RFID for Oil and Gas


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RFID for Oil and Gas

  1. 1. RFID for Oil and Gas T.S.Rangarajan (ts.rangarajan@tcs.com) Head, RFID Solutions Tata Consultancy Services Ltd. (http://www.tcs.com/rfid) © Tata Consultancy Services ltd. 7 June 2006 1
  2. 2. Agenda What is RFID and how does it work? RFID Tags and their classification RFID readers RFID Middleware RFID applications and value chain TCS in RFID RFID case profiles from TCS Detailed case study – Virgin Atlantic Questions from Petrofed members 2
  3. 3. What is RFID and how does it work? RFID identifies individual items Aircraft assemblies Aircraft sub assemblies Aircraft components RFID tags consist of Integrated chip Integrated antenna Varieties: Passive tags, active tags with (battery) power source, etc RFID readers can “read” many tags Line of sight not required Anti-collision prevents interference RFID readers may be Handheld or stationary RFID equipment has its own allotted frequency band 3
  4. 4. RFID - a bird’s eye view Reader broadcasts signal through antenna Antenna reads the data Reader sends data/info to and sends to reader Antenna computer for processing Reader Computer sends event based data to be stored on tag RFID Enterprise The Charged tag sends identifying Middleware Applications response back to the reader Polyethylene Media Chip Tag receives signal and gets charged Tag Copper coil antenna • Uses radio waves or micro waves for quick & automatic identification • Detection/data transfer is contact-less and doesn’t need line of sight • Tags can store data and help maintain historical information 4
  5. 5. RFID tags 125 kHz 13.56 MHz UHF 902-928 MHz 2.45 GHz 5
  6. 6. Classification of RFID tags 6
  7. 7. RFID tags and their frequencies Read range – 2 meters Low ( 125-134 kHz) Great penetration Slow data rate Costlier tag antennas Multiple tags cannot be read together Read range – 1 meter High Frequency (13.56 Good penetration MHz) Simultaneous read capability @ 50 tags Most progress on standard setting Read range –10 meters. UHF (868, 902-928 MHz) Fast data rate Simultaneous read capability @ 50 tags 2.45 GHz Read range – 1 meter Very fast data rate • Spectrum use is often regulated by governments (13.56MHz designated for ISM applications in most countries) • UHF frequencies (850 - 960 MHz) for RFID vary from country to country • Read range is greater with battery powered tags (active/semi passive) 7
  8. 8. RFID readers Basic readers Provide serial port interface Host initiated Request-Response protocol Basic commands includes reading a block, writing a block and locking Advanced readers Provide serial and ethernet interface TCP/IP stack included - provide Telnet and http interface Provide command line and web interface Advanced command set Provide advanced digital inputs and outputs Autonomous mode - response on user defined triggers Heartbeat messages Advanced outputs formats - text, XML 8
  9. 9. RFID readers and antennae Readability and range depend upon the design of readers and antennae 9
  10. 10. RFID middleware RFID Data Characteristics High Volume - some applications may have > 100,000 readers generating terabytes of data Fast rate - several reads / second Multiple redundant reads of same tag data Reader health monitoring and management RFID Middleware Connects data from RFID readers to Enterprise applications Device monitoring and management Middleware features Device driver / control, diagnostics, remote maintenance, upgrades Data aggregation Data filtering and smoothing Event monitoring Connectivity 10
  11. 11. RFID applications and value chain Healthcare Manufacturing Transportation Retail Telecom •Asset Tracking Supply chain Airlines •Inventory •Asset Tracking •Patient tracking management & baggage management and Management •Personnel tracking distribution handling •Warehouse • Contact less Production •Boarding pass operation Payment solutions •Sterile Equipment management •Package •Supply Chain using mobile management Factory Tracking Management phones •Blood bags Automation •Container •Interactive Kiosk • Billing solutions tracking Maintenance / Tracking •Self check out at • Various Value •Anti counterfeiting condition •Yard POS Added Services of pharmaceutical products monitoring Management •Electronic Article •Medicine Asset •Toll collection Surveillance dispensing management •Fleet tracking •Rail car ID Analytics/ Reader Middle Systems Chips Inlays Tags Antenna Reader EAI Process Network ware Integration Redesign Silicon companies – TI, RFID Reader / Antenna makers – EMS, TI, IT Solutions & Services providers Philips , Siemens, Hitachi Matrics, Alien, Hitachi Tata Consultancy Services Tag manufacturers – RFID Software providers – OAT, Sun, Accenture, IBM GS, CGEY EMS, TI, Matrics, Alien ORACLE, SAP, Globeranger, Matrics, Wipro ConnecTerra Savi 11
  12. 12. Differentiation by synergy Strategic alliances RFID expertise & Assets • Oracle • RFID Lab since 2001 RFID Technology • Texas Instruments • RFID Center in Chicago expertise • Hitachi • Presence in Oracle Sensorworld, • Sun Microsystems UK • EMS • Hardware & middleware expertise • Tools & assets TCS RFID Member of Solutions Domain Technology experience expertise • Pharmaceuticals & Healthcare •Hospital Management system • Transportation & Logistics •Architecture • Retail & CPG • ERP / SCM / WMS • Manufacturing •Application development • Government • Utilities •Application integration (EAI) •Business Intelligence & DWH 12
  13. 13. TCS’ RFID Stack Process consulting Business Processes Data and event utilization Business Processes Strategy & Business case develop EPC / GTIN consulting Enterprise Applications Enterprise Applications Application Development Custom Modifications Application / Integration Application / Integration Servers Servers MIDDLEWARE Reader Interfaces, Reader Adapters, Filters and logger, Reader management Edge Processing Layer Edge Processing Layer RFID integration with EAI Hardware Interface Hardware Interface Layer Layer Site Surveys Reader and Tag Selection RF Engineering, RFID Hardware RFID Hardware Antenna placement & design , 13
  14. 14. TCS RFID expertise centers Objectives Details • Ability to run pilots and test full scale implementation Running real life scenarios for: projects with our customers. • Asset Management Zone • Presentation and demonstration facility for TCS- Sensor World, • Customer Experience Zone Oracle RFID solutions UK • Supply Chain Zone • To enable business mangers to see tangible • Product Zone evidence of the potential of RFID technologies to • Management Zone deliver business value • Demonstration and piloting of solutions in numerous RFID industry segments • Readers, antennas and tags: HF and UHF • Access to leading RFID tech • Middleware from Sun, Oracle Technology • Performance testing, analysis and benchmarking of Site Simulation Facility for Dock doors, smart shelf, Center, Chicago RFID hardware and middleware products. conveyors • Facilitate end-to-end integration testing • Established in 2001; approx. 20 researchers RFID Center of • Demonstrate industry specific RFID applications. • Hardware: HF, UHF and MW from TI, EMS, Hitachi • RFID physics related testing: Product evaluation and and Alien Excellence benchmarking. • Middleware: Sun, Oracle and Auto-Id Center Kolkata • Integrate RFID hardware and middleware • Antenna footprint Analysis, Power Spectrum analysis, Tag placement and readability tests 14
  15. 15. Enhancing airline MRO Operations Case Study Client: Scope High value rotable parts at Heathrow warehouse Integration with Enterprise MRO application Objectives To improve performance and reduce cost To improve the visibility of critical parts To provide clear measurement of the impact of the pilot To improve the service provided by the warehouse Benefits Reduction of cost of labor associated with managing goods/business processes Improve visibility into the incremental steps that are part of complex business processes Improve visibility into customer (Internal and External) demand Better forecasting Enhanced product visibility in the stores Eliminating the possibility of misplacement of high value assets Automatic recording of items’ entry and exit from the storage area Reduction of manual errors in data recording & data entry 15
  16. 16. Engagement with a leading CRO Scope: Specimen receipt management from investigator sites Sample management Courier Pickup During Transportation Mode Accessioning, RFID tagged Tubes Packaging Kit Samples Routing, Pain points addressed Aliquoting Lack of end-to-end visibility for sponsor Sample Draw Lab Testing and Results Long trial times for sponsor Visit Long lead-times for patients Scheduling Package Reception Expected benefits: Error Reduction at Investigator site Reduction in shipment and stability related issues Reduction in data management issues (automatic scanning) Chain of custody and effort reduction within central labs Advanced Capacity planning/forecasting and allocation Increased stakeholder Satisfaction Reduced loss of data points for clients Unique ID linked to back end system Reduced re-testing with patients (human aspect) for automated Kit production line 16
  17. 17. RFID enabled product authentication scenario: a prototype Technology Microwave RFID tags Handheld readers Data Web based authentication application cable Features Plastic Extremely small size of product “Nose” Tag is injection molded into product Metallic Handheld RFID reader used for reads part Tags commissioned and ids are registered in database Central authentication server TI Reader Thin authentication client Authentication client Web service based communication Benefits TI Reader Oracle 10g server Impossible to duplicate product ids Authentication client Product authentication server W indows 2000 server Counterfeits can be easily detected Oracle server No other technology allows embedded ids TI Reader Flexible and scalable architecture Authentication client 17
  18. 18. RFID based inventory management for Kansas DOT Client: Department of transportation, Kansas state, US of America Scope: Identify how RFID can provide an optimum level of information for Capital Inventory tracking These assets are dispersed over the entire State of Kansas and their value is $307,057,000+. The number of physical locations of the Capital Inventory is approximately 28 headquarters offices in Topeka and 159 statewide field offices Consumable Inventory tracking KDOT manages between $12 and $15 million in consumable inventory at any given time. There are 41 manned stock locations and approximately 420 unmanned locations statewide Materials Testing Deliverables: Study Report Impact on existing databases and applications Impact on existing processes Analysis of costs and benefits Suggested roadmap Technology Recommendation Report Includes hardware and software required for interfacing RFID system Details of suitable RFID tags and readers Middleware required Network requirement 18
  19. 19. RFID based inventory management Client: A leading medical equipment manufacturer. Pain Areas Inaccurate inventory records Data inconsistencies between the ERP and actual bin level status Every month, 2-3 days production is lost for cycle counting Solution Manual bin cards replaced by re-writeable RFID tags Reader applications developed to reduce errors Data integration was done with the ERP Benefits Instant visibility of stock due to real-time updation Elimination of error due to manual entry Automatic checking of parts being picked Cycle counting eliminated Technology Passive tags HF tags on Warehouse bins Handheld reader Integration with Oracle Apps 19
  20. 20. RFID based document tracking Client Indian defense division Scope Document and file tracking Features Handheld RFID reader integrated to PDA Automated document inventory and tracking application Synchronized with desktop document management application Document issue history available in document itself Benefits Improved document inventory visibility Reduction in misplaced documents Reduced effort in tracking classified documents Technology High Frequency RFID tags from TI Handheld RFID reader 20
  21. 21. RFID based car tracking Client A leading auto auction house, US Pain Areas Difficulty in locating individual cars in an area spread across 80 acres Manual identification and tracking process extremely time consuming, error prone Mandatory verification of buyer ID and vehicle ID at exit cumbersome Solution RFID tags fitted to each vehicle Identify and track vehicles at entry, parking lot, detail shop, run lines and exit Integration with existing auctioning application Metrics collection on vehicle sales and cycle times Status reports and dashboard Verification of buyer id and vehicle Id at exit Technology Active tags on vehicles to be identified and tracked Fixed and Handheld readers Benefits Ensure complete up to date inventory Replace labor intensive bar code system Automatic billing Enhanced security Market intelligence 21
  22. 22. RFID based asset management Client: A premier Electrical equipment manufacturer Scope: Asset and equipment tracking at power plants Technology Passive tags on equipment /asset to be tracked and maintained Active tags in case assets may move over a wide area Gate and Handheld readers Features Identify location of equipment / assets Asset / Equipment identifies itself Data storage capabilities - update equipment history on tag Handheld displays equipment details to field worker Automatic upload of field data to servers after field work is completed Integration with Asset Management application ( Oracle database) Benefits Accurate identification RFID Reader Superior performance in harsh environment Local data storage and availability without need of data networks Reduced workload and increase in efficiency 22
  23. 23. RFID based quality system for tobacco RFID based management of quality tests on tobacco samples in a cigarette factory Objectives Reduce time required for testing lab samples Reduction of manual effort in data recording & data entry Reduce data entry errors Features Identification and Tracking of tobacco samples Automatic data capture at sample collection site and laboratory RFID tags metallic tobacco containers Specially designed tags to withstand high temperature cycles Integration of RFID reader with weigh scales Automated capture of tag id and weight from weighing scale Technology Data logging to QMS database Passive HF Tags ( TI) Reports and query support HF Fixed Reader ( Custom designed) Handheld Readers ( Psion Teklogix) RFID Based Tobacco Quality Management MySQL database .Net application 23
  24. 24. RFID based lorry tracking inside a refinery Salient Features of Lorry tracking System Application Zonal tracking of lorries inside the facility Application developed on MS DOTNET platform Integrated with photo-pass system Integration with SAP ERP Accessible through Mobile platform Scope of work Hardware: Procurement from NEDAP, Netherlands Installation at site Testing and system configuration Application development: Requirements gathering and SRS preparation Software development Integration: Interfacing various hardware components like RFID, photo pass camera, etc, Benefits Providing an interface for integration with SAP systems at multiple instances Higher customer satisfaction: as real-time status of the location of the lorry will be communicated to the owner of the lorry as well as the Support: consignee. Training and implementation support Better queue management: as the information of the movement of traffic is available at the entry point. Responsiveness: of the system to manage any changes in the filling order Reduction in administrative effort Arresting discrepancies in scheduled orders 24
  25. 25. RFID based body shell tracking in automobile paint shop Body shell tracking in an automobile paint shop Technology Low Frequency ( 134 KHz) RFID tags from TI High temperature tags capable of withstanding 350 deg C Fixed RFID reader Features RFID tags used for identifying and tracking body parts in paint shop Fixed RFID readers placed at 7 locations in paint shop Benefits Tags placed on skids that carry the body shell Automated identification of body shell Readers integrated with plant automation Decentralized control of manufacturing system ( PLC) based on RFID tag Body Serial number, colour code, model description code etc. is associated with RFID tag and used at different locations 25
  26. 26. Virgin Atlantic and RFID What are the expected benefits of using RFID technologies? Process efficiencies – Data capture;Data accuracy Improved turn around performance of components through stores. Increased visibility of parts and materials within the maintenance environment More accurate inventory control at the point of entry to the aircraft stores Consequential benefits – process control In addition to these benefits, the wider benefits include: Greater ability to comply with expected guidelines from EASA (European Aviation Safety Agency) concerning traceability and authenticity of aircraft components Integration with the RFID specifications proposed by Boeing and Airbus for use within the aircraft supply chain 26
  27. 27. The Pilot Study The high level scope of the pilot was: To RFID tag all rotable parts within the Heathrow warehouse To integrate with Ultramain process To provide automated tag printing to work in line with existing Goods inwards process The objectives of the pilot were: To demonstrate the potential savings of using RFID tags To improve the visibility of critical parts To provide clear measurement of the impact of the pilot To improve the service provided by the warehouse To test the technology 27
  28. 28. The Pilot Study - architecture P re s e n ta tio n la y e r M id d le w a re la y e r D a ta la y e r K P I in te rfa c e A p p lic a tio n E d g e A p p lic a tio n D a ta h u b K P I A n a ly s is E d g e S e rv e r R e a d e r S e rv e r D a ta h u b in te rfa c e U ltra m a in In te rfa c e P rin te r In te rfa c e 28
  29. 29. Pilot Environment Quarantine Back Office Wireless network First Stage Inspection Bins Handheld Printer Binning Area RFID Label Component Preload / Bulk Bulk Racking Repair Section / Deferred Defect Dispatch Location Barcode Back Office 29
  30. 30. KPI measurement Each stage of process is measured •Average times •Data accuracy – compare Ultramain with data hub •Identify supply blockages •Identify fast track items •Item life cycle 30
  31. 31. Questions from responses LPG Cylinder tracking – cost, availability Oil Tanker tracking Document tracking Asset tracking Access control Oil retail outlets Handsfree RFID based payments at pumps Tag life cycle management Safety in inplant use? Hazardous use Reading accuracy and inteference Integration with backend Preventing adulteration and pilferage 31
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