the internet of things · what is the “internet of things” really if you take away the hype?...

2016-02-29

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The Internet of Things:past the hype, what does it propose

to the aggregates industry?

Peter Radziszewski*, Janne Kytökari,

Sudarshan Martins

* presenter

2016-02-29

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Introduction

Peter Radziszewski, VP Research, Technology Development & Engineering

Previously to joining Metso in 2012, Peter spent 20 years in academia working

on topics from wear to grinding to sensors development to lunar mobility.

Currently, Peter is with the Grinding Media Solutions team addressing the

challenges related to wear.

Janne Kytökari, Global Director, Monitoring & Control Engineering

Janne leads product development efforts implementing advanced measurement

technologies, equipment connectivity and automated data collection and

analysis.

Sudarshan Martins, Industrial Post-Doctoral Researcher

Sudarshan has supported a number of innovation and sensor development

concepts in support of machine intelligence development.

Need a

photo

Introduction

A leading process performance

provider, with customers in the

mining, oil and gas, and

aggregates industries, Metso has

its corporate headquarters in

Helsinki Finland, offices in 50

countries and manufacturing

facilities on five continents.

Metso’s services and solutions

improve the availability and

reliability in minerals processing

and flow control, providing

sustainable process improvements

and profitability.

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Objectives

What is the “Internet of Things” really if you take away

the hype?

How much data is enough and how do you select the

important vs. the “nice to have”?

What does this mean for aggregate customers and

OEMs?

Where are the benefits and what comes next.

Objectives


the hype?




OEMs?


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What is the “Internet of Things” really if you

take away the hype?

A quick “Google” search of the “Internet of Things” (IoT) would indicate

some 725 million results (Nov 24, 2015)

one result for every 7 people!

as one tech consultant exclaimed:

“IoT fever is off the chart”!

Consider two concepts:


take away the hype?

(i) The TALK - Gartner Hype cycle

(ii) The WALK - Technology adoption lifecycle

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take away the hype?


take away the hype?

The Gartner hype cycle

https://en.wikipedia.org/wiki/Hype_cycle

Gartner Inc. developed a now

“branded” methodology to

understand and interpret

technology hype in graphical

format. Although this hype curve

methodology has its detractors,

the curve nevertheless

generalises the evolution of

“hype” around a given

technology over time.

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take away the hype?

“IoT fever is off

the chart”

– Sam Whitmore,

consultant to tech-industry

publicists

2015

Gartner Hype Cycle – new technologies





take away the hype?

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take away the hype?

https://markabouzeid.wordpress.com/2011/11/28/technology-adoption-lifecycle-revisited/

Technology adoption lifecycle (or

development) is typically described

with an “S” curve where the change

in a performance metric is illustrated

as a function of time.


take away the hype?

2015

Gartner Hype Cycle – new technologies

“Machine to Machine”

(M2M) communication

– “sliding into

the trough”

(Gartner, 2015)

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take away the hype?

time

ap

pro

pri

ate

KP

I

The TALK

The WALK

M2M

communication

IoT

IoT

Platform

All of these

players

express

how they

see IoT

differently…


take away the hype?

There are a number of players in the IoT field.

These include but are not limited to:

ARM, Atmel, Bosch, Cisco, Ericsson, GE, Google,

IBM, Intel, MicroSoft, Oracle, Siemens, ...

…and us.

ARM

Cisco

Oracle

GE Mining

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However, fundamentally, IoT

breaks down to three things:

1. Things embedded

(connected) with sensors,

2. Networks to connect them,

3. Systems to process the data.

Which becomes…


take away the hype?

In our world, “things” cover the

mineral and aggregate

processing space and include

such things as crushers,

screens, etc.


take away the hype?

screens

crushers

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However, “things” also

includes the ore or the

aggregate.


take away the hype?

“Mine-to-Mill”

Consider the “mine-to-mill”

case.

ore

Furthermore, the “whole

thing” could be greater than

the sum of the “things”…


take away the hype?

plant control

&

optimisation

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There are a number of IoT platforms on which to

develop.

These include but are not limited to:

Zatar, Yaler, Thinfspeak, SeeControl, Kaa, HP

Cense, Carriots, Bugswarm, …


take away the hype?

Or one can support the

development of a

proprietary IoT platform

developed in order to

guarantee customers that

the data is secure and only

known people can view it.


take away the hype?

Or one can support the

development of a

proprietary IoT platform

developed in order to

guarantee customers that

the data is secure and only

known people can view it.

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take away the hype?

The interface to

this network is

accomplished

by a Quake

Global

communications

system.


take away the hype?

Difference between “TALK” and “WALK” could be due

to perceived need for sensors and actual need for

sensors…

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Objectives


the hype?




OEMs?


Doable: Yes Sensible: Perhaps not

How much data is enough and how do you

select the important vs. the “nice to have”?

Consider:

“Most IoT data are not used currently. For example, only 1 percent of data from

an oil rig with 30,000 sensors is examined. The data that are used today are

mostly for anomaly detection and control, not optimization and prediction, which

provide the greatest value.”

McKinsey (2015), IoT: mapping the value beyond the hype

The curse of big data…

Many people when they are asked what data will they want from the equipment

will say: “Everything available.”

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Sensible: Perhaps not



It’s a common mistake to think that by collecting all the data we can do big data

analytics, find out cause-effect patterns and detect problems in advance. A lot

of the data will be left unused while occupying disc space. It’s more sensible to

create KPIs, cumulative values etc. at the machine level and carefully select

the important raw values for remote data collection.

Consider the following two cases…

The curse of bag data…

Many people when they are asked what data will they want from the equipment

will say: “Everything available.”

Doable: Yes

How much data is enough:

CASE: Fleet Management

Using a satellite connection one can collect

alarms and machine hours that are used to

plan maintenance, estimate the need of

spares and wears, and to derive a utilization

KPI. Together with fuel consumption and

production tonnage information the

customers are able to get a good

understanding of the state of the machine

and process.

Amount of data per day: ~ 0,1 Mbits

(adjacent picture of a Lokotrack is 3,8 Mbits)

Cost of communication / month: 30-40$

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Measuring the right values

CASE: Screen monitoring

What is measured?

Simple vibration measurements

only from all corners to find out:

• Stress to the screen body

• Correct operating angle

• Correct operating speed

• Length of the stroke

As well as housing temperature

and bearing wear.



Provides a lot of

data in raw format

most of which is

not interesting.

Only after

analysis we find

out what the

condition of the

screen actually

looks like.

Although such data is

valuable, it has little value to

the operator.

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On the other hand,

the processed

data can be linked

to plant

automation

system, collected

for history and

reported in

different formats

such as a visual

format.

Ultimately, through continuous monitoring

and analysis of the screen’s vibration,

one can be alerted to improper motion

caused by the following events:

• Flapping media

• Uneven feed

• Broken springs

• Natural frequency

• Insufficient structural

support

• Improper counterweight

settings

• Structural interference

• Excessive material build-

up

• Incorrect run speed

• Worn bearings



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• Can you spare the cost of data transfer and data storing for the next five

years without any issues?

• Can you utilize the data already?– Fuel consumption, alarms, operator identifier are all very useful information as such

– Oil pressure, temperature are not very useful

– “Oil pressure over limit X” counter, “max temperature during the last hour”, “temperature less

than Y” alarm can be all very useful.

• If not, do you have an idea where the data would be useful in the future?

Did you answer no, no and no? Most likely you should not start collecting.

Objectives


the hype?




OEMs?


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What does this mean for aggregate customers

and OEMs?

“Change is inevitable.

Progress is optional.”

Tony Robbins

It is all about decisions and supporting

those decisions with knowledge and

information of both your market and the

state of your capabilities.

If the next guy feels that they can get a

competitive advantage over you by

gathering quickly such knowledge and

information, well then…

Brazilian client:

What does this mean for aggregate customers

and OEMs?

“Information is power”

--Humfrey, Piers Anthony

For OEMs, there is technically no option.

If we do not develop IoT capabilities to our

equipment, somebody else will do it without

us. And we will start to lose “power” over

our own equipment, its development and

improvement.

Consider where we are going…

…Fleet management

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Objectives


the hype?




OEMs?


Where are the benefits

and what comes next.

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PRISMA

The

“Internet

of

Metso Things”

(IoMT)

PRISMA Client Offices

Track Machine and Capacity Utilization

Data AssuranceTrack and Analyze Maintenance Costs

Monitor Operator Performance

Analyze Energy Consumption

Plan & Schedule Maintenance,

Service

Compare with machine type average and maximum

Root Cause and Reliability Analysis

Plan logistics and inventoryExcessive Wear

Alarms Recommend & Schedule Wears

and Spares

Analyze process control variables &

set-point estimation

Monitor Alarms

Track Equipment & Process parameter

changes

Advanced Screen Monitoring

Monitor Crusher Performance

and Wear

Order spares


and Wear

Manage Maintenance &

Inspection

Monitor Energy Consumption

Monitor Process Performance & Quality

Track Inventory Quantity


Track Feed Quantity

Conveyor Power, Wear




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Th

e p

roc

es

s v

iew

Track overall utilization and effectiveness

Improve control loop design

Identify the need for parts

Track energy consumption

Track quality

Track maintenance

Monitor operator performance

Help in decision making process

Track timing of deliveries and work orders

Identify process bottlenecks



PRISMA

The

“Internet

of

Metso Things”

(IoMT)

PRISMA Client Offices

Track Machine and Capacity Utilization

Data AssuranceTrack and Analyze Maintenance Costs

Monitor Operator Performance

Analyze Energy Consumption

Plan & Schedule Maintenance,

Service

Compare with machine type average and maximum

Root Cause and Reliability Analysis

Plan logistics and inventoryExcessive Wear

Alarms Recommend & Schedule Wears

and Spares

Analyze process control variables &

set-point estimation

Monitor Alarms

Track Equipment & Process parameter

changes

Advanced Screen Monitoring


and Wear

Order spares


and Wear

Manage Maintenance &

Inspection

Monitor Energy Consumption

Monitor Process Performance & Quality



Track Feed Quantity





including, in

the future,

process

control and

optimisation

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Take Aways

What is the “Internet of Things” really if you take away the hype?

To be completed by the participant

Take Aways

How much data is enough and how do you select the important vs. the

“nice to have”?


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Take Aways

What does this mean for aggregate customers and OEMs?


Take Aways

Where are the benefits and what comes next?


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Acknowledgements

The authors would like to acknowledge the support and encouragement in the

preparation of this presentation of:

Ms Caroline Lecomte - Global Business Development Manager, Aggregates Life

Cycle Services,

Mr Rick Richardson - Director of Aggregates Services, USA and Canada,

Michelle Branzolewski - Product Specialist, ExperTune.

Thank you!

Nota Bene: “PRISMA is a fictional name for a new product

line that will be officially launched in April at the Bauma 2016

trade fair in Munich Germany.”

Crusher Particle Size

Distribution (PSD)

monitoring

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Online particle size distribution

(PSD) measurement for dry

material have been around for a

number of years. PSD

measurement systems are

designed to be meet the

requirement of the aggregate

industry.

The PSD value indicates the quality

of crushing. The particle size should

remain as set but at the same time

there should not be too much fines.

Crusher PSD monitoring

Crusher PSD monitoringKnowing the PSD value is but the first step

in understanding the reasons of good and

bad quality. With it we know the time when

certain quality occured.

With analytics we can combine information

from multiple sources such as:

• PSD measurement

• Crusher automation system

• Service history

• Weather condition data

Weather conditions like heavy rain, snow,

ice can impact the process and affect the

quality.

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Ore Tracking

from Mine to Mill

Ore Tracking from Mine to Mill

The Problem: “…devastating

problem with throughput…

…pockets of extremely hard

ore… …but we just didn’t

know when… …for

throughput to suddenly

drop…”

The Alternative: $24 million

crushing plant

The Solution: SmartTAGTM

and blast design

Phu Kham case (Lopez-Pacheco (2015), Confronting

complexity, CIM Magazine, v.10, n.7, 26-27.

Phu Kham

open pit

copper-gold mine

in Laos

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The ore tracking system employs robust

passive radio frequency (RFID) tags which

are placed with the ore in the mine and the

starting location of each unique tag is stored

in a database.

The tags survive blasting and travel with the

ore through the process where antennas

detect them at critical points in the process

ahead of the milling circuit.

They make it possible to link the physical ore

properties associated with the ore in the

mine to the time-based performance data of

the plant.


For geometallurgical modelling to be effective it is necessary to have a high degree of

confidence in the data collected, and to link the plant performance with the ore properties.

Such an ore tracking system can automatically update block models and mine plans with

actual plant performance data in real time.

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Ore Tracking from Pit-to-Port

Pit-to-Port Product tracking

can use the same system to

track product through the

complete supply chain.

Properties such as grade,

shape, texture, moisture,

ash, sulphur, phosphorus,

energy content, etc can be

tagged and tracked which

facilitate optimisation of plant

operation, sorting, blending

and homogenisation to

maximise the value of the

final product

Plant wide optimisation

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Plant wide optimisation

Plant wide optimisationOptimize the performance of the entire plant:

Save Energy

Reduce Maintenance Costs

Increase Production

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Plant wide optimisationFour Lafarge - Holcim Plants – Brazil (2007)

Brazilian Aggregate Client

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Customers start to be more demanding

about getting the data from their

equipment.

In one such case, a big Brazilian

customer wanted to get data from their

Metso manufactured portable crushing

plant.

They use a REST API provided to collect

the data to their own system and they can

also use a web interface to view the data

from anywhere in the world.


Brazilian aggregate client

In stead of Metso specifying what data to collect

the customer identified the data points and KPIs

they were interested in. Some examples:

• Maximum value for temperature within a three minute

period > follow up on maximum value trend

• Counter for pressure value over limit X within a day

• Level values send once per minute

• Equipment on/off value. Every change to be recorded.

• Safety switch. Every activation recorded.

1.The frequency of measurement depends

on the speed of change of that value

2.Digital values need to be recorded only

as they change

3.With some values the number of

abnormal events is more important than

the magnitude.

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Fleet Management System


Objective: Fleet

Management installed in

300 Lokotracks by the end

of 2016.

Currently (24/02/16): over

100 LokoTracks tracked

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