How Does it Work?
To bring IT and OT systems together, the OT layer consisting of SCADA systems, PDMS and DCS systems, and IoT sensors attached to plants must first be interfaced with the right network technology (like industrial routers) to enable transmission of data to IT systems. Then, leveraging a modern data platform brings all the data from the systems into a data warehouse, where real-time data is loaded, making it ready for various use cases. Finally, predictive and descriptive use cases are implemented by applying AI and ML algorithms to this data. Moreover, the same architecture can also be used to build control systems that enable automated remote orchestration core operations like drilling, extraction, refining, logistics, etc.
IT-OT Convergence Benefits
Shot In The Arm For Oil and Gas Industry
The oil and gas industry essentially sets itself up for many business benefits with IT-OT convergence. For instance, asset-intensive upstream and midstream operations can achieve maximal uptimes, proactively schedule downtimes for maintenance, run the oil wells and minimum viable levels, and maximize the efficiency with which the plant churns out revenues for the bottom-line. Here are a few key benefits of IT-OT convergence in the O&G sector.
Cost Efficiencies
By leveraging predictive maintenance use cases, IT-OT convergence empowers O&G businesses to minimize their spending on maintenance operations. Predictive maintenance can be applied to plant machinery, drilling equipment, logistics fleet, water-hauling equipment, and almost any machine that requires maintenance. Moreover, by using descriptive data, engineers at the control room can observe critical data points on assets usually inspected by workers on the field, thereby cutting down non-value-adding work-hours. Lastly, insights from operational data can be used to build automated control, which ultimately reduces the number of FTEs required to perform tasks on the field. All these factors bring significant cost efficiencies to O&G operations.
Safer Workplaces
Several hazards result in safety incidents at O&G sites every year. However, IT-OT convergence enables remote or automated orchestration of hazardous tasks that were, until now, performed by workers. Moreover, wearable safety devices can be integrated into a centralized communication system and configured for triggering alarms when a hazard is detected nearby or when unsafe situations like falling objects or hazardous chemicals are detected at a location. Lastly, drones with inbuilt imaging sensors are being used to detect mishaps across remote sites - these can be used to dispatch help to the site at the earliest, thereby enabling just-in-time mitigative actions and making the field safer for all employees.
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Better Production Uptime
Predictive maintenance uses the vibration, sound, or infrared signatures generated by equipment to identify precursors to machine failure. This helps engineers identify failures before they happen and synchronize maintenance cycles for assets across the plants/wells to minimize production downtime. In addition, when this data is analyzed with a historical operational footprint, it can also help identify the right times to abandon an asset, thereby mitigating outages that result from critical failures arising from exhausting the asset’s life.
Environmental Compliance
More and more O&G companies are being fined for surpassing the provisioned emission levels or disposal of waste arising from exploration activities outside the allocated disposal sites. Compliance checks can be built into the IT layer with IT-OT convergence, and processes can be standardized with appropriate guardrails. For instance, disposal activities can be configured to check whether the waste management truck fleet’s round trips touch the location of the provisioned site. Similarly, emission levels can be tracked at the plant level by monitoring the emission signature from several assets, tracking power consumed by the operational activity from non-renewable sources, and generating automated compliance audit sheets.
Innovation
Because IT-OT convergence creates an interface between operational data and IT systems through an operational data platform (ODP), it unlocks a variety of opportunities for O&G businesses. An ODP Is essentially a value store, which is leveraged to build new use cases by making use of data streams from across systems to optimize, learn, and build better control mechanisms for production operations. Therefore, IT-OT convergence is a key milestone in unleashing the benefits of AI, ML, automation, and other emerging technologies in the O&G sector.
Higher Production Levels