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RFID-Based
Plant Data Collection&Management Systems
Italteleco at a glance:


Employees: 95

Business Areas:

•Document Management
•Management&Customization of Intergraph Sma...
RFID-Based applications developed by Italteleco:




            Blinding Management



            Scaffolding Management...
Software Requirements Specification


All the applications will be used in petrochemical plants during normal
construction...
Chosen Technology


1) It must be possible to install the applications on mobile devices
2) It must be possible to use the...
Chosen Technology


3) Items identification must be univocal
4) It must be possible to write information on the RFID tags
...
Chosen Technology


5) Applications must be interfaceable with other DB-based applications
6) It must be possible to acces...
Blinding Management


 About 2000 blind flanges are involved in the shutdown of a medium-
 sized plant. Flanges are insert...
Blinding Management
Data Preparation

 Blind positions are identified with a univocal code on the P&ID and on the blinding...
Blinding Management
Data Preparation

 Blind positions are identified with a univocal code on the P&ID and on the blinding...
Blind Management
Data Preparation

 Blind positions are identified with a univocal code on the P&ID and on the blinding pl...
Blinding Management
Data Preparation

 Information relative to blinding plans and blinds positions are loaded into the Dat...
Blinding Management
Data Preparation

 Properties shown in the figure are associated to every blind (fully customizable on...
Blinding Management
Operation

 For every blind position, an RFID tag is initialized with the blind identification code an...
Blinding Management
Operation




         Application login (using an RFID tag)   Main Menu
Blinding Management
Operation




               Blinding plans list   Blinding plan: checking general status
Blinding Management
Operation




               RFID Tag Reading   Setting status to “Identified”
Blinding Management
Operation




            Setting Status to “Inserted”   Setting Status to “Removed”
Blinding Management
Operation




           Interference Blinds: setting status to “Inserted” and registering start of ac...
Blinding Management
Accessing information

 Data from the field is synchronized daily (or at every shift change) with the ...
Blinding Management
Accessing Information

 Data from the field is synchronized daily (or at every shift change) with the ...
Scaffolding Management


  Scaffolding management software has
  allows management of scaffolding
  information such as po...
Scaffolding Management
Data Preparation

According to the information extracted from the “scaffolding
requirement form” an...
Scaffolding Management
Data Preparation

RFID tags are initialized with the scaffolding univocal identification code
and i...
Scaffolding Management
Operation

Using the PPC operators can register and manage the following
information:

•Scaffolding...
Scaffolding Management
Operation




         Application login (using an RFID tag)   Main Menu
Scaffolding Management
Operation




     Scaffolding data, operable/not operable status menu   Assigning the “Operable” S...
Scaffolding Management
Operation




            Registering begin of activities   Registering end of activities
Scaffolding Management
Operation




          Assigning the “Not Operable” Status   Successful information registration c...
Scaffolding Management
Accessing Information




         All the information are accessible through a web interface based...
Scaffolding Management
Accessing Information




              Plant view on Google Earth: selected scaffoldings are highl...
Scaffolding Management
Accessing Information




     Plant detail view:plot plan, 3D Model, Scaffoldings: Operable scaffo...
SmartPlant P&ID Mobile


SmartPlant P&ID Mobile has been developed to allow plant operators,
construction and maintenance ...
SmartPlant P&ID Mobile
Description of the system

SmartPlant P&ID mobile manages the following
SmartPlant P&ID objects:

•...
SmartPlant P&ID Mobile
Description of the system

A desktop application uses “Llama” libraries (Logical Model
Automation) ...
SmartPlant P&ID Mobile
Operation




              Unit Selection   Queries can be performed manually or using an RFID TAG
SmartPlant P&ID Mobile
Operation




              Query Results   Object visualizaton on the P&ID
SmartPlant P&ID Mobile
Operation




      Properties are categorized like on SPPID   Modification of a property on a pipe...
SmartPlant P&ID Mobile
Sample applications




Adding appropriate values of “Construction Status” allows a simple work pro...
SmartPlant P&ID Mobile
Sample Applications




Field data are written on the P&ID when data is synchronized: update time a...
SmartPlant P&ID Mobile
Sample applications




Items for which field data are available are easily identified with an appr...
Conclusions

Using RFID-based applications provides the following benefits:

•   Process management improvement
     •   P...
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Rfid Applications

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Transcript of "Rfid Applications"

  1. 1. RFID-Based Plant Data Collection&Management Systems
  2. 2. Italteleco at a glance: Employees: 95 Business Areas: •Document Management •Management&Customization of Intergraph SmartPlant applications •High definition laser scanning •As-Built Surveys •Development of mobile plant data management applications •Plant shutdown planning •Design of pressure vessels •Installation and maintenance of electrical/instrumental plants •Hardware&Software assistance and commercialization
  3. 3. RFID-Based applications developed by Italteleco: Blinding Management Scaffolding Management SmartPlant P&ID Mobile
  4. 4. Software Requirements Specification All the applications will be used in petrochemical plants during normal construction, operation and maintenance, they must therefore comply with the following requirements: 1) It must be possible to install the applications on mobile devices 2) It must be possible to use the applications in explosion risk areas 3) Items identification must be univocal 4) It must be possible to write information on the RFID tags 5) Applications must be interfaceable with other DB-based applications 6) It must be possible to access data from Intranet/Internet
  5. 5. Chosen Technology 1) It must be possible to install the applications on mobile devices 2) It must be possible to use the applications in explosion risk areas • Development Environment: Microsoft .NET Compact Framework Palm Sized PC (PPC) characteristics : • Operating System: Windows Mobile • RFID Scanner: 125 kHz • ATEX Certification
  6. 6. Chosen Technology 3) Items identification must be univocal 4) It must be possible to write information on the RFID tags RFID TAG characteristics : • Operating Frequency: 125 kHz • Chip: HITAG S 2048 (read/write) • ATEX Certification • Easily identifiable (yellow colour) Low operating frequency and RFID scanner’s characteristics require physical contact between RFID scanner and tag in order to complete any operation: It is therefore impossible either to operate on the wrong tag or to record wrong Information.
  7. 7. Chosen Technology 5) Applications must be interfaceable with other DB-based applications 6) It must be possible to access data from Intranet/Internet A desktop application ensures data synchronization between PPCs and DBs used to manage the various processes. Real-time access to information is ensured either by standard features of the interfaced data management systems or by a dedicated web interface, devoloped according to the Customer’s requirements
  8. 8. Blinding Management About 2000 blind flanges are involved in the shutdown of a medium- sized plant. Flanges are inserted and then removed in about 40 days. This process must be correctly managed and controlled, in order to ensure high safety levels and avoid problems that could lead to unwanted accidents and/or delays. It is therefore necessary: To verify the status (inserted/removed) of every blind flange. To verify the status of every interference blind flange (common to several blinding plans) To verify the completion status of every blinding plan To easily identify any potential problem
  9. 9. Blinding Management Data Preparation Blind positions are identified with a univocal code on the P&ID and on the blinding plan of each equipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.
  10. 10. Blinding Management Data Preparation Blind positions are identified with a univocal code on the P&ID and on the blinding plan of each equipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.
  11. 11. Blind Management Data Preparation Blind positions are identified with a univocal code on the P&ID and on the blinding plan of each equipment/piperun: Interference blinds (common to several blinding plans) are identified in this phase.
  12. 12. Blinding Management Data Preparation Information relative to blinding plans and blinds positions are loaded into the DataBase (in this case: Intergraph Directa): Relations are created between objects. Database data are daily synchronized with data from the field.
  13. 13. Blinding Management Data Preparation Properties shown in the figure are associated to every blind (fully customizable on request)
  14. 14. Blinding Management Operation For every blind position, an RFID tag is initialized with the blind identification code and initial status: initial status is set to “To be identified”, meaning the blind position has to be identified on the field. •Initialized tags are then mounted on a metallic support which is then placed in the correspondent blind position. •User registers, with the PPC, the correct placement : status is set to “Identified” •During the shutdown operations, users , using the PPC, register insertion/removal of blind flanges: Status is set to “Inserted”/”Removed” •Removal of interference blinds can be registered on the system only when all the operations concerning the blinding plans on which the interference blind appears have been completed. Users are constantly reminded that they are working on interference blinds.
  15. 15. Blinding Management Operation Application login (using an RFID tag) Main Menu
  16. 16. Blinding Management Operation Blinding plans list Blinding plan: checking general status
  17. 17. Blinding Management Operation RFID Tag Reading Setting status to “Identified”
  18. 18. Blinding Management Operation Setting Status to “Inserted” Setting Status to “Removed”
  19. 19. Blinding Management Operation Interference Blinds: setting status to “Inserted” and registering start of activities
  20. 20. Blinding Management Accessing information Data from the field is synchronized daily (or at every shift change) with the main DB: users can access information via the document management system (in this case: Intergraph Directa) Icons are coloured according to the blind status.
  21. 21. Blinding Management Accessing Information Data from the field is synchronized daily (or at every shift change) with the main DB: users can access information via the document management system (in this case: Intergraph Directa)
  22. 22. Scaffolding Management Scaffolding management software has allows management of scaffolding information such as position, volume, status (operable/not operable), work begin/end. A Google Earth interface allows visual check of space usage, operability, activities. About 1200 scaffoldings are involved in the shutdown of a medium-sized plant
  23. 23. Scaffolding Management Data Preparation According to the information extracted from the “scaffolding requirement form” and to the estimated position of the scaffolding, a database record is created.
  24. 24. Scaffolding Management Data Preparation RFID tags are initialized with the scaffolding univocal identification code and initial status;tags are then fastened to a signboard on the scaffolding.
  25. 25. Scaffolding Management Operation Using the PPC operators can register and manage the following information: •Scaffolding Operability •Begin of activities •End of activities
  26. 26. Scaffolding Management Operation Application login (using an RFID tag) Main Menu
  27. 27. Scaffolding Management Operation Scaffolding data, operable/not operable status menu Assigning the “Operable” Status
  28. 28. Scaffolding Management Operation Registering begin of activities Registering end of activities
  29. 29. Scaffolding Management Operation Assigning the “Not Operable” Status Successful information registration confirmation
  30. 30. Scaffolding Management Accessing Information All the information are accessible through a web interface based on Google Earth
  31. 31. Scaffolding Management Accessing Information Plant view on Google Earth: selected scaffoldings are highlighted
  32. 32. Scaffolding Management Accessing Information Plant detail view:plot plan, 3D Model, Scaffoldings: Operable scaffolding:green – not operable: red
  33. 33. SmartPlant P&ID Mobile SmartPlant P&ID Mobile has been developed to allow plant operators, construction and maintenance personnel, to access, view and modify SmartPlant P&ID information using a Palm Sized PC (PPC) Using RFID tags to identify equipments, instruments, piperuns, piping components, etc. queries on the system are automatically performed.
  34. 34. SmartPlant P&ID Mobile Description of the system SmartPlant P&ID mobile manages the following SmartPlant P&ID objects: •Equipments •Equipment Components •Instruments •Instrument Loops •Nozzles •Piperuns •Piping Components Graphic P&ID can be visualized on the PPC: an intelligent zoom is performed on the selected object (not working, in this version on piperuns)
  35. 35. SmartPlant P&ID Mobile Description of the system A desktop application uses “Llama” libraries (Logical Model Automation) and SmartSketch libraries to connect to SPPID database and performs the following operations: •Reads properties values of the various objects •Generates a mobile DB, which is transferred on the PPC •Converts graphic P&IDs from .pid to .dwg format •When properties are modified on the PPC, updates SmartPlant P&ID’s DB
  36. 36. SmartPlant P&ID Mobile Operation Unit Selection Queries can be performed manually or using an RFID TAG
  37. 37. SmartPlant P&ID Mobile Operation Query Results Object visualizaton on the P&ID
  38. 38. SmartPlant P&ID Mobile Operation Properties are categorized like on SPPID Modification of a property on a piperun
  39. 39. SmartPlant P&ID Mobile Sample applications Adding appropriate values of “Construction Status” allows a simple work progress monitoring: In the above figure, piperuns with hydrotest completed are highlighted in blue (data registered with PPC). Every construction status can be traced from prefabrication to “Ready for Start-Up”
  40. 40. SmartPlant P&ID Mobile Sample Applications Field data are written on the P&ID when data is synchronized: update time and cost is significantly reduced
  41. 41. SmartPlant P&ID Mobile Sample applications Items for which field data are available are easily identified with an appropriate display set
  42. 42. Conclusions Using RFID-based applications provides the following benefits: • Process management improvement • Process monitoring is easier with consistent, verified data • Problems are easily identified and managed • Identification errors are not possible • Easy and fast transition to the new system • Applications are designed to be as similar as possibile to the traditional working procedures (applications are fully customizable according to the Customer’s specifications • Training time for a low-skilled user: 2 hours. www.italteleco.it
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