"Wireless Retrofits in Process Industries for Enhanced Plant ...

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  • On an industry wide basis, just by the numbers, the opportunity to make use of stranded smart transmitter data is huge. HART is nearly 40% of installed base [20+ million] An estimated 85% of these HART devices are stranded – they are connected to analog-only loops. If you run the numbers, there are an estimated (39% x 55 million) x 85% = 18 million stranded HART devices.
  • Plant Asset management assesses performance, availability, and reliability of machinery, production, and automation assets. PAM capabilities includes process monitoring, smart devices, calibration and compliance management. Integration is necessary for PAM Plant Asset Management also can determine the nature of potential problems and utilizes equipment modeling to optimize performance of all plant assets
  • Profitability is no longer just about growing sales; it's also about organizational efficiency. Plant Asset Management can improve the performance of each asset Although originally aimed at maintenance PAM is much more Predictive Condition Monitoring provides early failure warnings resulting in increased availability and significant cost savings. Downtime and production interruptions can be avoided using PAM strategies. Process modeling and simulation techniques are becoming popular for asset optimization.
  • "Wireless Retrofits in Process Industries for Enhanced Plant ...

    1. 1. Wireless Retrofits for Enhanced Plant Asset Management July 07 Vancouver, BC Paul Sereiko
    2. 2. Speaker Background <ul><li>Paul Sereiko </li></ul><ul><ul><li>Professional </li></ul></ul><ul><ul><ul><li>President and CEO, AirSprite Technologies </li></ul></ul></ul><ul><ul><ul><ul><li>Industrial wireless sensing software and infrastructure </li></ul></ul></ul></ul><ul><ul><ul><li>Founding CEO, Sensicast Systems, Inc. </li></ul></ul></ul><ul><ul><ul><ul><li>Wireless sensor networking solutions </li></ul></ul></ul></ul><ul><ul><ul><li>EVP Marketing, PinPoint Corporation </li></ul></ul></ul><ul><ul><ul><ul><li>Real-time wireless location systems </li></ul></ul></ul></ul><ul><ul><li>Professional Affiliations </li></ul></ul><ul><ul><ul><li>Co-chair, ISA-SP100 Marketing Working Group </li></ul></ul></ul><ul><ul><ul><li>HART Communication Foundation, Marketing Group </li></ul></ul></ul><ul><ul><li>Education </li></ul></ul><ul><ul><ul><li>BC Computer Engineering, University of Illinois, Champaign </li></ul></ul></ul><ul><ul><ul><li>MBA, Northwestern University (Kellogg) </li></ul></ul></ul><ul><ul><li>Contact </li></ul></ul><ul><ul><ul><li>[email_address] </li></ul></ul></ul><ul><ul><ul><li>508.281.2720 </li></ul></ul></ul>
    3. 3. Agenda <ul><li>2008 – The Year of Industrial Wireless? </li></ul><ul><li>Plant Asset Management Baseline </li></ul><ul><li>Turbocharging PAM with Wireless Retrofits </li></ul><ul><li>Suggested Best Practices </li></ul><ul><li>Conclusions and Q&A </li></ul>
    4. 4. 2008 – The Year of Industrial Wireless? <ul><li>Maybe … </li></ul><ul><ul><li>Standards emerging: </li></ul></ul><ul><ul><ul><li>Wireless HART, spec approval by 2007 year end </li></ul></ul></ul><ul><ul><ul><li>ISA100, spec approval during 2008 </li></ul></ul></ul><ul><ul><li>Mesh networking reliability challenge resolved: </li></ul></ul><ul><ul><ul><li>Dust SmartMesh >99.9% data throughput </li></ul></ul></ul><ul><ul><li>Early adopter products enjoying commercial success: </li></ul></ul><ul><ul><ul><li>Emerson 1420, etc. </li></ul></ul></ul><ul><li>Maybe not … </li></ul><ul><ul><li>Security </li></ul></ul><ul><ul><li>Interoperability and compliance </li></ul></ul><ul><ul><li>Integration with existing business processes </li></ul></ul>
    5. 5. Whatever the Year – Most Want Wireless for Monitoring and Alerting Source: ISA SP100 Survey
    6. 6. Typical Wireless Deployment – ALL NEW! <ul><li>New wireless transmitters: </li></ul><ul><ul><li>Expensive </li></ul></ul><ul><ul><li>How do I provision these? </li></ul></ul><ul><li>New network: </li></ul><ul><ul><li>Where do I put these repeaters? </li></ul></ul><ul><ul><li>How do I know the signal is actually getting through? </li></ul></ul><ul><ul><li>Can I trust the data on the other end? </li></ul></ul><ul><ul><li>What if my control process gets all messed up? </li></ul></ul><ul><li>New software: </li></ul><ul><ul><li>How do I integrate this stuff with my existing systems? </li></ul></ul><ul><ul><li>Is this really going to work with my DCS? </li></ul></ul>Gateway DCS & Host Applications Repeater Repeater
    7. 7. An Alternative – Retrofit Your Wired Instrumentation <ul><li>Add wireless adapters to existing 4-20mA-only smart devices (e.g. HART) </li></ul><ul><li>Continuously access smart device info </li></ul><ul><ul><li>Device status </li></ul></ul><ul><ul><li>Diagnostics </li></ul></ul><ul><ul><li>Configuration </li></ul></ul><ul><li>Use standards (e.g. OPC) to connect data to enterprise systems … PAM, CBM, etc. </li></ul><ul><li>Bypass the DCS </li></ul>Existing HART Devices Wireless Adapters Analog Only I/O Gateway Legacy DCS 4-20 mA Signal OPC & Host Applications PV Data HART Data
    8. 8. Why Retrofit? Continuously Use Valuable Data in Stranded HART Instruments <ul><li>35-40 data items in every HART device </li></ul><ul><ul><li>Device Identification </li></ul></ul><ul><ul><li>Basic Calibration data </li></ul></ul><ul><ul><li>Process Variables </li></ul></ul><ul><ul><li>Diagnostic Alerts </li></ul></ul><ul><li>Data is easily accessed by HART-enabled systems </li></ul><ul><li>Continuous, real-time access enables operation and asset management improvements </li></ul><ul><li>35-40 data items in every HART device </li></ul><ul><ul><li>Device identification </li></ul></ul><ul><ul><li>Basic calibration data </li></ul></ul><ul><ul><li>Process variables </li></ul></ul><ul><ul><li>Diagnostic alerts </li></ul></ul><ul><li>Data is easily accessed by HART-enabled Systems </li></ul><ul><li>Continuous, real-time access enables Operation and Asset Management improvements </li></ul>Screen image source: HART Communication Foundation SDC625 software
    9. 9. More Valuable HART Data…
    10. 10. Quantity of Stranded Data is Huge Source: ARC Advisory Group ~56 Million Devices in 2006 (Press, Temp, Flow, Level, Valve Positioners, Analytical) 23.5M 1.7M 5.6M 18.5M 6.7M 20.0M 3.5M
    11. 11. WirelessHART Adapter Example <ul><li>Connects anywhere on 4-20 mA loop </li></ul><ul><ul><li>Series connection enables loop power option </li></ul></ul><ul><ul><li>Parallel connection can simplify installation </li></ul></ul><ul><li>Sends/receives HART via wireless and wired transmission </li></ul><ul><li>Enables direct path to host applications, bypassing legacy DCS </li></ul>OPC & Host Applications (PAM, CBM, etc.) Existing HART Devices Gateway To DCS Series Adapter Parallel Adapter SEND HART commands Receive HART digital data
    12. 12. Wireless Adapters Enable New, Low-Cost Monitoring Points <ul><li>Need transmitter to retrofit (can be dumb or smart) </li></ul><ul><li>Need field power supply </li></ul><ul><li>Need wireless adapter </li></ul><ul><li>Don’t need a new, expensive wired loop </li></ul>+ - 4-20 mA Transmitter (Smart or Dumb) Wireless Adapter 24 V Field Powered OPC & Host Applications (CBM, Historians, PAM, Advanced Control, etc.) Gateway 4-20 mA and/or Smart Data
    13. 13. Wireless Connects Directly to Plant and Enterprise Applications Process Packaging, Warehouse CIP CIP Analog-only legacy control Ethernet IP Plant Control Network Enterprise Network ERP, MRP, Asset Mgmt DCS Wireless digital communication
    14. 14. Agenda <ul><li>2008 – The Year of Industrial Wireless? </li></ul><ul><li>Plant Asset Management Baseline </li></ul><ul><li>Turbocharging PAM with Wireless Retrofits </li></ul><ul><li>Suggested Best Practices </li></ul><ul><li>Conclusions and Q&A </li></ul>
    15. 15. PAM Manages Performance, Availability, and Reliability of Plant Assets Source: ARC Advisory Group PAM
    16. 16. PAM Solutions Monitor, Predict, and Optimize <ul><li>Monitor asset health, typically sensing in real time </li></ul><ul><li>Assess to predict potential problems </li></ul><ul><li>Optimize maintenance and operations decisions </li></ul>Sense Assess Decide Act <ul><li>Wired sensors </li></ul><ul><li>Wireless sensors </li></ul><ul><li>Virtual sensors </li></ul><ul><li>HART devices </li></ul><ul><li>Historians </li></ul><ul><li>Predictive analytics </li></ul><ul><li>Condition monitoring </li></ul><ul><li>Trending </li></ul><ul><li>Preventative maintenance </li></ul><ul><li>Predictive maintenance </li></ul><ul><li>Run to failure </li></ul><ul><li>Reliability-centered maintenance </li></ul><ul><li>Enterprise Asset Management (EAM) </li></ul><ul><li>Computerized Maintenance Management Systems (CMMS) </li></ul>Feedback / Improve
    17. 17. PAM Use Cases – Smart Valves <ul><li>Abnormal position vs. valve demand </li></ul><ul><li>Automated detection of valve or positioner malfunctions </li></ul><ul><li>Faster and control-room based troubleshooting and routine testing </li></ul><ul><li>More accurate problem diagnosis </li></ul><ul><ul><li>Fewer false positives and needless valve teardowns </li></ul></ul><ul><ul><li>Fewer unnecessary replacement parts </li></ul></ul><ul><li>Valves operate closer to rated performance </li></ul><ul><ul><li>Possible results: Increased plant capacity, higher yields, greater process efficiency </li></ul></ul>Screen image source: Emerson AMS ValveLink™ software
    18. 18. What’s Driving PAM? More and more plant assets Smaller size of field staff Aging boomer workforce retiring More loops per technician (500 to 2000) Less expertise per technician Managing plant assets now takes more than just the workforce
    19. 19. PAM Use Case – Measurement Instruments <ul><li>Detect and resolve problems more quickly and efficiently </li></ul><ul><ul><li>Alert operators and maintenance before process degrades </li></ul></ul><ul><ul><li>More efficiently schedule repairs </li></ul></ul><ul><li>Save labor on routine calibrations </li></ul><ul><ul><li>Don’t need to be located </li></ul></ul><ul><ul><li>No handwritten reports </li></ul></ul><ul><ul><li>Results are digitized and available as documents </li></ul></ul>
    20. 20. PAM Benefits Go Beyond Maintenance -60 -40 -20 0 20 40 Unplanned Breakdowns Spare Parts Inventory Costs Production Downtime Product Defects Plant Availability Workforce Efficiency Asset Performance % Improvement Beyond Maintenance Source: ARC Advisory Group Huge Opportunity for Users to Improve
    21. 21. PAM is Growing Rapidly Historical CAGR = 10.4% Source: ARC Advisory Group Worldwide Sales ($ millions)
    22. 22. Example Suppliers of PAM Systems <ul><li>ABB </li></ul><ul><li>Bently Nevada </li></ul><ul><li>Bruel Kjaer Vibro </li></ul><ul><li>Emerson Process Management </li></ul><ul><li>FLIR Systems </li></ul><ul><li>Honeywell </li></ul><ul><li>Invensys </li></ul><ul><li>Rockwell Automation </li></ul><ul><li>SKF Condition Monitoring </li></ul>
    23. 23. PAM Enables Predictive Monitoring & Maintenance <ul><li>“ Industry reports estimate that by changing 25% of all preventive maintenance to predictive maintenance, which is five times less costly than preventive maintenance, an organization could potentially realize an up to 60% reduction in maintenance expenses alone.” </li></ul><ul><ul><ul><li>Source: ‘Thar's Gold in That Plant-Floor Data' </li></ul></ul></ul><ul><li>By Howard Mars, InTech </li></ul><ul><li>$50,000,000 /year in maintaining 40,000 points = </li></ul><ul><ul><li>$1,250 per point/per year </li></ul></ul><ul><ul><li>Source: Chemical Industry Plant Manager </li></ul></ul>Predictive monitoring & maintenance require field data that is often unavailable other than via manual surveys, if at all.
    24. 24. Agenda <ul><li>2008 – The Year of Industrial Wireless? </li></ul><ul><li>Plant Asset Management Baseline </li></ul><ul><li>Turbocharging PAM with Wireless Retrofits </li></ul><ul><li>Suggested Best Practices </li></ul><ul><li>Conclusions and Q&A </li></ul>
    25. 25. Combine PAM and Wireless to Improve Operations and Maintenance <ul><li>Retrofit stranded HART devices to: </li></ul><ul><ul><li>Better manage instrument assets </li></ul></ul><ul><ul><li>Provide backup primary variable signals for operators </li></ul></ul>PAM Wireless <ul><li>Add measurement points via adapters to: </li></ul><ul><ul><li>Better manage machinery and production assets </li></ul></ul><ul><ul><li>Cut costs of new monitoring points </li></ul></ul><ul><ul><li>Enable process improvements </li></ul></ul>+ - 4-20 mA Transmitter (Smart or Dumb) 24 V Field Powered HART Transmitter Legacy DCS
    26. 26. Reaping the Benefits of Standards-Based Wireless and PAM WirelessHART adapters and new wireless measurement points enable continuous, predictive monitoring of assets. Waiting for manual surveys to identify equipment problems is often too long. WirelessHART adapters cuts time-to-resolution by continuously enabling remote diagnostics and problem solving. Detecting and troubleshooting instrument problems is time consuming. Automate collection of field data to let staff focus on highest value activities. Manpower reductions, aging workforce. Wirelessly access locked data via WirelessHART adapters for improved monitoring and PAM of automation assets. Valuable information locked in smart field instruments. Solution Problem
    27. 27. Reaping the Benefits of Standards-Based Wireless and PAM Broaden access to real-time data via retrofits of existing devices and addition of new points to improve decision making. Incomplete field-data picture complicates time-sensitive decisions. Comprehensive picture of plant health cuts operating costs and improves plant productivity. Extra costs of under (or over) maintaining assets. Wireless networks bypass legacy DCS and integrate real-time monitoring data with plant management and enterprise systems. Getting data needed for PAM from plant through DCS is difficult. Field-powered wireless adapters add new PAM (or process) measurement points without long wire runs and use existing 4-20 mA instruments. New monitoring points for equipment assets involves costly runs of wire between DCS and field. Solution Problem
    28. 28. Agenda <ul><li>2008 – The Year of Industrial Wireless? </li></ul><ul><li>Plant Asset Management Baseline </li></ul><ul><li>Turbocharging PAM with Wireless </li></ul><ul><li>Suggested Best Practices </li></ul><ul><li>Conclusions and Q&A </li></ul>
    29. 29. Enter Learning Curve for Standard-based Wireless in ‘07 <ul><li>Sessions like this </li></ul><ul><li>ISA 2007 exhibits (SP100, HART, vendors) </li></ul><ul><li>ISA SP100 involvement (users and vendors) </li></ul><ul><li>HART Communication Foundation involvement (mostly vendors) </li></ul><ul><li>HART Communication Foundation events </li></ul><ul><li>Vendors </li></ul>
    30. 30. Accelerate Learning Curve by Piloting <ul><li>Start piloting now! </li></ul><ul><ul><li>Certified standard-based products not available for at least a year </li></ul></ul><ul><ul><li>Learn how reliable and easy-to-use (or not) today's technology is </li></ul></ul><ul><ul><li>Learn about the RF nuances of your environment </li></ul></ul><ul><li>Stand-alone pilot </li></ul><ul><ul><li>Do not integrate pilot with existing processes </li></ul></ul><ul><ul><li>Set up test processes for the stand-alone system </li></ul></ul><ul><li>Retrofit </li></ul><ul><ul><li>Low-cost, low-risk piloting </li></ul></ul><ul><ul><li>No need to install new devices </li></ul></ul>
    31. 31. Deployments in ’08 and Beyond <ul><li>Use standard-based products </li></ul><ul><ul><li>Wait for availability </li></ul></ul><ul><ul><li>Extract upgrade commitment from vendor </li></ul></ul><ul><li>Understand use of data </li></ul><ul><ul><li>Who are the human users of the information generated? </li></ul></ul><ul><ul><li>What systems do they rely on? </li></ul></ul><ul><ul><ul><li>DCS? </li></ul></ul></ul><ul><ul><ul><li>Historian? </li></ul></ul></ul><ul><ul><ul><li>PAM? </li></ul></ul></ul><ul><li>Understand integration issues with existing processes </li></ul><ul><ul><li>Single HMI or NOT? </li></ul></ul><ul><ul><li>Process modifications or NOT? </li></ul></ul><ul><li>View wireless’s ability to bypass the DCS as strategic for plant management and enterprise applications </li></ul>
    32. 32. Agenda <ul><li>2008 – The Year of Industrial Wireless? </li></ul><ul><li>Plant Asset Management Baseline </li></ul><ul><li>Turbocharging PAM with Wireless </li></ul><ul><li>Suggested Best Practices for Wireless </li></ul><ul><li>Conclusions and Q&A </li></ul>
    33. 33. Conclusions and Q&A <ul><li>Retrofitting is the low-cost, low-risk first step into the world of standards-based industrial wireless networks </li></ul><ul><li>Wireless extends the reach and value of PAM solutions </li></ul><ul><ul><li>Enables economic monitoring of valuable field data </li></ul></ul><ul><ul><li>Enables bypass of DCS for integrating field data with plant management and enterprise systems </li></ul></ul><ul><li>Start piloting in ’07 to get ready for standards-based products in ‘08 </li></ul>

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