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Sulzer Technical Review 3/2018 Sulzer Technical Review 3/2018 Digital insights Turning pump data Rely on digital data for Using digital technologies Big data in into dollars mass transfer columns to create spare parts Sulzer’s factories 2 Imprint Sulzer Technical Review 3/2018 About Sulzer Sulzer’s core strengths are flow control and applicators. We specialize in pumping solutions and services for rotating equipment, as well as separation, mixing and application technology. Our customers benefit from a network of over 180 production and service sites around the world. Sulzer has been headquartered in Winterthur, Switzerland, since 1834. In 2017, we achieved sales of roughly CHF 3.0 billion with around 14’700 employees. Our shares are traded on the SIX Swiss Exchange (SIX: SUN). Pumps Equipment The Pumps Equipment division specializes in pumping solutions. Intensive research and development in fluid dynamics, process-oriented products and special materials as well as reliable service solutions help the company maintain its leading position in its focus market segments. Rotating Equipment Services The Rotating Equipment Services division provides cutting-edge maintenance and service solutions for rotating equipment dedicated to improving customers’ processes and business performance. When pumps, turbines, compressors, generators and motors are essential to operations, Sulzer offers technically advanced and innovative solutions. Chemtech The Chemtech division is represented in all important industrial countries and sets standards in the field of mass transfer and static mixing with its innovative solutions. The product offering ranges from process components to complete separation process plants. The customer support covers engineering services for separation and reaction technology and tower field services to perform tray and packing installation, tower maintenance, welding and plant turnaround projects. Applicator Systems Customers of the Applicator Systems division benefit from advanced solutions in the field of precise applications as well as two-component mixing and dispensing systems for adhesives, dental, healthcare and beauty applications. A global network ensures that local knowledge and competence help Sulzer to keep its leading position in its market segments. Order Sulzer Technical Review newsletter: www.sulzer.com/str-newsletter Publisher Imprint Sulzer Management Ltd © Sulzer Ltd 2018 – All rights reserved, reprints of articles and illustrations are permitted subject to the prior approval of the editor. P.O. Box The Sulzer Technical Review has been compiled according to the best knowledge and belief of Sulzer Management Ltd and the authors. 8401 Winterthur, Switzerland Editor-in-Chief: Nadia Qaud; Editorial Assistant: Tanja Bosshart Design: Pavla Balcarová, pb studio, CZ-Jaromer [email protected] Translations: think global Milengo GmbH, Berlin, Germany; Thore Speck, Flensburg, Germany www.sulzer.com/str Editing: Olivia Raths, Wetzikon, Switzerland; Bouqui Stautmeister, Winterthur, Switzerland Publication 3/2018 Photos and videos 100th year of the STR Cover: Sulzer ISSN 1660-9042 Pages 3, 10, 21, 27: Fotolia. All other photos and videos: Sulzer 3 Contents Sulzer Technical Review 3/2018 Digital insights Speeding up processes is the key to success and industrial agility. That is why most of the industries are in the midst of digital transformation. For all customers using pumps in their processes, Sulzer has developed a smart tool to make use of their operational pump data. The BLUE BOXTM software can process data from all pump manufacturers, not only Sulzer pumps. The main principle of the BLUE BOX tool is easy to explain: acquire data, analyze data, act on digital insights. We call it the “AAA principle.” By using BLUE BOX, customers can improve their operations and carry out better, targeted maintenance. The faster reaction times result in remarkable reliability and efficiency increases along with substantial energy and cost savings. We also like to share our own experiences with digital transformation in our factories. Read how we gained speed and increased our productivity remarkably for our injection-molding machines around the globe. Dr. Marc Heggemann, Head of Group Digital Solutions, Winterthur, Switzerland 4 Turning pump data into dollars Analyze your data with BLUE BOXTM 10 Rely on digital data for 14 Using digital technologies mass transfer columns to create spare parts Realize hydraulic design with Specialist parts manufacturing the SULCOLTM program center offers precision and speed 18 Big data in 24 News and events Sulzer’s factories How real-time data increase performance 4 Turning pump data into dollars Sulzer Technical Review 3/2018 Turning pump data into dollars Do you know which actions will optimize your pump installations and reduce operation and maintenance costs? You will if you acquire the right data in the field and evaluate it with Sulzer’s BLUE BOXTM. The BLUE BOX software can analyze data from any pump or pipeline equipment — not only Sulzer-made pumps. BLUE BOX combines the available data with Sulzer’s pump expertise and presents valuable insights, so pipeline operators can target their actions to optimize the performance of their pumps and pipelines. These days, everyone is talking about digitalization, big data, predictive analytics, digital twins, Internet of Things (IoT) and industry 4.0. The main idea behind these buzzwords is to optimize industrial workflows, performance and efficiency using digital data and to invent new business Click here to see a video models. Digital solutions can even help industrial pumping and pipeline operations reach their about BLUE BOX. sustainability goals by streamlining processes and, thus, saving energy and money. 5 Turning pump data into dollars Sulzer Technical Review 3/2018 BLUE BOX in action at Phillips 66 Sulzer has delivered a BLUE BOX solution that has been tailored to the requirements of Phillips 66, a leading US-based energy manufacturer and logistics company. Amongst other things, they operate two pipelines with 40 performance-critical pumps, which are a mixture of Sulzer and third-party manufacturers. BLUE BOX continuously monitors every pump. The management of Phillips 66 is committed to reducing the costs of energy and maintenance as well as improving pump availability. For pipeline operators, case studies reveal the potential for an annual cost reduction in the millions of dollars. BLUE BOX aims to reduce energy bills by 5% each year and to cut the costs associated with unplanned outages by 20%. The whole BLUE BOX package has been implemented through close cooperation between Sulzer’s experts and IT specialists at Phillips 66 to ensure seamless integration with the existing infrastructure. The dashboard reports allow operators to see all BLUE BOX information at a glance. All reports were configured to suit the individual needs of the Phillips 66’s key stake holders. Sulzer’s BLUE BOX is a software tool that captures essential process data. This data is used to improve performance, increase reliability and optimize system settings. The output of BLUE BOX supports managers in interpreting data quickly and making fast, fact-based decisions. Accelerate performance on the digital highway Pipeline installations can spread across continents, and the pumps are not always easy to reach, which complicates the data collection. To optimize the reliability, efficiency and performance of pumping equipment, operators must know the actual, real-time values. The first move towards digitalization is to acquire data (Fig. 1). To gather data for BLUE BOX, there are several approaches: Instrumentation of the pump itself (integrated data collection) Installed supervisory control and data acquisition systems (SCADA) Data use from a data storage system (e.g. process historian for pipelines) It is important to judge the overall efficiency of installations, and Sulzer’s engineers have emphasized the use of data from all possible sources. BLUE BOX is able to import all data — regardless whether it is from a Sulzer pump or a pump from another manufacturer. ata e d ir u umps q er p 2 c oth . d A A an S . s u n p lz 1 e a m r l u ’s y p r a z e d e z v l a u n w S c e i d t h a n B a l y L t i c U O s E p e e n r g B a i t n e o O B r t e f ’ ne s X 3 a n . d A S ulz c er’s services t on in sights Fig. 1 The three main steps on the digital highway. 6 Turning pump data into dollars Sulzer Technical Review 3/2018 The Sulzer team designed BLUE BOX to be implemented with a minimal footprint on a customer’s site and to collect data from their existing data collection systems. This allows customers to gain insights into the behavior of both Sulzer and third-party pumps. We support pump experts with BLUE BOX and make it easy for them to use the analyzed data. It enables them to act proactively instead of reacting to problems, thus gaining speed and efficiency. Just don’t expect a real box. BLUE BOX is a software tool. Matthew Anderson, Data Analytics and Smart Technologies Manager, Winterthur, Switzerland The second stage is to analyze and understand all data. There is no substitute for the years of expertise that real-life pump operators and OEMs have. BLUE BOX integrates the collective experience that Sulzer has accumulated throughout its rich history. Thanks to its automatic data collection and digital processing abilities, BLUE BOX has a broader information base. This ability is what makes BLUE BOX the digital advisor for the pump experts and allows them to see all data at a glance. As a third stage — to take full advantage of BLUE BOX — customers have to act and optimize the pumps in real life. They might need to check the hardware, perform maintenance, improve settings, refurbish a piece of equipment, or request a personal consultation from a Sulzer service engineer.
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