Initial Rollout Activities
The CSM had begun collaborating with the Proclndustries enterprise-wide rollout team, discussing the best ways to make the initial rollouts successful. For the next few weeks, the team considered the CSM's suggestions. At their next meeting, Peter presented their enterprise rollout plans:
- 1. Follow the lead of the South Texas refinery, which has updated their process block and process control diagrams based on latest Occupational Safety and Health Administration (OSHA) 29 CFR 1910 compliance regulations.
- 2. Define KPIs for each site, each unit, and by discipline (e.g., production, maintenance, energy usage). Aggregate and roll up information across the enterprise.
- 3. Monitor key production metrics for each unit: feed rate, energy, fuel, water, yield, flows, and so forth.
- 4. Monitor real-time equipment performance as they had done at the South Texas refinery to ensure that pumps, compressors, turbines, condensers, chillers, and other critical assets operate within acceptable ranges and issue alerts when they diverge from these ranges. Ultimately, send these alerts directly to the Proclndustries asset management and maintenance system.
- 5. Monitor key raw materials and product quality variables. The team plans to integrate each site's laboratory information management system (LIMS) data into that refinery's EIDI.
- 6. Establish baselines for the refinery's energy and water consumption. Monitor vessels, tubes, pipes, condensers, and columns for energy leaks, fouling, and contamination in order to reduce unnecessary energy consumption. Quantify and store incremental improvements. Communicate these successes to management and the sustainability team.
- 7. Establish connectivity to the Proclndustries' production scheduling system.
- 8. Configure the EIDI using the same AF database approach in which the team configures a hierarchical model of the data for each site, reusing much of the asset templates that contain equipment information, input data source, online calculations, and alerting information for each type of asset.
- 9. Develop and implement the digital plant templates used at the South Texas refinery, tailored for each refinery. Define production event frames that leverage the digital plant template.
The CSM reviews the preceding items and recommends that the teams schedule two jump-start workshops. The first workshop will be conducted to review Proclndustries' specific business goals, with recommendations on how best to design EIDI connectivity and workflow to accommodate Peter's business objectives. The second jump-start workshop will cover best technical and configuration practices to derive these business values.
The team provides a general timeline for the enterprise-wide rollout for each refinery and the course is set. Figure 11.4 shows a typical workflow for enterprise-wide EIDI deployments.
Life cycle of EIDI rollouts across the enterprise.
EIDI Architecture and Cybersecurity
Once Proclndustries leadership approved the enterprise-wide EIDI rollout, their IT department started investigating the integration of all process control systems with the laboratory and equipment monitoring systems. IT Manager Pat Verlaine has been concerned about the safety of the networks and about cybersecurity threats, once the operational technology (ОТ; refinery systems) and IT systems converge on a larger scale.
To meet the needs of security and data reliability, Pat determined the need to deploy redundant EIDI servers for refinery operations and production data using a demilitarized zone (DMZ) strategy. He also saw a need for a mirrored site outside the DMZ. During enterprise-wide rollout meetings, the team stated the need for separate test and development servers, so that EIDI software upgrades and cybersecurity updates are more easily integrated. IT/OT cybersecurity convergence has the potential to solve many industrial cybersecurity challenges (Kanellos et al. 2019).