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The onshore digitalization wave with Industry 4.0, new technology and market trends are changing the requirements for maritime control systems.
Marked trends drives towards green technology, digitalization, improved efficiency, cost reduction, more reliable solutions, safer systems and more focus on life-cycle cost.
Another driver is that innovation in digitalization is a way to sustain and improve the competitiveness for Western-Europe and US suppliers in the face of lower labour costs and competition from Asia.
The first solutions that can be labelled “Marine 4.0” are entering the market:
- Performance monitoring
- Condition based monitoring and predictive maintenance
- Remote access and trouble shooting
- Remote controlled operations
- Autonomous operations going towards autonomous vessels
The main barriers for moving faster towards developing Maritime 4.0 applications are often human and organisational:
- Internal resistance from specially the aging workforce in adopting new technology, work methods and processes
- Lack of skills in the workforce and lack of understanding of the benefits new technologies bring
- Unwillingness in standardisation of products and processes
- Limited resources assigned to design and plan the future solutions
Internet of things (IoT), artificial intelligence (AI), data analytics, cloud, big data are important technologies in meeting the new market trends. One challenge is to combine these computer science technologies with the traditional automation. Traditional automation systems often use PLC’s and IEC 61131 programming and are not suitable for utilizing these new technologies.
How can modern control system development tools, like CDP Studio, bridge the gap and allow companies start to develop reliable Maritime 4.0 ready control systems efficiently?
CDP Studio is an integrated development environment (IDE) using computer science technologies, but specially adapted for developing automation and control systems. It supports graphical programming interface similar to a PLC function block editor, has advanced auto generation of software code to assist engineers with only basic high-level programming skills and has the full-blown feature set expected by skilled software engineers.
For a SME, they only require one engineer able or willing to make high level software code to start the journey towards Maritime 4.0 applications. The rest of the team can continue to use their skill and competence on automation systems in a new tool, but in a familiar environment; thereby alleviating the adoption resistance to new technologies. This also reduces the effort and simplifies the training.
Another technical barrier is to set up a development environment as it is very different from the traditional PLC technologies. CDP Studio comes with the complete development environment out of the box and it is automatically installed and maintained. This feature is also appreciated by skilled software engineers.
CDP Studio has inherent properties supporting for standardizing products or product building blocks. This allows teams to share these in a controlled manner, reducing development and testing effort at the same time as increasing reliability and quality.
The competence gap is often seen as lack of skills in an automation engineer, but a capable software developer skilled in the computer science domain has a gap in understanding of automation systems, industrial protocols, industrial IO modules etc. CDP Studio also lower this competence gap as the automation technologies are easily available without detailed understanding of the technologies.
CDP Studio integrates the technologies and allows computer science engineers to easily use automation technologies and enables automation engineers to utilize the new technologies.
CDP Studio has been used in the marine industry for more than 15 years and developed to cover the new reality of Industrial Internet of Things, advanced sensors, digital twins, and modern technologies. The below examples demonstrate benefits for the product manufactures and the end customer.
Electrical XMT Handling System - Odfjell Deepsea Nordkapp platform
Digital twin, simulation, digitalization, green technology, safe and reliable, cost reduction
A custom-built X-mas tree electrical handling system with active heave compensation was delivered to the Odfjell Deepsea Nordkapp platform. The delivery included a digital twin and a full training simulator. The system is used for handling heavy subsea equipment on and in the proximity of subsea well heads. Safe and reliable operations of the system is of absolute importance.
Product vendor benefits
A digital twin was made with the integrated simulator module CDP Sim. This allowed the engineers continues testing during system development, both on their individual computers and HIL (hardware in the loop) with the actual control system. The flexibility saved time during development and ensured a high reliability as different critical situations could be thoroughly tested before delivery.
End customer benefits
The smart design with layers of physical and control system redundancy allows Odfjell to run operation without having other equipment on standby for safety which is required on other rigs. The training simulator on board the rig enables operator training before any critical operation.
The solution allows Odfjell to conduct operations safer and more efficiently. The all electric system is a greener alternative compared to more traditional hydraulic solutions.
Winches, Cranes and LARS – REV Ocean
Standardization, improved efficiency and cost reduction, green technology
REV Ocean, a unique exploration and research vessel with a focus to find solutions to environmental challenges and will investigate the entire marine ecosystem. The research equipment includes a LARS (Launch and Recovery System) for UAV, different scientific winches, fishing system and cranes.
Although the systems are unique to REV Ocean, the control system is built by already developed functional modules (high level building blocks) that are tested, and version controlled together with some custom functions. In this way, a unique solution benefit from standardization, thereby achieving cost reduction, faster project execution and a reliable system.
The all electric solution supports REV environmental and green vision.
Autonomous Gangway – Uptime International
Autonomy, digital twin, safe and reliable, Combining computer science with traditional automation
The active motion control (AMC) gangways are used for personnel and equipment transfer to offshore windmills and oil rigs. The new auto- landing feature increases safety and reduces cost as an operator is not required for the landing or to sit and monitor the operation while the system is in use.
The control system runs on powerful industrial computers for fast calculations, integration of 2D cameras and 3D sensors in combined with standard industrial automation I/O component and instrumentation. Thus, giving both high degree of flexibility and reliability in an advanced, distributed and real-time system.
Digital twins, simulation and HIL test setup like the Odfjell Nordapp rig was used verify the control system quality and operational safety.
Underwater Drone Docking Station – Blue Logic / Equinor
Improved efficiency, cost reduction, cloud
The Blue Logic charging station is part of Equinor’s vision to have a network of subsea charging station on the NCS (Norwegian Continental Shelf) to allow autonomous UAVs from any supplier to dock, charge and transfer data. This can give Equinor cost reduction in operating their subsea oil installations and for any UAV operator to compete for the jobs.
A vendor independent development platform allows the use of hardware from various vendors reduces the development time and provides a seamless integrated user experience for operational efficiency. The solution combines the control function with a small SCADA system and can ensure that the vendor specific data is transferred to the correct cloud service.
Remote Monitoring and Cloud Connection
Improved efficiency, cost reduction, life-cycle cost, cloud
The above cases all include the Marine 4.0 functions as data logging for condition-based maintenance, remote monitoring and support; all are functions important for life-cycle cost. Flexible tools as CDP Studio enables you to collect information from any PLC, computer system or sensor and scales from simple collect and forward solutions to an edge server with local data storage, advanced calculations, provide onboard information to the crew and transfer the right data at the correct time to any cloud service.
CDP Studio provide key qualities that are important when developing maritime control, automation and monitoring systems.
The strictly modular structure used when building systems with CDP Studio, combined with the built-in tools for testing, analysis and simulation, helps to build rugged, reusable software components. CDP Studio also works well with third party automated testing tools and version control systems.
As a true cross platform development tool, CDP Studio let you use equipment from different vendors, combine Windows and Linux on x86 and ARM architectures; even in the same distributed control system giving you full flexibility.
Modern marine systems need to interface operational data from multiple sources as well as deliver data to a cloud-based analytics service or other onboard systems. This asks for data processing beyond traditional automation. CDP Studio combines a powerful automation framework with an openness to additional software elements in C++, Python, Java, HTML5 and opensource.
The extreme modularity of CDP Studio is a key to build robust systems, enable teamwork, simplify testing, improve reusability, and help maintenance. In other words; increase quality and reduce development cost.
End User Value
The value of software tools is measured in saved developer hours; the hours to build the environment and toolchains, as well as maintaining these, are non-productive direct cost. A development platform with relevant protocols and HW integrations in place,
saves even more hours. CDP Studio let you focus on your core competence and add real value to the end user.
The HMI design is fully integrated in the development tool to achieve advanced interaction between the control core and the visual presentation.