissions monitoring system providers (Thermo Fisher, Sick)
• Software suppliers (GE, Wind River, OSI Soft)
• Digital processing hardware (ABB, Yokogawa)
The acceleration in interest and investment in the Internet of things (IoT)
coupled with increasing complexity of precipitator operations make third party
services increasingly attractive. Many of the precipitators now being installed
are in Asian and African countries where precipitator knowledge is lacking. TRK
has demonstrated the value in making instant expertise available. Subject matter
experts abound in the U.S. where the number of precipitators in operation is
shrinking. This talent can be applied to help operators thousands of miles away
thanks to the increasingly sophisticated digital communications.
Remote services for precipitators have been in development for 30 years.
Services for other power plant components can be developed based on the
precipitator experience. This provides the opportunity to expand into third
party services for the entire power plant. McIlvaine projects this potential at
$125 billion/yr. for third party services for the full range of power plants
including nuclear, fossil and renewable.
For more information click on: N018 Electrostatic Precipitator World Market
IIoT is Creating New Market Paths to the $700 Million Gas Turbine and
Reciprocating Engine Air Filter Repair, Replace and Service Market
The Industrial Internet of Things (IIoT) is a powerful new force shaping the way
air filters for gas turbines and reciprocating engines are purchased. The impact
of IIoT is being continually assessed in the 59EI Gas Turbine and Reciprocating
Engine Supplier Program. The markets for air filters for these plants are
analyzed in N022 Air Filtration and Purification World Market.
The inventory of existing gas turbine plants is growing at six percent per year
and, in the next few years, the base will grow to two million MWs. There are
30,000 individual units which routinely require service, replacement or repair
of air filters used for intake air in gas turbines and for inlet air filtration
of compressors, diesel and gas engines. The market for replacement filters and
services is $700 million per year and will grow by more than six percent per
year.
IIoT provides remote delivery of comprehensive information about the operation
and health of air filters. This data can be analyzed to identify problems and
will create opportunities for the sale of better filters, media, coatings and
smarter filters to replace the existing ones. There is much controversy on
whether high efficiency microfiberglass filters for GT intakes justify the extra
cost. With IIoT the answers for each specific plant will be available.
IIoT is creating new channels to market in contrast to the sale of products
directly to a single end user.
End Users
Large end users are creating fleetwide purchasing and monitoring systems.
Southern Company operates over 280 power generation units at 73 power plants
including gas turbine, combined cycle, steam (coal), hydro and solar. Southern
Company implemented the first phase of their fleetwide monitoring and
diagnostics (M&D) center in 2007.
Duke Energy is growing its fleetwide monitoring and diagnostics center. Duke’s
efforts promise to result in maintenance savings and availability improvements,
while increasing equipment health visibility and optimizing logistics of
maintenance.
The one hundred largest operators of gas turbines around the world account for
most purchases. Therefore, working with them should be a high priority. Each of
these plants is identified in Gas Turbine and Reciprocating Engine Supplier
Program.
Filter manufacturers have the opportunity to offer programs to service and
replace all the filters in the fleet. With IIoT cost effective maintenance can
reduce costs for the end user while increasing margins for the supplier. When
the small compressor filters are included there are many thousands of filters in
a large fleet. The cost of purchase and storing small filters is much higher for
an individual user than it is for a company supplying all filters. Some of the
toughest applications for filters are in remote areas or on floating platforms
in oceans. Remote monitoring and central supply is particularly advantageous for
these applications.
Gas Turbine Plant Providers
Gas turbine suppliers have remote monitoring centers primarily focused on the
health of rotating parts such as turbines. However, this is being expanded. MHPS
just opened a remote monitoring center in the Philippines. It is monitoring the
balance of plant in addition to the turbines. A filter supplier offering remote
filter monitoring for all units can team with a turbine plant supplier for joint
analysis of the operating data.
Process Providers
Suppliers of gas turbine intake systems or plant compressed air are also
purchasers or influencers relative to products. A plant air compressor supplier
can share remote data with the filter supplier.
Automation Suppliers
ABB can provide all required gas turbine control and protection functions
utilizing the very same ABB DCS platform that controls the rest of the plant.
The typical gas turbine functions implemented include fuel control, startup
sequence, speed-load-temperature closed loop control, overspeed protection,
anti-surge protection, generator protection, auxiliary control, condition
monitoring, auto-synchronization, excitation, frequency control, etc. Parameters
such as the pressure drop across the air filter are important. Both the filter
supplier and the automation supplier can share relevant data.
Subject Matter Experts
When problems arise which cannot be handled by the dedicated supplier personnel,
it is necessary to turn to subject matter experts. An air filter problem for one
supplier can turn into an opportunity for another as a result of the
recommendations of a subject matter expert. Another opportunity is to supply a
better and more expensive product. Mann & Hummel supplies filters with
nanofibers for higher performance. So, where gas or diesel engines are operating
in dusty areas, the additional cost can be justified. Air filter suppliers need
to encourage the participation of subject matter experts who understand the
product and can provide lowest total cost of ownership advice.
Knowledge System Providers
Emerson’s use of Seek software allows incorporation of insights and background
data which can be opportunistically displayed to help solve problems as they
occur.
The gathering and organization of this data for use in the software system is a
major challenge. McIlvaine is providing this data in its air filter and gas
turbine related services but also in systems structured for a single utility.
The beta site is for Berkshire Hathaway Energy (BHE) which operates hundreds of
gas turbine and other power plants.
O&M Third Party Providers
Many gas turbine combined cycle power plants are operated and maintained by
third parties. The developments in remote monitoring are making it more
attractive to sub contract to a company specializing in O&M. These providers
include specialized service companies such as Wood Group and EthosEnergy, power
plant operators such as Uniper and RWE who are leveraging their experience to
help others, and the plant suppliers such as Siemens and GE who have
build/own/operate (BOO) contracts.
Air filter suppliers have an opportunity in an expanding gas turbine market to
take advantage of the IIoT driven changes and to increase not only revenues but
gross margins and profits as a percent of those revenues. This will require
direct high level communication with several types of organizations.
For more information, click on: 59EI Gas Turbine and Reciprocating Engine
Supplier Program.
For more information, click on N022 Air Filtration and Purification World
Market.
IIoT is Creating New Market Paths to the $400 Million Gas Turbine and
Reciprocating Engine Liquid Cartridge Replace and Service Market
The Industrial Internet of Things (IIoT) is a powerful new force shaping the way
liquid cartridges for gas turbine combined cycle systems and reciprocating
engines are purchased. The impact of IIoT is being continually assessed in 59EI
Gas Turbine and Reciprocating Engine Supplier Program. The markets for
cartridges for these plants are analyzed in N024 Cartridge Filters: World
Market.
The inventory of existing gas turbine plants is growing at six percent per year
and in the next few years the base will grow to two million MW. There are 30,000
individual units. There are hundreds of thousands of stationary engines using
gas or oil for fuel. These units routinely require service, replacement of
cartridges used for fuel oil, hydraulic fluids, coolants and lubrication.
Additional cartridges are used in water intakes, cooling and condensate for heat
recovery steam generators. Some cartridges are also used in wastewater
treatment. This includes direct filtration of wastewater but also filtration of
chemical solutions used in the wastewater treatment processes. The market for
replacement filters and services is $400 million per year and will grow by more
than six percent per year.
IIoT provides remote delivery of comprehensive information about the operation
and health of cartridges. This data can be analyzed to identify problems and
will create opportunities for the sale of better filters, media, coatings and
smarter filters to replace the existing ones. IIoT is creating new channels to
market in contrast to the sale of products directly to a single end user.
End Users
Large end users are creating fleetwide purchasing and monitoring systems.
Southern Company operates over 280 power generation units at 73 power plants
including gas turbine, combined cycle, steam (coal), hydro and solar. Southern
Company implemented the first phase of their fleetwide monitoring and
diagnostics (M&D) center in 2007.
Duke Energy is growing its fleetwide monitoring and diagnostics center. Duke’s
efforts promise to result in maintenance savings and availability improvements,
while increasing equipment health visibility and optimizing logistics of
maintenance.
The one hundred largest operators of gas turbines around the world account for
the majority of purchases. Therefore, working with them should be a high
priority. Each of these plants is identified in Gas Turbine and Reciprocating
Engine Supplier Program.
Filter manufacturers have the opportunity to offer programs to service and
replace all the filters in the fleet. With IIoT cost effective maintenance can
reduce costs for the end user while increasing margins for the supplier. There
are many thousands of filters in a large fleet. The cost of purchase and storing
small filters is much higher for an individual user than it is for a company
supplying all filters. Some of the toughest applications for filters are in
remote areas or on floating platforms in oceans. Remote monitoring and central
supply is particularly advantageous for these applications.
Gas Turbine and Engine Providers
Gas turbine suppliers have remote monitoring centers primarily focused on the
health of rotating parts such as turbines. However, this is being expanded. MHPS
just opened a remote monitoring center in the Philippines. It is monitoring the
balance of plant in addition to the turbines. A filter supplier offering remote
filter monitoring for all units can team with a turbine plant supplier for joint
analysis of the operating data.
Process Providers
Suppliers of lubrication systems or plant compressed air are also purchasers or
influencers relative to products. A plant air compressor supplier can share
remote data with the filter supplier. Since lubrication fluid quality,
temperature and dirt on the filter are all parameters in determining pressure
drop there is need for joint application of expertise.
Automation Suppliers
ABB can provide all required gas turbine control and protection functions
utilizing the very same ABB DCS platform that controls the rest of the plant.
The typical gas turbine functions implemented include fuel control, startup
sequence, speed-load-temperature closed loop control, overspeed protection,
anti-surge protection, generator protection, auxiliary control, condition
monitoring, auto-synchronization, excitation, frequency control, etc. Parameters
such as the pressure drop across the filter are important. Both the filter
supplier and the automation supplier can share relevant data.
Subject Matter Experts
When problems arise, which cannot be handled by the dedicated supplier
personnel, it is necessary to turn to subject matter experts. A filter problem
for one supplier can turn into an opportunity for another because of the
recommendations of a subject matter expert. Suppliers need to encourage the
participation of subject matter experts who understand the product and can
provide lowest total cost of ownership advice.
Knowledge System Providers
Emerson’s use of Seek software allows incorporation of insights and background
data which can be opportunistically displayed to help solve problems as they
occur.
The gathering and organization of this data for use in the software system is a
major challenge. McIlvaine is providing this data in its cartridge and gas
turbine related services but also in systems structured for a single utility.
The beta site is for Berkshire Hathaway Energy (BHE) which operates hundreds of
gas turbine and other power plants. It also operates 71 compressor stations. So,
it purchases many thousands of cartridge filters per year. The system has
information such as the performance of Cuno string wound filters in one
condensate system and the performance of Pall filters in another where the
string wound filters were replaced with more efficient ones. This human
generated data can be utilized with the machine generated data to determine
where more efficient and expensive filters should be installed.
O&M Third Party Providers
Many gas turbine combined cycle power plants are operated and maintained by
third parties. The developments in remote monitoring are making it more
attractive to sub contract to a company specializing in O&M. These providers
include specialized service companies such as Wood Group and EthosEnergy, power
plant operators such as Uniper and RWE who are leveraging their experience to
help others, and the plant suppliers such as Siemens and GE who have
build/own/operate (BOO) contracts.
Cartridge filter suppliers have an opportunity in an expanding gas turbine
market to take advantage of the IIoT driven changes and to increase not only
revenues but gross margins and profits as a percent of those revenues. This will
require direct high level communication with several types of organizations.
For more information, click on 59EI Gas Turbine and Reciprocating Engine
Supplier Program.
For more information, click on N024 Cartridge Filters: World Market
IIoT is Creating New Market Paths to the $100 Billion Gas Turbine Repair,
Replace and Service Market
The Industrial Internet of Things (IIoT) is a powerful new force shaping the way
gas turbine products are purchased. The impact of IIoT is being continually
assessed in 59EI Gas Turbine and Reciprocating Engine Supplier Program.
The inventory of existing gas turbine plants is growing at six percent per year
and in the next few years the base will grow to two million MW. There are 30,000
individual units which routinely require service, replacement or repair of
instrumentation, valves, pumps, filters, nozzles, and other components. There is
a continual need for filter elements, treatment chemicals, lubricants,
catalysts, reagents and other consumables. The market for replacement products,
repair and services is $100 billion per year and will grow by more than six
percent per year.
IIoT provides remote delivery of comprehensive information about the operation
and health of individual components. This data can be analyzed to identify
problems and will create opportunities for the sale of better products to
replace the existing ones. IIoT is creating new channels to market in contrast
to the sale of products directly to a single end user.
End Users
Large end users are creating fleetwide purchasing and monitoring systems.
Southern Company operates over 280 power generation units at 73 power plants
including gas turbine, combined cycle, steam (coal), hydro and solar. Southern
Company implemented the first phase of their fleetwide monitoring and
diagnostics (M&D) center in 2007.
Duke Energy is growing its fleetwide monitoring and diagnostics center. Duke’s
efforts promise to result in maintenance savings and availability improvements,
while increasing equipment health visibility and optimizing logistics of
maintenance.
The one hundred largest operators of gas turbines around the world account for
the majority of purchases. Therefore, working with them should be a high
priority. Each of these plants is identified in Gas Turbine and Reciprocating
Engine Supplier Program.
Gas Turbine Plant Providers
Gas turbine suppliers have remote monitoring centers primarily focused on the
health of rotating parts such as turbines. However, this is being expanded. MHPS
just opened a remote monitoring center in the Philippines. It is monitoring the
balance of plant in addition to the turbines.
Process Providers
Suppliers of heat recovery steam generators, ultrapure water, emission controls
and water treatment are also purchasers or influencers relative to products.
Nalco has a water quality remote monitoring center which operates around the
clock.
Automation Suppliers
ABB can provide all required gas turbine control and protection functions
utilizing the very same ABB DCS platform that controls the rest of the plant.
The typical gas turbine functions implemented include fuel control, startup
sequence, speed-load-temperature closed loop control, overspeed protection,
anti-surge protection, generator protection, auxiliary control, condition
monitoring, auto-synchronization, excitation, frequency control, etc.
Yokogawa has various programs including one which monitors the wastewater from
the plant. The automation supplier can be working directly with the end user and
not necessarily through the process supplier.
Subject Matter Experts
When problems arise, which cannot be handled by the dedicated supplier
personnel, it is necessary to turn to subject matter experts. A product problem
for one supplier can turn into an opportunity for another as a result of the
recommendations of a subject matter expert. Product suppliers need to encourage
the participation of subject matter experts who understand the product and can
provide lowest total cost of ownership advice.
Knowledge System Providers
Emerson’s use of Seek software allows incorporation of insights and background
data which can be opportunistically displayed to help solve problems as they
occur.
The gathering and organization of this data for use in the software system is a
major challenge. McIlvaine is providing this data in its gas turbine related
services but also in systems structured for a single utility. The beta site is
for Berkshire Hathaway Energy (BHE) which operates hundreds of gas turbine and
other power plants.
O&M Third Party Providers
Many gas turbine combined cycle plants are operated and maintained by third
parties. The developments in remote monitoring are making it more attractive to
sub contract to a company specializing in O&M. These providers include
specialized service companies such as Wood Group and EthosEnergy, power plant
operators such as Uniper and RWE who are leveraging their experience to help
others, and the plant suppliers such as Siemens and GE who have
build/own/operate (BOO) contracts.
Suppliers have an opportunity in an expanding gas turbine market to take
advantage of the IIoT driven changes and to increase not only revenues but gross
margins and profits as a percent of those revenues. This will require direct
high level communication with several types of organizations.
For more information, click on 59EI Gas Turbine and Reciprocating Engine
Supplier Program.
IIoT is Creating New Market Paths to the $1 Billion Gas Turbine Plant Pump
Repair, Replace and Service Market
The Industrial Internet of Things (IIoT) is a powerful new force shaping the way
pumps for gas turbines are purchased. The impact of IIoT is being continually
assessed in 59EI Gas Turbine and Reciprocating Engine Supplier Program. The
markets for pumps for these plants is analyzed in N019 Pumps World Market.
The inventory of existing gas turbine plants is growing at six percent per year
and in the next few years the base will grow to two million MW. There are 30,000
individual units which routinely require service, replacement or repair of pumps
used for intake water, boiler feedwater, condensate, cooling, turbine inlet
water injection, reagent delivery, treatment chemical delivery, lubricant and
hydraulic fluid circulation. The market for pump replacement products, repair
and services is $1 billion per year and will grow by more than six percent per
year.
IIoT provides remote delivery of comprehensive information about the operation
and health of pumps. This data can be analyzed to identify problems and will
create opportunities for the sale of better pumps, pump materials and smarter
pumps to replace the existing ones. IIoT is creating new channels to market in
contrast to the sale of products directly to a single end user.
End Users
Large end users are creating fleetwide purchasing and monitoring systems.
Southern Company operates over 280 power generation units at 73 power plants
including gas turbine, combined cycle, steam (coal), hydro and solar. Southern
Company implemented the first phase of their fleetwide monitoring and
diagnostics (M&D) center in 2007.
Duke Energy is growing its fleetwide monitoring and diagnostics center. Duke’s
efforts promise to result in maintenance savings and availability improvements,
while increasing equipment health visibility and optimizing logistics of
maintenance.
The one hundred largest operators of gas turbines around the world account for
the majority of purchases. Therefore, working with them should be a high
priority. Each of these plants is identified in Gas Turbine and Reciprocating
Engine Supplier Program.
Gas Turbine Plant Providers
Gas turbine suppliers have remote monitoring centers primarily focused on the
health of rotating parts such as turbines. However, this is being expanded. MHPS
just opened a remote monitoring center in the Philippines. It is monitoring the
balance of plant in addition to the turbines.
Process Providers
Suppliers of heat recovery steam generators, ultrapure water, emission controls
and water treatment are also purchasers or influencers relative to products.
Nalco has a water quality remote monitoring center which operates around the
clock.
Automation Suppliers
ABB can provide all required gas turbine control and protection functions
utilizing the very same ABB DCS platform that controls the rest of the plant.
The typical gas turbine functions implemented include fuel control, startup
sequence, speed-load-temperature closed loop control, overspeed protection,
anti-surge protection, generator protection, auxiliary control, condition
monitoring, auto-synchronization, excitation, frequency control, etc.
Yokogawa has various programs including one which monitors the wastewater from
the plant. The automation supplier can be working directly with the end user and
not necessarily through the process supplier.
Subject Matter Experts
When problems arise, which cannot be handled by the dedicated supplier
personnel, it is necessary to turn to subject matter experts. A pump problem for
one supplier can turn into an opportunity for another as a result of the
recommendations of a subject matter expert. Pump suppliers need to encourage the
participation of subject matter experts who understand the product and can
provide lowest total cost of ownership advice.
Knowledge System Providers
Emerson’s use of Seek software allows incorporation of insights and background
data which can be opportunistically displayed to help solve problems as they
occur.
The gathering and organization of this data for use in the software system is a
major challenge. McIlvaine is providing this data in its pump and gas turbine
related services but also in systems structured for a single utility. The beta
site is for Berkshire Hathaway Energy (BHE) which operates hundreds of gas
turbine and other power plants.
O&M Third Party Providers
Many gas turbine combined cycle power plants are operated and maintained by
third parties. The developments in remote monitoring are making it more
attractive to sub contract to a company specializing in O&M. These providers
include specialized service companies such as Wood Group and EthosEnergy, power
plant operators such as Uniper and RWE who are leveraging their experience to
help others, and the plant suppliers such as Siemens and GE who have
build/own/operate (BOO) contracts.
Pump suppliers have an opportunity in an expanding gas turbine market to take
advantage of the IIoT driven changes and to increase not only revenues but gross
margins and profits as a percent of those revenues. This will require direct
high level communication with several types of organizations.
For more information, click on 59EI Gas Turbine and Reciprocating Engine
Supplier Program.
For more information, click on N019 Pumps World Market.
Gas Turbine Opportunities for Valve Companies Shaped by IIoT
There are many new gas turbine combined cycle power plants (GTCC) under
construction and in operation. This represents a market potential of $3.5
billion/yr. for valve suppliers. However, the Industrial Internet of Things (IIoT)
is creating a metamorphosis in the route to market and profitability. This
market is being continually assessed in N028 Industrial Valves: World Market.
Each gas turbine project is tracked in 59EI Gas Turbine and Reciprocating Engine
Supplier Program.
Smart valves provide a route to increase revenue and profitability. Both on/off
and control valves have “smart” capabilities. An on/off valve can be supplied
with a controller which is intelligent, having digital communication and a
microprocessor capable of on-board diagnostics. The controller can detect
deteriorating valve performance. Diagnostics also include high and low
temperature monitoring. The on/off valve diagnostics make it possible to more
accurately predict the need for maintenance based on how hard the valve is
working and how it is performing.
Control valves are critical components in plant automation. Their intelligence
can be leveraged to maximize plant improvements. Emerson is incorporating smart
valve technology to provide a control Valve Condition Monitoring diagnostic
service performed by certified Fisher valve and instrument product experts
focused on providing predictive analysis of a facility’s control valves. Its
purpose is to identify potential failures and avoid them before they cause
unsafe operating conditions and/or unplanned downtime.
Emerson has partnered with software company, Seeq, to improve the data
visualization tools used to predict future valve problems. Seeq expertise has
helped Fisher Valve Division build a collaborative environment connecting
customers with local Fisher service experts and global valve experts. This
environment enables data from multiple sources to be visualized and aggregated.
It allows authorized people located around the world to look and work on the
same data for predictive maintenance and operational improvements.
This initiative is part of the IIoT metamorphosis. Most valve manufacturers do
not have the infrastructure to be IIoT leaders. So, they need to identify and
work with all the relevant participants.
End Users
Large end users are creating fleetwide monitoring systems. Southern Company
operates over 280 power generation units at 73 power plants including gas
turbine, combined cycle, steam (coal), hydro and solar. Southern Company
implemented the first phase of their fleetwide monitoring and diagnostics (M&D)
center in 2007.
Duke Energy is growing its fleetwide monitoring and diagnostics center. Duke’s
efforts promise to result in maintenance savings and availability improvements,
while increasing equipment health visibility and optimizing logistics of
maintenance.
The one hundred largest operators of gas turbines around the world account for
the majority of valve purchases. Therefore, working with them should be a high
priority.
Gas Turbine Plant Providers
Gas turbine suppliers have remote monitoring centers primarily focused on the
health of rotating parts such as turbines. However, this is being expanded. MHPS
just opened a remote monitoring center in the Philippines. It is monitoring the
balance of plant in addition to the turbines.
Process Providers
Suppliers of heat recovery steam generators, ultrapure water, emission controls
and water treatment are also purchasers or influencers relative to valves. Nalco
has a water quality remote monitoring center which operates around the clock.
Automation Suppliers
ABB can provide all required gas turbine control and protection functions
utilizing the very same ABB DCS platform that controls the rest of the plant.
The typical gas turbine functions implemented include fuel control, startup
sequence, speed-load-temperature closed loop control, overspeed protection,
anti-surge protection, generator protection, auxiliary control, condition
monitoring, auto-synchronization, excitation, frequency control, etc.
Yokogawa has various programs including one which monitors the wastewater from
the plant. The automation supplier can be working directly with the end user and
not necessarily through the process supplier.
Subject Matter Experts
When problems arise which cannot be handled by the dedicated supplier personnel,
it is necessary to turn to subject matter experts. A valve problem for one
supplier can turn into an opportunity for another as a result of the
recommendations of a subject matter expert. McIlvaine is encouraging individuals
to focus on niches and become experts on very narrow subjects.
Knowledge System Providers
Emerson’s use of Seek software allows incorporation of insights and background
data which can be opportunistically displayed to help solve valve problems as
they occur.
The gathering and organization of this data for use in the software system is a
major challenge. McIlvaine is providing this data in its valve related services
but also in systems structured for a single utility. The beta site is for
Berkshire Hathaway Energy (BHE) which operates hundreds of gas turbine and other
power plants.
O&M Third Party Providers
Many gas turbine combined cycle power plants are operated and maintained by
third parties. The developments in remote monitoring are making it more
attractive to sub contract to a company specializing in O&M. These providers
include specialized service companies such as Wood Group and EthosEnergy, power
plant operators such as Uniper and RWE who are leveraging their experience to
help others and the plant suppliers such as Siemens and GE who have
build/own/operate (BOO) contracts.
Valve manufacturers have an opportunity in an expanding gas turbine market to
take advantage of the IIoT driven changes and to increase not only revenues but
gross margins and profits as a percent of those revenues. This will require
direct high level communication with several types of organizations.
For more information, click on 59EI Gas Turbine and Reciprocating Engine
Supplier Program
For more information, click on N028 Industrial Valves: World Market
Industrial IoT and Remote Operations and Maintenance Will Generate Revenues in
Excess of $1.4 Trillion
Industrial IoT combined with remote operations and support will be worth $1.4
trillion in 2030. This is the conclusion of the McIlvaine Company in N031
Industrial IoT and Remote O&M.
Industrial IoT or IIoT is growing faster than IIoT generally and will eventually
be a much larger market. It will also be a catalyst for major industry changes
which Accenture predicts will add $14 trillion to the global economy in 2030.
One near-term achievement is asset management but longer term IIoT will
transform the process industries and allow individuals to focus on problem
solving and collaboration as machines replace some of their prior duties. It
will result in better products produced at lower cost. It will be a catalyst for
more rapid development of new products. This includes products made by the
process industries and products used in the process industries.
One of the most important opportunities is remote monitoring along with remote
operation and maintenance support. Remote monitoring centers have been set up by
suppliers and end users such as power plants. Initially they were used primarily
to warn the operator of problems such as vibration of rotating parts or
temperature increases due to lube oil problems. However, the development of
inexpensive sensors and sophisticated software, remote operations and
maintenance management will not only be possible but will result in better
outcomes.
Software platforms which allow systems to communicate with each other will allow
collaborative remote monitoring. System, component and consumable suppliers will
collaborate with the operators and subject matter experts to solve problems and
improve operations with the introduction of innovative solutions.
The resultant revenues accruing from this development will be $1.4 trillion by
2030. This includes $590 billion of new revenues and $870 billion of revenues
which would have otherwise been generated by traditional market routes.
Shaping and forming such as machining are not included. There is a big market
already in this area and includes semiconductors, automotive and other
industries using castings, forgings, etc. However, the lubrication monitoring in
these machining applications is included.
There is much of the new revenue which will be attributed to onsite investments.
Many plants will install many thousands of new sensors and will use
sophisticated software in the plant to take advantage of the IIoT. The biggest
growth area will be in the hardware, software and service revenues generated
offsite. This remote O&M will create a market exceeding $500 billion by 2025.
The power industry segment includes nuclear, fossil and renewables along with
transmission. It is therefore the largest segment. Oil and gas IIoT is rapidly
growing and will be the second largest segment in 2025.
The transportation segment primarily includes aerospace and automotive
manufacturing plants but also includes remote monitoring of off-road machinery.
It does not include machining applications within these manufacturing plants and
it does not include on-road vehicle IIoT.
For more information on N031 Industrial IoT and Remote O&M (Formerly Air and
Water Monitoring) click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/106-n031
$5 Billion Cleanroom Market will be Increasingly Impacted by IIoT Technologies
This year cleanroom operators will invest more than $5 billion in new cleanrooms.
This is the latest forecast in World Cleanroom Markets. These investments
include enclosures as well as the air treatment to keep air pure. The Industrial
Internet of Things (IIoT) is already being utilized in many cleanroom
facilities. However, the future promises radical changes due to IIoT.
Sensors detect air flow and cleanliness at various points in the cleanroom. With
the laminar air flow concept and velocities approaching 100 fpm a 30,000-sq. ft.
semiconductor cleanroom is moving 3 million cfm. This air movement requires fans
which use large amounts of energy. IIoT offers a route to reduce this energy
consumption through two options. One is better control of the air flow in the
traditional ballroom cleanroom. A ballroom cleanroom is one where a number of
people in special clothing are operating the equipment. These people are the
largest source of contamination. However, their movement within the cleanroom
has recently been identified as being an important factor. With IIoT it is
possible to supply sensors which measure velocity at various points within the
cleanroom and at the same time measure air purity. By using variable speed fans
tied to the measurement system, the air flow and energy consumption can be
varied to maintain cleanliness with less total energy consumption.
ENVIRCO® offers a complete family of control solutions providing machine
intelligence to monitor and control cleanroom environments of all sizes. It
features various fan filter unit control options from single FFUs to multiple
FFUs organized in a zone. Multiple zones can each be independently managed by
remote control from outside cleanroom.
The Vaisala continuous monitoring system offers: remote access, and scalability
up to thousands of monitored locations, it provides customizable reporting for
easy cleanroom certification and classifications. Other features are:
• Gap-free and protected data records required in GxP environments
• Audible and visual alerts, as well as alarming
• Measurement of humidity, temperature, differential pressure, flow, particulate
and more
The need for IIoT is even greater if the ballroom cleanroom is replaced by a
series of minienvironments. Robots rather than people perform the tasks. Air
flow requirements are greatly reduced. These robotic operations are only
accomplished by the use of large numbers of sensors and sophisticated software
to cause the robots to perform the delicate tasks required.
Some years ago, it appeared that ballroom type designs would soon be extinct.
However, progress in reducing the cost of automation has been slower than
anticipated. Nevertheless, with the acceleration of IIoT technologies the use of
minienvironments and robots will continue to gain market share as the cost and
performance of robots improves. One example of an improvement is a smaller
cleaner option. ABB Robotics has introduced an ISO 5 (Class 100) Cleanroom
version of the IRB 120, its smallest ever multipurpose 6-axis robot. The
component materials of the IRB 120 prone to particle generation have been
modified to eliminate the potential for contamination of the manufacturing area
and the parts being processed.
IIoT extends to the management of cleanroom supplies. According to the latest
McIlvaine forecast, cleanrooms will spend $8.1 billion for cleanroom supplies in
2017. The cost of selecting, procuring, and storing large numbers of small items
such as gloves, cleanroom paper, etc. is hundreds of millions of dollars per
year. Several companies offer automated options. VWR has offered services in
this segment for decades. VWRCATALYST onsite services help streamline
procurement, optimize inventory levels and reduce administrative cost.
Presently several vendors offer individual IIoT solutions to cleanroom
operators. With new open software platforms, it will be possible to integrate
and optimize these systems and to also include subject matter expertise which is
of equal importance.
For more information on N6F World Cleanroom Markets, click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/474-n6f-world-cleanroom-markets
IIoT and Thermal Gas Treatment: The Opportunity and the Challenge
The industrial internet of things (IIoT) combined with remote operations and
maintenance promise to make the reduction of air pollutants by thermal treatment
much more cost effective.
Thermal treatment includes flaring, controlled combustion, catalytic oxidation,
regenerative catalytic oxidation and regenerative thermal oxidation. For some
applications, there are chemical challenges with a range of toxics to be
removed, but the toxics which can be formed in the process need to be
considered. Where there are low fuel values such as solvent treatment from
textile or printing operations, it is economical to use regenerative oxidizers.
This means alternating flow through three large vessels with lots of dampers,
valves, and other components which must be optimally controlled.
Another variable is product value. Low value solvents might be used in the
morning and they can be combusted but if high value solvents are used in the
afternoon they can be recovered. In an oil shale operation, byproduct gas can be
flared when gas prices are low and captured when prices rise.
The cost of common sensors to measure temperature, pressure, etc. are shrinking.
New instruments such as tunable diode lasers can measure O2 and CO at any point
in a combustor. These developments create a $21 billion opportunity for
suppliers.
2021 Thermal Treatment Market ($ Millions)
Application Initial System Sale IIoT and Remote O&M
Industrial Thermal Treatment 3000 5000
Oil and Gas Thermal Treatment and Flaring 5000 8000
Total 8000 13,000
$21 billion total market potential for supplier offering
systems and remote O&M
With the new open access platforms and the cloud, it is now possible for
operators and their suppliers to view all the relevant information at any
location. Furthermore, the impacts on the balance of plant can be constantly
included in decision making.
Thermal gas treatment is widely used in the oil and gas industry, refining and
chemical processing. A chemical plant may be switching products and the solvents
used to make those products on a regular basis. New regulations require oil
shale drillers to flare or capture byproduct gas.
The integration of information for the plant operator is only the first step.
Remote monitoring will enable remote operations and maintenance. This means that
a plant in a developing country can be operated with the same expertise as one
in a country steeped in thermal oxidation control experience.
The cost of sensors is falling while the ability to measure critical parameters
is expanding. Wireless telemetry makes possible communication of vast amounts of
information at low cost. So how does the thermal treatment industry take
advantage of this opportunity? The answer lies in climbing the pyramid.
Emerson calls the decision pyramid DIKW. At the bottom, you have data. Next is
information, followed by knowledge. At the top is wisdom. Here is how that
pyramid can be applied to thermal treatment.
Means Parameter
Data Sensors, Instruments, Wireless Telemetry Vibration, Temperature, Pressure,
VOC, N2O, CO, CO2, etc.
Information Historian, Edge Computing, Permitted Emissions Burner Damper
Setting, Air Volume, Emission Totals
Knowledge Data Analytics – Clean or Regenerate Catalyst, Cost of Solvents, Cost
of Natural Gas Loss of VOC reduction efficiency, increased pressure drop,
emission trends.
Wisdom Remote Monitoring, Subject Matter Expertise, Knowledge Systems Decide
when to switch from recovery to combustion. Optimize combustion.
The market opportunities for IIoT are analyzed in N031 Industrial IoT and Remote
O&M. (Formerly Air and Water Monitoring) click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/106-n031
The thermal oxidation market opportunities are analyzed in: N007 Thermal
Catalytic World Air Pollution Markets click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/105-n007
IIoT and NOx Control: The Opportunity and the Challenge
The industrial internet of things (IIoT) combined with remote operations and
maintenance promise to make the reduction of NOx much more cost effective.
Luminant and Duke Energy already have remote centers monitoring the rotating
parts at all their plants. Yara has a remote center monitoring the levels of NOx
reagent in storage and automatically setting delivery schedules for the next
truckload when required. Thermo Fisher has a remote center monitoring the NOx
and other emissions continuously.
MHPS has a remote center in the Philippines and is expanding into monitoring of
combustion in coal-fired plants. Siemens has licensed tunable diode laser
instrumentation and can determine O2 and CO levels at any point in the
combustion zone. GE has neural networks which learn from burner damper settings
and optimize their location. They have SootOpt which controls cleaning of the
boiler tubes but balances NOx caused by additional energy consumed in the soot
blower vs NOx resulting from inefficiency from ash laded tubes.
Flowserve has remote monitoring of valves and pumps. Howden has remote
monitoring of fan and compressor operations. These systems can reduce the cost
of NOx control maintenance by being proactive as opposed to predictive or
reactive. Several companies offer remote monitoring of coal flow and insure that
the correct weight (not volume) is introduced into the boiler.
With the new open access platforms and the cloud, it is now possible for
operators and their suppliers to view all the relevant information at any
location. Furthermore, the impacts on balance of plant can be constantly
included in the decision making with inclusion of other centers such as the one
created by Nalco to measure water quality impacts.
The integration of this information for the plant operator is only the first
step. Remote monitoring will enable remote operations and maintenance. This
means that a plant in a developing country can be operated with the same
expertise as one in a country steeped in NOx control experience. Uniper (the
large German utility) and India Power have a joint venture to provide O&M
services to Indian power plants. Luminant is offering to use its remote center
to provide monitoring activities for industrial plants in Texas and other areas.
The cost of sensors is falling while the ability to measure critical parameters
is expanding. Wireless telemetry makes possible communication of vast amounts of
information at low cost. So how does the NOx control industry take advantage of
the opportunity. The answer lies in climbing the pyramid.
Emerson calls the decision pyramid DIKW. At the bottom you have data. Next is
information, followed by knowledge. At the top is wisdom. Here is how that
pyramid can be applied to NOx control.
Means Parameter
Data Sensors, Instruments, Wireless Telemetry Vibration, Temperature, Pressure,
NOx, NH3, N2O, CO2, etc.
Information Historian, Edge Computing, Permitted NOx and NH3 Emissions Burner
Damper Settings, flow of coal, urea, air. Emission Totals
Knowledge Data Analytics
• Clean Catalyst
• Rejuvenate Catalyst
• Regenerate Catalyst Trend in loss of NOx removal, increased pressure drop but
also mercury oxidation.
Wisdom Remote Monitoring, Subject Matter Expertise, Knowledge Systems How do you
schedule catalyst replacement for each layer with both mercury and NOx as
considerations?
The market opportunities for IIoT are analyzed in N031 Industrial IoT and Remote
O&M. (Formerly Air and Water Monitoring) click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/106-n031
The NOx market opportunities are analyzed in N035 NOx Control World Market
click on:
http://home.mcilvainecompany.com/index.php/markets/2-uncategorised/104-n035
Nine Free Webinars on IIoT and Remote O&M
The Industrial Internet of Things (IIoT) and remote operation and maintenance
will combine to create a market worth $1.4 trillion in 2030 according to the
latest forecasts in N031 Industrial IOT and Remote O&M Market Report published
by the McIlvaine Company. A series of nine webinars will provide some of the
conclusions from the report. The presentations will be followed by a discussion
period where participants can share their views and ask questions. Each webinar
will be scheduled on a Thursday at 10 a.m. CDT. Participation is free.
Schedule
February 16: IIoT and Remote O&M Markets
Questions to be addressed include: Why combine IIoT and Remote O&M forecasts?
Why will this market grow at 13%/yr.? What are the major markets segmented by
industry, region, and product? What are the limiting factors to growth? How do
suppliers best take advantage of the opportunity?
February 23: Gas Turbine, Reciprocating Engine IIoT and Remote O&M
This industry segment has made the most progress in leveraging IIoT for remote
O&M services. Turbine and component suppliers have remote monitoring centers
operating around the clock. This session will explain why a 2030 forecast of $30
billion is predicted. It will answer the question as to how established
technologies such as remote vibration analysis will be combined with analytics
and decision making relative to all components in the balance of the plant.
March 2: Coal-Fired Power IIoT and Remote O&M
This session will build on nine hours of webinars recently conducted on
optimizing NOx emissions, 42 years of data analysis in Coal-fired Power Plant
Decisions and a previous McIlvaine report entitled Information Technology in
Electricity Generation. It will discuss the basis for an $80 billion 2030
forecast for coal-fired IIoT and remote O&M with a focus on the potential for
utilities in developing countries to take advantage of the world’s expertise
through services from international consortia.
March 9: Pump IIoT & Remote O&M
The potential for pump suppliers to add $20 billion of annual revenue and create
new market routes for pumps valued at $25 billion will be discussed along with
the evolution from vibration and lube oil monitoring to maximizing efficiency
and minimizing maintenance costs. Based on the research in N019 Pumps World
Market the session will discuss the various routes to market (system suppliers,
third party O&M providers, and direct to end users).
March 16: Industrial Valve IIoT & Remote O&M
The role industrial valves will play in expanding the market to $1.4 trillion
while generating $20 billion in additional valve revenues and carving new routes
for valve sales worth $30 billion will be explained. Insights from N028
Industrial Valves: World Market will be leveraged to predict the evolution of
smart valves, valve inventory management programs such as being offered by GE,
integration with third party programs and the role for subject matter experts.
March 23: Oil and Gas IIoT and Remote O&M
McIlvaine predicts this market will grow to $168 billion by 2030. Insights from
N049 Oil, Gas, Shale and Refining Markets and Projects will be used to describe
the present disparate programs and the eventual amalgamation to interactive
systems using open platform software. Safety, security, maintenance,
environment, and efficiency will be considered. The webinar will include uses in
the upstream, midstream and downstream segments of the industry.
March 30: Filtration and Separation IIoT and Remote O&M
The basis for a $350 billion 2030 market will be provided. The broad range of
applications as delineated in many market reports “MARKETS” will be analyzed.
This includes thousands of applications including ones as diverse as vibration
monitoring and polymer dosage for centrifuges to filter condition monitoring for
stationary IC engines. Clarcor already provides a total filtration solution
package which includes replacing of all filters in a plant as needed. Donaldson
offers a filter program for off road engines.
April 6: Water & Wastewater IIoT and Remote O&M
Municipal water and wastewater treatment systems are challenged by long
pipelines subject to leakage, corrosion, odors and blockages as well as by
maintaining valves and pumps in remote locations. New wireless technologies are
already enthusiastically embraced. McIlvaine will provide insights based on
several of its services: 62EI North American Municipal Wastewater Treatment
Facilities and People Database and 67EI North American Public Water Plants and
People as well as on ongoing private studies on subjects such as aeration
compressors. This market is projected to reach $168 billion in 2030.
April 13: Air Pollution Control
The basis for a $60 billion 2030 IIoT forecast will be explained. Continuous
emissions monitoring systems are now required in many industries in many
countries. Typically minute by minute emissions of each pollutant are
transmitted to owners as well as enforcement agencies. There is a huge potential
to integrate the information from these systems with combustion and other
process optimization systems to operate plants based on both total economic and
environmental cost of ownership. McIlvaine will be providing insights based on
included in N027 FGD Market and Strategies, N035 NOx Control World Market, N021
World Fabric Filter and Element Market, N018 Electrostatic Precipitator World
Market. Remote operation and maintenance of electrostatic precipitators is well
established and successful. This success is a model for other IIoT initiatives
and will therefore be examined in detail.
Subsequent webinars. The following subjects will be included in future IIoT
webinars:
• Subjects: cleanrooms, ultrapure water, water & wastewater treatment chemicals
• Industries: chemical, pharmaceutical, mining, semiconductor, pulp & paper,
food
Brief analyses of these opportunities are found at:
• $125 Billion/yr. Power Plant IIoT Instrumentation, Software and Service
Opportunity
• IIoT and the Stainless Steel Industry
http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree/DescriptionTextLinks/SS_world_article_1-19-2017.pdf
• $5 Billion Cleanroom Market will be Increasingly Impacted by IIoT Technologies
• Industrial IoT and Remote Operations and Maintenance Will Generate Revenues In
Excess Of $1.4 Trillion
Recorded Interviews. Periodic recorded webinars with suppliers, consultants and
end users will be linked from this page as well as being displayed in Hot Topic
Hour recordings. Much of the future sensor input will be related to
environmental performance. This in turn is tied to the regulations. Recently we
conducted an interview with Patricia Scroggin of Burns & McDonnell.
You can view it at: Meeting the new ELG and CCR requirements- options explained
by Patricia Scroggin (Interview Dated: 1/20/2017).
To register for the webinars, click on: Hot Topic Hour Schedule and Recordings
For details on the report click on: N031 Industrial IOT and Remote O&M
The analysis and forecast of IIoT instrumentation, software and service
opportunities in Power Generation is included as a special report in N031 Air
and Water Monitoring: World Market.
LINKEDIN
Participate in the LinkedIn Discussion Groups
If you are a subscriber to 44I Coal-fired Power Plant Decisions, you are
eligible to participate in the following LinkedIn discussions. (If you are just
a tracking system subscriber you can add the 44I for just $800 plus
$80/additional user/yr. You can add application and technical information or any
other information which will help power plants select the lowest total cost of
ownership products. The discussions are a bridge between the webinars and the
intelligence system which includes the database. So, you can also send us case
histories and white papers. The postings will be monitored to eliminate
commercial messages which are not constructive. The service is free of charge to
any power plant in the world. So, keep in mind that viewers might be from Asia
or Africa. To join one of the discussion groups just click on the LinkedIn group
and ask to join.
Power plant high performance pumps
Coal combustion residues and wastewater emissions
Power plant ultrapure water
Fabric Filters
Dry Scrubbing
Mercury removal from exhaust gas
NOx Scrubbing
Coal-fired power plant instrumentation and controls
Flue gas desulfurization
Power Plant Lubrication
Bob McIlvaine
President
847-784-0012 ext. 112
rmcilvaine@mcilvainecompany.com
www.mcilvainecompany.com