Lack of data visibility in existing plants hinders Industrial IoT deployment…but non-invasive instrumentation upgrade is a key part of the solution. - Harry Sim, CEO, Cypress Envirosystems

1. Industrial IoT will not
Reach its Full
Potential…Unless it
Solves this Challenge*
Harry Sim, (408) 307-0922
harry.sim@CypressEnvirosystems.com
*Hint: Digitization of existing plants

2. 2
IoT – Connect EVERYTHING

3. 3
Industrial Internet of Things (IoT)
Sources:
http://reports.weforum.org/digital-transformation/electricity-an-industry-ready-for-digitization/
https://industrial-iot.com/2017/12/data-state-iiot-adoption-maturity/
https://www.mckinsey.com/industries/semiconductors/our-insights/the-internet-of-things-sizing-up-the-opportunity
Nearly two-thirds (77%) of all
businesses plan to increase
their IoT investments over the
next 12 months - BSquare

4. 4
Benefits of Industrial IoT
Gathering lots of data
from smart devices –
use analytics to drive
benefits
Source: Areva-IBM

5. 5
Case Study: Nuclear Generation
AREVA Partners with IBM’s Watson
Internet of Things (IoT) to Offer
Next-Generation Data Analytics to
the Nuclear Industry
Dec 2017
GE signs Exelon in
its largest power-plant
software deal
Nov 2016
Digitization of the U.S. nuclear fleet is seen as key to reducing operation
and maintenance (O&M) costs and increasing the competitiveness of
nuclear power amid rising gas-fired and renewable energy capacity.
In December 2015, the Nuclear Energy Institute (NEI) launched the
Delivering the Nuclear Promise (DNP) Strategic Plan, calling on operators
to reduce generating costs by 30% between 2016 and 2018.
Source: https://analysis.nuclearenergyinsider.com/us-utilities-must-commit-digitization-cut-operating-costs-30

6. 6
Vision of Industrial IoT
Thousands of sensors ready to feed data
to intelligent cloud
Source: GE Predix

7. 7
Reality of IoT
Legacy mechanical, manual instrumentation for flow, temperature,
pressure, pneumatic actuators – cannot communicate with cloud

8. 8
Difficulty of Digitizing Existing Plants
• Just to read a simple pressure process value:
- Run wires (power and/or signal)
- I/O panels, termination
- Break seals, leak checks, material compatibility,
safety checks
- Engineering assessment, documentation
- Process downtime
- Cybersecurity concerns
Typical traditional solution:
INVASIVE AND COSTLY
There are thousands of these devices
with critical process data, but it costs over
$20,000 to instrument each one using
conventional technology, plus cost of
process downtime.

9. 9
Need for Non-Invasive Digitization Technology
• Sensors which do not affect existing system:
- No breaking seals, no leak checks, no wetted parts
- Lightweight, no structural impact
- No power wires, no signal wires
- Little/no engineering review/analysis
- Takes minutes to install, no plant downtime required
- No new software to install, works with existing plant
infrastructure

10. 10
Example: Wireless Gauge Reader
• “Electronic Eyeball” reads gauges and
transmits readings wirelessly
• Non-invasive, clamp-on to existing
gauges in minutes
• Different adapter sizes to
accommodate different gauge
diameters and types
• No downtime, no leak check, no
wiring, no drawings

11. 11
Example: Valve Health Monitoring
Feed water valve fault detection
• Actuator position
• Main pneumatic pressure supply
• Regulated pneumatic pressure
• Output pneumatic pressure
Is input pressure correct?
Is output pressure signal correct?
Is the valve in the right position?
Is the valve stroking correctly?
Hundreds of these valves per site – a single failure can
lead to process shutdown and massive cost

12. 12
Wireless Communication Architecture
WFM
WSTM
WSTM
WGR
WGR
WGR
WRE Repeater
WRE Repeater
WRE Repeater
WRE Repeater
WTR
WSTM
Green Box
Controller
LAN
OPC, RESTful API
Built-in
Web PageOptions:
• 2.4GHz
dedicated
wireless
network
• 900MHz LoRA
using Plant
Distributed
Antenna System
Industry Standard OPC and RESTful API interfaces for
Integration with Cloud and 3rd Party Applications
HMI, Cloud
Applications

13. 13
Current Deployments – Power Generation
• 3 Nuclear Power Plants
• 1 Coal fired plant
• EPRI demo center – planned
• Typical Time Schedule for Deployment
- 200 units – one week, no operational downtime
- Scalable to 10,000 units or more per site
- 10% of the cost of conventional approaches
- 1/20th of the time to implement vs. conventional
approaches.

14. 14
Deployment in Other Industries

15. 15
Summary
• IoT, big-data and analytics technologies promise to unlock huge savings
and value in existing plants, but digitization is key.
• Digitization of legacy plants is a very expensive, disruptive process using
conventional technologies.
• Non-invasive technologies offer a fast, low-cost, proven solution to
achieve digitization without disruption to operations – for nuclear
power, at 10% of the cost, 1/20 of the time needed for alternative
solutions.
• Further discussion:
Harry Sim
Cypress Envirosystems, Inc.
Email: harry.sim@CypressEnvirosystems.com
Phone: (408) 307-0922