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Mcilvaine Insights

 

No. 1   February 9, 2017


WELCOME

Weekly selected highlights in flow control, treatment and combustion from the many McIlvaine publications.

·       Why One Weekly Comprehensive Insights Publication Rather than Many

·       Water Treatment Chemicals Market will be shaped by IIoT

·       $18.7 Billion Market for Sedimentation and Centrifugation Solutions by 2026

·       NOx Control Market Opportunity is $38 Billion per Year

·       Remote Support is a $1.6 Billion Potential Business for Precipitator Product and Service Companies

·       IIoT is Creating New Market Paths to the $700 Million Gas Turbine and Reciprocating Engine Air Filter Repair, Replace and Service Market

·       IIoT is Creating New Market Paths to the $400 Million Gas Turbine and Reciprocating Engine Liquid Cartridge Replace and Service Market

·       IIoT is Creating New Market Paths to the $100 Billion Gas Turbine Repair, Replace and Service Market

·       IIoT is Creating New Market Paths to the $1 Billion Gas Turbine Plant Pump Repair, Replace and Service Market

·       Gas Turbine Opportunities for Valve Companies Shaped by IIoT

·       Industrial IoT and Remote Operations and Maintenance Will Generate Revenues in Excess of $1.4 Trillion

·       $5 Billion Cleanroom Market will be Increasingly Impacted

by IIoT Technologies

·       IIoT and Thermal Gas Treatment:  The Opportunity and the Challenge

·       IIoT and NOx Control:  The Opportunity and the Challenge

·       Nine Free Webinars on IIoT and Remote O&M


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

pic1

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 360T 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:AM 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:
    • Combustion optimization software
    • Improved instrumentation for in furnace measurements
    • Remote monitoring
    • Third party O&M capability
    • New chemicals for reduction and oxidation
    • Catalytic filtration
    • 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.

pic2

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.

pic2

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.

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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.

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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.

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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.

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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.

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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.

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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. 

pic1

 

 

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:

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 Industrial IOT and Remote O&M.


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
This email address is being protected from spambots. You need JavaScript enabled to view it.
www.mcilvainecompany.com

 


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