What is Pervasive Sensing and how does it tie in to the Internet of Things? Eric will explain the connection and discuss the strategies companies can take to use familiar devices in new ways to improve process, reliability, energy efficiency and safety. These strategies are available today with immediate financial returns that allow companies to scale growth without scaling problems and driving global competitiveness. From the 2014 Taking Shape Summit: The Internet of Things & the Future of Manufacturing.

1. Pervasive Sensing
Eric Milavickas
Emerson Proces Management
www.360mn.org

2. Pervasive Sensing A Strategy That’s Changing the Fundamentals of Automation
NAME: Eric Milavickas
TITLE: Director, Emerson Smart Wireless

3. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 3
•What is Pervasive Sensing
–Strategy: The more you sense, the more you solve
–Easily improve: Process – Reliability – Energy – HSSE
–Using familiar devices in new ways
•Applying these strategies
–Available today with immediate payback
–Scale your growth without scaling your problems
–Become more competitive
Agenda

4. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 4
Key Challenges Facing Manufacturers
Amount of a typical refinery
maintenance budget that is
spent on corrosion
remediation and repairs
36%
Potential improvement in the industrial sector’s lifecycle energy use
50%
Annual investment in safety, health and environment by U.S. chemical industry
$16B
Environmental expenditures
toward remediation and
spills spent annually.
$1.5B

5. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 5
Advanced Sensors Enable Manufacturers to Tackle Their Biggest Challenges
•Immediate response
•Plant shutdown
•Maximum focus
•Already automated
•Information overload
PROCESS-CRITICAL
PROCESS SENSING Critical to Core Operations
•SIL
•ESD
•Fire & Gas
•Compliance
•PID
•Optimization
•Alarm
•Batch
Process Control
Process Safety

6. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 6
Advanced Sensors Enable Manufacturers to Tackle Their Biggest Challenges
PERVASIVE SENSING
Expanded View of Business
Reliability
Energy
HSSE
Process Safety
Process Control

7. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 7
PERVASIVE SENSING
Advanced Sensors Enable Manufacturers to
Tackle Their Biggest Challenges
PROCESS RELIABILITY
HSSE ENERGY

8. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 8
Advanced Sensing for Your Biggest Challenges
Pervasive Sensing
=
Definition of Pervasive
•per·va·sive; adjective [per-vey-siv]
•Existing in every part of something : lots of, spread everywhere : spreading to all parts of something
Strategic Interpretation
Strategic Interpretation
Actionable Information
Advanced
Sensing
Wireless
Non-intrusive
Self-powered Maintenance free
Calibration free

9. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 9
Internet of Things (IoT)
•Development of the Internet in which everyday objects have network connectivity, allowing them to send and receive data.
Internet of Everything = CISCO Smarter Planet = IBM Internet of Your Things = Microsoft The Next Network = Siemens Industrial Internet = GE

10. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 10
•Emerson is the IoT leader in the Process industry and it’s:
–here today
–about connectivity
–using devices you already have today
–letting automation work for you
Pervasive Sensing is Emerson’s IoT
Lack capability of selling sensors or implementing industrial sensing technology
Lack domain expertise critical to effectively analyzing data and recommending actions
Primary interest is in selling consulting hours
Supplier Barriers

11. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 11
The More You Sense, the More You Solve
Enhance the focus. Expand the strategy. Enjoy the impact.
SAFETY
ENERGY
ENVIRONMENTAL
REGULATION
RELIABILITY
SAFETY
ENERGY
PROCESS RELIABILITY
HSSE
Improving your
Operational Excellence
by using the power of
advanced sensing
everywhere to gather data
and transform it into
actionable information.

12. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 12
Industry Leaders Recognize the Value of Implementing Pervasive Sensing Strategies
Deploying wireless infrastructure to grow measurements by 60%
32,000 Points!
Site Safety
+2,000
Reliability
+8,000
Energy Efficiency
+2,000
20,000 wired I/O points Plus an additional 12,000 pervasive sensors
…..industry leaders and the facilities around the world are already using the pervasive sensing strategy to get results, and they are doing it in a big way.

13. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 13
Process
Pressure
Temperature
Level
Flow
Analytical
Advanced Sensing for Your Biggest Challenges
PROCESS
Mobility
Mobile maintenance
Mobile operations
PROCESS

14. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 14
Wireless Mobile Worker Improves Efficiency
Checkout time was reduced by half. 2 weeks from four. Required manpower was reduced by half. Virtually no loop troubleshooting during startup.
Ergon executed a turnaround and DeltaV migration that required loop checking 300 loops and indicators and verification of approximately 100 DVC valve actuators. Ergon targeted 10, 24 HR shifts.
Ergon Refining
“Mobile Worker with Emerson’s Wireless Plant Network gave Ergon flexibility and increased efficiency on our turnaround. It allowed us significant cost savings, and may be used a tool by Engineering and Operations in the future. We cut way back on the communication form the field to the control room. We used to have to ask the console operator to run the valves up and down to prove the connection, now we do it all outside from the Toughbook”. Steve Elwert, Ergon Refining
PROCESS
CHALLENGE
2 Mobile worker equipped checkout crews were deployed. Cabinets were staged in advanced and hardware checked with Mobile Worker.
SOLUTION
RESULTS

15. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 15
Advanced Sensing for Your Biggest Challenges
RELIABILITY
Essential Asset Monitoring Heat exchangers Pumps Blowers Cooling towers Compressors Air cooled heat exchangers
RELIABILITY
RELIABILITY

16. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 16
RESULTS
Heat Exchanger Monitoring
Efficiency gained in energy savings was estimated at $55K per heat exchanger, per year.
Investment payed back under 90 days for each exchanger.
CHALLENGE
Crude unit was subject to preheat train fouling.
No data to quantify how much energy was being lost, or when (and which) exchangers to clean.
Conoco Philips
“Due to monitoring, customer can now able to maximize heat exchanger operation and maintain the tubes more effectively to prevent costly heat losses and avoid disruptive tube ruptures. In addition, they created a safer work environment for all.” - Randy Stout, Emerson
Analyze the efficiency of heat exchangers using heat duty calculations through wireless temperature and flow measurements. Installed without any interruption to process.
SOLUTION
RELIABILITY

17. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 17
RESULTS
Pump Monitoring
•No fires in 5 years due to early detection on three pump failures 1st year. Avoided shut downs!
•Monitor 158 pumps at 1/10th the cost of the manual process of just a few pumps.
CHALLENGE
Need to prevent a vapor cloud release when pumps fail to protect staff and environment.
Only able to monitor a few essential pumps, but not sure which pumps need service.
Flint Hills Pine Bend
““Today, I’m happy to report that FHR Pine Bend has not had a single pump fire in more than 5 years!. Now that we can monitor all our pumps we can plan preventive maintenance instead of being reactive. - Flint Hills Pine Bend, Emerson Exchange 2013
Utilize Essential Asset Monitoring to measure the seal for gas leaks of essential pumps throughout their operation. Use monitoring to know which pumps need service.
SOLUTION
RELIABILITY

18. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 18
Safety shower monitoring
Gas detection
Leak detection
PRV release
Hydrocarbon detection
Advanced Sensing for Your Biggest Challenges
Tank overfill/spill detection
Corrosion
Effluent discharge
Interlocks on gates/doors
Access Awareness
Personnel location tracking
HSSE
Health, Safety, Security & Environment
HSSE
HSSE

19. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 19
Detecting Hydrocarbon Leaks
Tanks spills monitored to improve employee safety and avoid environmental incident. Demonstrates regulation compliance.
Detecting and monitoring hydrocarbon leaks around tanks, valves and pipe flanges because level continuously fluctuates due to changing process demands.
BP
“Wireless breaks the cost paradigm by reducing maintenance visits, time-consuming physical monitoring, and injury-related occurrences. Furthermore Wireless was easy to install. Minimizing the engineering department efforts by allowing members of maintenance to install and maintain the equipment.” Tom Kenis, E&I, BP Geel (Belgium)
CHALLENGE
Non-intrusive solution to detect liquids leak around the tanks, sump wells, and curbs of pump skids.
SOLUTION
RESULTS
HSSE

20. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 20
Energy and Utilities
Steam trap monitoring
Instrument air monitoring
Compressed air monitoring
Natural gas monitoring
Water/Wastewater
consumption and discharge
Energy Advisor
Remote monitoring
Advanced Sensing for Your Biggest Challenges
ENERGY
ENERGY

21. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 21
Pressure Relief Valve & Steam Trap Monitoring
The first audit showed 25% of steam traps were failing, that were unknown.
Payback in one year in energy savings by correcting issue.
Continually reduce environmental impact by reducing energy usage, but unable to determine how much energy they were wasting.
Fluor Global Services
“A simple cost analysis based only on energy savings, the installation of the steam trap monitoring was easily justified, because the solution paid for itself within one year. Not to mention the savings from avoiding equipment damage, and avoiding safety or environmental incidents”
- Fluor Global Services , Emerson Exchange 2013
CHALLENGE
Monitoring of 187 steam traps and 63 pressure relief valves to ensure proper operation, avoiding equipment damage and wasted energy via lost steam.
SOLUTION
RESULTS
ENERGY

22. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 22
INFORMATION COST
INFORMATION BENEFIT
HIGH
LOW
Now is the Time
HSSE
Reliability
Energy
Process Control
Process Safety
LOW
HIGH
Previously
•cost was high
•info benefit was low
•previously immeasurable
•data was raw
•technology complex to install Now
•innovative sensors
•wireless communications
•non-intrusive installation
•mobile and location technology
•advanced analytic capabilities
•embedded expertise
•power technology

23. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 23
Pervasive Sensing a Reality, Not a Trend
Home Car Retail Plant

24. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 24
•What is Pervasive Sensing
–Strategy: The more you sense, the more you solve
–Easily improve: Process – Reliability – Energy – HSSE
–Using familiar devices in new ways
•Applying these strategies
–Available today with immediate payback
–Scale your growth without scaling your problems
–Become more competitive
Summary

25. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 25
Pervasive Sensing Opportunities in Your Business
Gas Leak
Blower Monitoring
Natural Gas Monitoring
Compressed Air
Air Cooled Heat Exchanger
Hydrocarbon Detection
Gas Detection
Effluent Discharge
Corrosion
Compressor
Mobile Operations
Leak detection
Interlocks gates/doors
Tank overfill/spill detection
Remote Monitoring
And Many More…
PRV Release
Steam Trap Monitoring
Pump Health Monitoring
Heat Exchanger Monitoring
Cooling Tower Monitoring
Measure Utilities
Safety Shower Monitoring
Mobile Maintenance

26. [File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 26