Case Study

Industrial IoT and Cloud Services Integration

IoT for Water Supply

Enhancing Water Supply Management at Georg Fischer Piping Systems

Category: Software. Due Dilience, Business Model
Client: Georg Fischer Piping Systems (GFPS)
Date: 2021-2022
Regions: Switzerland, Germany

Abstract

This case study explores the integration of industrial IoT and cloud services, Hycleen Automation, into existing control systems at Georg Fischer Piping Systems (GFPS). The integration aimed to reduce energy consumption, ensure optimal hygiene standards, and maintain compliance for buildings like hospitals and care homes. The project involved a comprehensive analysis of business models, technical functions, and organizational requirements. Key steps included protocol selection, physical layer assessments, and lifecycle management.

The integration process involved several phases, including requirements gathering, QFD analysis, prototype development, and final vendor selection. The outcome was a cloud-based solution that enhanced operational efficiency, improved hygiene compliance, and enabled predictive maintenance. The transformation positioned GFPS as a leader in smart water management, demonstrating the potential of IIoT and cloud technologies in revolutionizing traditional industrial processes.

Challenge

Georg Fischer Piping Systems (GFPS), a leading flow solutions provider, faced several challenges in integrating their Hycleen Automation System, an industrial IoT solution for water supply management, into existing control systems. The primary objectives were to reduce energy consumption, ensure optimal hygiene standards, and maintain compliance for buildings such as hospitals, care homes, and large residential complexes.

Legacy Infrastructure

The existing Hycleen Automation System required on-site management and lacked remote accessibility, which often led to neglected inspections and increased risks of improper operation. This limitation hindered GFPS’s ability to provide efficient and timely services to their clients.

Data Management and Analysis

With the growing complexity of water management systems, GFPS needed a solution to collect, analyze, and act upon vast amounts of data generated by sensors and devices across multiple locations. The challenge was to transform this data into actionable insights for operational optimization and predictive maintenance.

Scalability and Integration of industrial IoT and Cloud Services in corporate IT

As GFPS expanded its operations globally, the company faced difficulties in scaling its IoT solution across different countries and integrating it with various existing building management systems. The need for a unified, scalable platform that could accommodate diverse regulatory requirements and technical specifications became apparent.

With quite strict requirements in IT-architecture and IT-security, GFPS, or rather GF as a world-wide group, needed the solution to fit exactly their existing rules.

Solution

To address these challenges, GFPS implemented a comprehensive industrial IoT and cloud services solution that leveraged device and cloud services integration.

Cloud-Based Remote Access

GFPS transformed their product by retrofitting it with IoT capabilities. This involved:

1. Upgrading the firmware of the Hycleen master device to support cloud communication.

2. Implementing a cloud-native IIoT solution that integrated sensors, connectivity, and analytics.

3. Developing a user-friendly interface for remote monitoring and control.

Advanced Data Analytics

The industrial IoT and cloud services solution incorporated advanced AI/ML algorithms to analyze real-time data from machines and devices. This enabled:

• Actionable insights for operational optimization

• Predictive maintenance capabilities

• Remote monitoring of critical system parameters

Scalable and Secure Architecture

GFPS implemented a hybrid solution that combined cloud voice and traditional line routing to accommodate varying regulatory requirements across different countries. This approach allowed for:

• Consolidation of calling solutions through Microsoft Teams

• Integration of Luware for enhanced contact center functionality

• Seamless addition of new users, features, and functionality without significant infrastructure investments

Project Phases

The integration project was executed in several phases:

1. Requirements Gathering: Comprehensive analysis of business model, features, and benefits.

2. QFD Analysis: Mapping technical functions to organizational requirements.

3. Make-Buy Decisions: Evaluating in-house development versus third-party solutions.

4. Vendor Listings and RFQ: Identifying potential partners and requesting quotations.

5. Prototype Builds: Constructing and assessing three prototype iterations.

6. Final Vendor Selection: Choosing the most suitable technology partners.

Results

The integration of industrial IoT and cloud services into GFPS’s Hycleen Automation System yielded significant benefits across multiple areas.

Improved Operational Efficiency

A key benefit is less service cost for GFPS and reduced waiting times for customers. With predictions using AI/ML in the Industrial IoT and cloud services can be dispatched even before issues arise.

1. Remote Monitoring and Control

• Facility managers can now access and control multiple water installations across various buildings from any location.

• Real-time monitoring through well-prepared dashboards provides instant visibility into system performance.

2. Automated Processes

• Hydraulic balancing and flushing are now automated, ensuring optimal water circulation and hygiene.

• Consumption-controlled flushing optimizes water usage and energy consumption.

3. Predictive Maintenance

• Advanced analytics enable proactive identification of potential issues, reducing downtime and maintenance costs.

Enhanced Hygiene and Compliance

1. Legionella Prevention

• Continuous monitoring of water temperature and flow helps prevent the growth of Legionella bacteria.

• Controlled thermal disinfection can be executed remotely when necessary.

2. Regulatory Compliance

• Automated logging and reporting of critical data points ensure compliance with hygiene regulations for sensitive environments like hospitals and care homes.

Energy and Resource Savings

1. Optimized Water Usage

• Smart flushing algorithms reduced unnecessary water consumption by flushing only the required volume.

2. Energy Efficiency

• The system’s ability to balance hot and cold water circulation led to significant energy savings.

Scalability and Integration

Industrial IoT and cloud services has many interaction points for humans-in-the-loop (alarms, logging, reports etc.). Therefore communications need to be integrated and deployment happens within the same VDC.

1. Unified Communication Platform

• Integration with corporate IT allowed GFPS to consolidate their communication systems, such as e-mail, SMS and video conferencing) across global services and back-office facilities.

2. Flexible Deployment

• The hybrid cloud solution enabled GFPS to comply with varying international regulations while maintaining a consistent user experience.

3. Seamless Integration

• The Hycleen System can now be easily integrated into existing building management systems, expanding its applicability across various building types.

Customer Experience Improvement

1. Proactive Service

• Remote alarming capabilities allow GFPS to set up individual alarms triggered by specific data values, enabling proactive customer support.

2. Streamlined Maintenance

• Customers can request maintenance services by granting GFPS remote access to their installation and data.

3. Continuous Improvement

• Remote updates ensure that the Hycleen Master always has the latest firmware, providing customers with ongoing enhancements and features.

Business Model Transformation

Using industrial IoT and cloud services is always tightly integrated into the business model. As some services are renewd and changed the aspects of the business model need to be transformed.

1. Shift to Service-Oriented Model

• The cloud-based solution has enabled GFPS to transition from a product-centric to a service-oriented business model, offering ongoing value to customers.

2. Data-Driven Decision Making

• Access to comprehensive operational data allows GFPS to make informed decisions about product development and service offerings.

3. Expanded Market Reach

• The scalable, cloud-based solution has positioned GFPS to expand into new markets and building types more efficiently.

Vendor Selection and Partnership

The rigorous vendor selection process led by sensaco and undertaken by GFPS yielded significant benefits in the implementation and ongoing success of the IoT integration project.

1. Strategic Partnerships

• GFPS formed key partnerships with industry leaders in cloud services and IoT platforms, ensuring access to cutting-edge technologies and expertise.

• These partnerships facilitated smoother integration and provided ongoing support for system upgrades and maintenance.

2. Customization Capabilities

• The selected vendors demonstrated strong capabilities in customizing their solutions to meet GFPS’s specific requirements, particularly in adapting to various international regulations and building management systems.

3. Scalability and Future-Proofing

• The chosen technology stack proved highly scalable, allowing GFPS to easily expand the Hycleen system to new markets and building types without significant re-engineering.

• Vendors’ commitment to continuous innovation ensured that the Hycleen system could evolve with emerging technologies and market demands.

4. Total Cost of Ownership

• Through careful vendor selection, GFPS optimized the total cost of ownership for the IoT integration project, balancing initial implementation costs with long-term operational efficiency.

5. Knowledge Transfer

• The selected vendors provided comprehensive training and knowledge transfer programs, enabling GFPS staff to effectively manage and maintain the new IoT-integrated systems.

6. Ecosystem Development

The vendor selection process led to the creation of a robust ecosystem of technology partners, fostering innovation and collaborative problem-solving in future projects.

The key result from vendor selection is the seperation into responsibilities the client’s IT organisation had, managing the cloud as a virtual data center, providing service level agreements, IT security roles handed over when the product was finally run through penetration tests, and a industry-specific backbone of services provided by and licensed from a leading IoT software vendor.

Furthermore, integration of the IoT-vendor’s services into GFPS’ IT and service organisation was a hard requirement on overall lifecycle viability of the solution.

This strategic approach to vendor selection and partnership management significantly contributed to the overall success of the IoT integration project, positioning GFPS for long-term growth and innovation in the smart water management sector.

In conclusion, the integration of industrial IoT and cloud services has transformed GFPS’s Hycleen Automation System into a cutting-edge, remotely manageable solution. This transformation has not only improved operational efficiency and hygiene standards but also positioned GFPS as a leader in smart water management systems. The success of this integration demonstrates the potential of IIoT and cloud technologies in revolutionizing traditional industrial processes, paving the way for more sustainable and efficient building management practices.

A project as described in this case study needed vendors of general infrastructure, that is, a hyperscaler providing a VDC operated by GF. Furthermore, standard IoT operations was licensed off-the-shelf from the vendor who finally integrated Hycleen Automation. Sensaco’s contribution was to introduce industrial IoT and cloud services in workshops to the internal GFPS team, driving and executing vendor selection, and finally helping with key software architecture elements of the industrial IoT solution. Furthermore, yet another software partner did provide necessary resources to implement the customer-specific cloud services.

Further case study references and success stories regarding industrial IoT and GFPS’ solution approach:

Successful refurbishment of the hot water energy system (with industrial IoT). This case study gives further insights into how industrial IoT for building tec can reduce energy consumption. Specifically, refurbishment of older buildings using water control automation and industrial IoT clouds is discussed and savings by roughly 20% are claimed.
Germ-free drinking water in the Senior Citizens Residence. Potable water free of bacteria is of utmost importance in any health-care setting. This case discusses care-homes and applies to hospitals as well.
The Hycleen Automation System (…) retrofitted in just 4 months using akenza’s (industrial) IoT platform. Akenza was one of the IoT-platforms shortlisted for Hycleen Connect. The case study highlights implementation within 4 months of development and smooth integration into IT-operations.