Whereas robotics have been crucial to factory and warehouse automation for decades, the technology in process industry applications continues to be relatively new and emerging. Savvy operators are realizing the value of robotics in enhancing process safety and efficiency in daily operation and maintenance activities. Robots are performing operator runs in hazardous areas and drones have been deployed on inspections routes in difficult-to-access locations across process complexes. Yet, process operators still face many challenges when it comes to widely adopting robots. How can users integrate robotics into existing operations, control systems and standard operating procedures? Can they use the data collected from robots and combine it with artificial intelligence to provide actionable knowledge? Where do robotics reside on the digital transformation roadmap that ultimately leads to autonomous operations? In this session, participants will learn about Yokogawa's robotics vision, which steps beyond Industry 4.0 and digital transformation to achieve industrial autonomy.
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Robotics - Mainstream or Marginal for Process Industries?
1. Penny Chen
Sr. Principal Technology Strategist
Yokogawa Corporation of America
November 10, 2020
Robotics – Mainstream
or Marginal for Process
Industries?
2. Agenda
1. Why Robotics Now
2. Challenges in Process Industry
3. Robotics Applications
4. Yokogawa Robotics Service Platform
5. Yokogawa’s Robotics Vision
4. Robotics change how we do business
Robots are
not new
In recent years,
Robot Industry has
been growing
dramatically
Robotics have
fundamentally
changed how we
do business
Robots Business
opportunities are
real
5. Robotics change how we do business
Robotics
Manufacture
Subsea
Automobile
Mining
Agriculture
Security
Healthcare
Life Science
Warehouse
Oil & Gas
*Images are for illustration purpose only.
6. Why now? Technology advancing has never alone
Internet and Wireless enables connectivity
anywhere & anytime
Advance Sensing and MEMs enable Robot
become more capable and smaller in size
Autonomous Vehicle and Smartphone are
driving down the component cost
Cloud Technologies and Artificial Intelligence/Machine
learning enables actionable data analysis
Source: https://www.slideshare.net/Yole_Developpement/sensors-for-drones-and-robots-market-opportunities-and-technology-revolution-2016-report-by-yole-developpement?from_action=save
8. Challenges in Process Industries are unique
Dangerous
Dull/Dirty
Demanding
Distant
• Tasks that are hazardous & unsafe for humans but are
necessary
• People become ineffective ( & inefficient) at “repetitive” and
“routine” tasks progressively due to complacence
• Individual knowledge & experience dependent - inconsistent
outcomes
• Permanent sensing is either not feasible or expensive
• Tasks in inaccessible areas – confined space, at height,
away from civilization
*Images are for illustration purpose only.
9. Key Drivers Using Robotics – Safety & Cost
Safety –
Personnel and Asset
Environment –
harsh and hazard
environment, reduce
accidents
Economic –
Efficiency and
profitability
*Image is for illustration purpose only.
10. Human vs Robot – Each has its advantages!
Source: Shell report – Robotics, Sensing and Process Control Capabilities
Though less versatile than human engineers, robotic systems can operate
continuously, maintain consistently high performance and function in a huge
range of temperatures and air quality conditions. -- Shell
ROBOTS
24/7 Operations
Air Quality
Temperature Range
Consistency
Speed
Versatility
HUMAN
Compare Human and Robots, Robot technology climbing the
technology ladder -- Shell
Surveillance
and inspection
Maintenance
Autonomy
Normally
Unmanned
Facilities
Robotised
Facilities
The robot technology ladder will take
us from the use of robots for
surveillance and inspection activities
to the development and operation of
fully robotised facilities.
11. Human vs Robot – Each has its advantages!
Source: Yokogawa proprietary research by Omdia
13. Example of Robot Operators in Unattended Facility
First Generation
Second Generation
Third Generation
-- CHIMP
ExR1 running on unattended NAM
I can
detect it!
I can
fix it!
Source: https://www.yokogawa.com/eu/blog/oil-gas/en/robots-oil-gas/
Source: Total ARGOS project site at http://argos.ep.total.com/en/
14. Examples of Inspection Drones
Chimney Inspection using
ROAV (Remotely
Operated Aerial Vehicles)
without process shutdown
in 2013
Source: Shell report – Robotics, Sensing and Process Control Capabilities
15. Examples of Inspection Drones
Today, drones inspect flare tips,
floating roof tanks, pipelines, etc.
regularly.
Source: Yokogawa Corporate of America User Conference 2018
*Images are for illustration purpose only.
16. Petrobot Project by SPRINT Robotics
Remote inspection of pressure vessels and above ground storage tanks
(This project finished in Oct 2016. It is managed by SPRINT Robotics.)
• The SPRINT Robotics Collaborative aims
to achieve field use of robotics for
inspection and maintenance of capital
intensive infrastructure assets on a very
large scale within the next ten years.
• Using robotics in the domain of technical
inspection and maintenance of capital
intensive infrastructure is of vital
importance because of the urgency to
minimize the impact on safety and the
environment.
• In addition, robotic inspection and
maintenance may reduce shutdown
times, preventing human entry of vessels
and other equipment, as well as reduction
of costs related to services required to
enable human entry.
Source: http://petrobotproject.eu/
17. Benefits Using Robotics for Industrial Automation
Main drivers triggering investment in robotics and automation solutions
100% = 85 respondents
Reduce cost (e.g., for production)
Improve quality
Increase productivity through R&A
Improved capabilities of robots (technology driven)
Enable higher flexibility in production
Reinforcing safety increase (e.g., tasks are too dangerous for employees)
(Physical) unburdening of employees
Respond to labor shortage
Decreasing robot prices
New application enabled by new R&A technology
New applications in production require additional equipment
Brand perception
82
55
54
54
49
42
36
34
31
24
19
2
0
Primary potential benefits
Increase efficiency
and productivity
Reduce error,
re-work, and
risk rates
Improve safety for
employees in
high-risk work
environments
Perform lower value, mundane
tasks so humans can work
collaboratively to focus on more
strategic efforts that cannot be
automated
Enhance revenue by improving
perfect order fulfillment rates,
delivery speed, and ultimately,
customer satisfaction
Source: McKinsey Global Robotics Survey 2018
Source: Deloitte “using autonomous robots to
drive supply chain innovation”.
18. End User Demands & Value
End users see the cost of robots as a key challenge to their greater use.
Cost of robots
General lack of experience with automation
Lack of homogeneous programming platforms/interfaces
Lack of integrators working across
OEMs/geographies/industries
Lack of availability of fitting robot or automation solution
Safety concerns or unknown safety requirements
No possibility of retrofits/no compatibility with existing
equipment
Contracts with existing labor force
Cost of training
16
15
13
12
9
8
3
3
2
53
23
28
27
25
22
34
13
18
Customers indicating top challenge, % Customers indicating top 5 challenge, %
Source: McKinsey Global Robotics Survey 2018
19. End User Demands & Value
“Cost of robots” drops 50% in every 10 years
• Many promise or successful Robot & Drone technology
trials have been done. each trial was deigned for a
particular applications. It is hard to scale.
• Each robotics has its own interface, type of data storage
on premise or in the cloud -- data silos
• Large amount of data have been collected, needs data
orchestration and analysis using AI/ML to provide
actionable knowledge
• Integrate robotics into existing operations, control
systems and standard operating procedures
21. Yokogawa Role – Integration Solution Provider
A customer driven initiative to
• Enable fast and seamless adoption
of robotics
• Help avoid creation of new Silo-ed
systems
• Contribute technical and business
know-how of Process Industry
in-line with customer expectations
• Identify and fill gaps in vision of
future of IA
• Provide RaaS (Robot-as-a-Service)
End User
(Customer)
Integration
Solution Provider
Technology
Provider (Partner)
*Logos are for illustration purpose only.
22. Yokogawa Role – Integration Solution Provider
Applications
Yokogawa
Robot OEMs
Robot
Hardware
Robot
Firmware
Basic Control
Software
Advanced
Control
Software
APIs Integration
23. Robots bring eye, ear, nose, hands to the Facility
Robots Sensor Payload
• Heterogeneous, multiple robots expand the scope of operations and
maintenances
• Transparent connectivity with existing IA systems and user applications
• Value-added applications with data collected by robots, systems, and
sensors that support customer’s decision making
Yokogawa Robotics Service Platform offers the following
Visual inspection
Thermal inspection
Gas Detection
Sound Detection
Vibration Measurement
Scraping and Painting
Automated Sampling
Electric Component Replacement
Non-critical Startup and Shutdown
Multi-Arm Coordination for Complex Tasks
Autonomous Navigation
Integrated HMI
Data Analysis (AI&ML)
Robots Fleet Management
Key Functions
MobileRobotsBasicFunctions
*Images are for illustration purpose only.
24. One platform -- many robots, many applications
Robot Fleet Management
Coordinate – Collect -- Control
IA System Interface
Existing
Control
System and
Asset
Management
System
Pipeline
Inspection
Surveillance
First
Responder
Emission
Detector
Subsea
platform
monitoring
Data Aggregate
& Analysis
Single Integrated
HMI
Robot
Partners
Pressure
Vessel
Inspection
Tank
Inspection
Security
&
Safety
*Logos are for illustration purpose only.
25. The First Robotics Partner -- ExRobotics
Scope: Operator Round Automation at large
refinery in South Asia
• Robot function as co-operator perform
some routing operator run within facility
• 24/7 operator run
*Image is for illustration purpose only.
27. From Human-Centric to Machine-Centric Operations
Unattended Remote Operations
Consolidated Control Room
Robots & Drones
Devices
AI /ML,
AR/VR
Autonomous
AI control
Automated Semi-Autonomous Operations Autonomous
Automation System
& Sensors
COVID-19 speedup robot
adoption for remote control
for unattended facility
*Images are for illustration purpose only.
29. The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders.
Robotics – Mainstream for
Industry Autonomy
Let’s work together regardless of
whether you are asset owner, system
integrator, or robot/drone technology
solution provider. The goal is to
remove the need for human to work in
hazardous environment and improve
quality of life.