iiot infrastructure design concept - fieldbus · today maintenance data and some operations data is...
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Digital Transformation- for operational excellence
Topics Covered
The case for change: Operational excellence Digital transformation of operation and
maintenance Deploy digital operational infrastructure
Operational ExcellenceThe case for change
Plant Challenges: The Case for Change
HS&E
FewerIncidents
FasterResponse timeReducedNon-compliance
Production
HigherQuality/YieldGreaterThroughput
HigherProductivity
GreaterFlexibilityReducedOperation cost
Energy & Losses
ReducedEmissions and carbon footprint
LowerEnergy consumption and cost
Availability
Reliability & Maintenance
Maintenance costs
Equipment Life
Integrity
Digital TransformationThe new way of running and maintaining the plant
Digital Transformation: Reliability & Maintenance
ISO 55000 API 691 API 570
Digital testing Digital inspection Availability
Reliability & Maintenance
Maintenance costs
Equipment Life
Integrity
Digital Transformation: Health, Safety, and Environment
ISO 45001 ISO 14001 OHSAS 18001
Digital distress callsDigital safety checks
HS&E
FewerIncidents
FasterResponse timeReducedNon-compliance
Digital Transformation: Production
ISO 9001 ISO 29001
Digital operator rounds Digital milk run
Production
HigherQuality/YieldGreaterThroughput
HigherProductivity
GreaterFlexibilityReducedOperation cost
Digital Transformation: Energy Efficiency & Loss Control
ISO 55001
Digital energy management Digital loss control
Energy & Losses
ReducedEmissions and carbon footprint
LowerEnergy consumption and cost
Digital Operational InfrastructureA second layer of automation
Second Layer of Automation Integrated with Existing Operational Infrastructure and IT Infrastructure in a Digital Plant
Real Time
Analytics
Sensing
PervasiveNetworking
BI
Second Layer of Automation
ERP
MES
DCS
IO
Sensors & ActuatorsExisting Automation
L3.5 Integration
Digital Operational Infrastructure – Field Communications Key Role
DCS Hardware
DCS Software
Historian, CMMS
DMZ
ERP
Sensors & Actuators
BI Dashboards
Operational Dashboards
WirelessHARTFieldbus
Valve Analytics
Equipment Analytics
Vibration CorrosionAcoustics PowerPosition
FieldComm
Messaging OPC-UA
Vibration Analytics
Corrosion Analytics
Second Layer of Automation Existing
Can’t Diagnose Equipment Problems Using Existing Process Data
Operations need new information to run the plant better Condition monitoring only for turbomachinery is not enough Need sensors on other equipment as well I&C department must deploy and support these sensors
Reliability
Maintenance
Integrity
Quality
Energy HS&E
Production
Process
Data Driven Operations
Sensor data helps people do their work better and faster
Management Operations EnergyManager
Maintenance• Turn off• Reduce speed
• Clean• Repair• Replace
• KPI• KPI
Analytics
“Things”
Sensors
Solutions Determine Sensor Requirements
Each solution require different sensorsHealth, Safety, Environment Reliability & Maintenance
• Emergency Safety shower and eyewash• Manual valve position• Relief valve release• Shutdown valve position and performance• Hydrocarbon leak/spill detection• Storage tank breather valve• H2S• Independent tank overfill• Effluent temperature
• Pump & mechanical seal• Blower/fan• Air cooled heat exchanger• Non-process centrifugal compressor• Cooling tower• Pipe corrosion• Manual data collection rounds• Instrumentation and valves• Heat tracing system
Production Energy & Losses• Operator rounds• Offsite tank farm storage tank• Wellhead and control panel• Process troubleshooting • Control valve and damper position• Local control panels• Rotating kiln and reactor• Offsite pump• Consumables inventory• Non-wireless devices• Temperature profile
• Steam trap failure• Heat exchanger fouling• Cooling tower excess cooling• Air cooled heat exchanger excess cooling• Relief valve seat passing• Energy management
This not all you can do, just a subset of standard solution packages. Specific to each industry there are many applications possible. Users have discovered hundreds of unique applications.
If it won’t break, don’t
sense it
Ubiquitous Sensors on the Equipment
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Lots of sensors are installed on plant equipment Faster data collection
o More predictive; act before outright failure Automatic the data collection
o Save timeo More time available to carry out fixes
T
A
V
T
A
V
P
DP
P
L
P
Equipment
Pressure
Temperature
Fluid Level
Vibration
Corrosion
Acoustic Noise
Software and Analytics Does Not Replace Everything You can’t detect equipment problem by
analyzing process data Example:
o A pump bearing problems has little effect on discharge pressure
o By the time changes in pressure is noticeable it is too late
The fastest way to detect a problem is by direct sensing
Must add new sensors By sensing directly, analytics becomes
very simple Correct issue early, before failure
Infrastructure to Handle Missing Measurements Today maintenance data and some operations data is collected manually
o Not enough data for condition monitoringo Not enough data for ISO 50001 energy managemento Many other blind spots
Hardwiring additional 4-20 mA and on-off sensors for all this would be impractical:o Very costlyo Risk of damaging existing installation
Pervasive Networking
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Hundreds or thousands of new sensors are required Not economical or practical to run a pair of wires for a 4-20 mA or
on-off signal for every measurement signal Need Digital Field Networks
o Wirelesso Fieldbus
The only practical way to connect these sensors using digital networking
Pervasive Networking
Digital sensors with digital multi-device networking from the very first metero Low costo Proven
Add wireless sensor networks; site-wideo Covering measurements left out in the original design Energy efficiency Reliability
o Typically simple individual measurementso Easy to integrate with the existing control system or historiano Wireless technology is proven
Sensors can easily be added to existing fieldbus networks Fieldbus sites also deploy wireless sensor networks
FOUNDATION Fieldbus for Digital Transformation- Build on the Fieldbus You’ve Got Add instruments for equipment condition and performance monitoring
o On premises or IIoT Fieldbuses usually not fully populated Add sensors for condition monitoring and energy management
Process Control & Monitoring
Control System
Condition Monitoring & Energy Management etc.
Condition Monitoring System & Energy Management System etc.
WirelessHART for Digital Transformation- Build on the Wireless Infrastructure You’ve Got Add instruments for equipment condition and performance monitoring
o On premises or IIoT Gateways usually not fully populated Add sensors for condition monitoring and energy management
Process Monitoring
Control System
Condition Monitoring & Energy Management etc.
Condition Monitoring System & Energy Management System etc.
Predictive Process Equipment Analytics
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Condition monitoring of pumps, cooling towers, compressors, blowers, heat exchangers, fans, and air cooled heat exchangers etc.
Detect developing equipment problems earlyo Servicing while it is still simple, fast and at low costo Before outright failure causes shutdowns and expensive repairs
Not All Applications Require Analytics Apps
Simple monitoring adequateo Vibrationo Corrosiono Temperatureo Pressureo Pressure drop
Analytics software required:o Pumpo Compressoro Heat exchangero Cooling towero Fan/blowero Air cooled heat exchangero Steam trapo Control valve
Historian is the Platform Middleware Historian is the Platform :
o Collects data from multiple sources; DCS, SIS, PLC, AMS, MHM...o Stores ito Makes it available to various applications such as analyticso Across the enterpriseo Displayo Reportingo Common security mechanismo etc.
Use existing historian for the architectureo Integrate new sensors and appso Through DCSo Or direct from WirelessHART and Fieldbus gateways
No need to rip and replace historian (big, costly, project) Protects the investment
Historian
Data Source
Data Source
Software App
Software App
Architecture
Use existing historiano Reduced complexityo Lower investment
costo Lower ongoing
support cost No second platform
system layer Analytics apps plug
directly into the historian
Historian
ReliabilityEngineer
Pump Health Heat Exchanger Performance
EnergyManager
Energy Management
DCS SIS PackagePLC
WirelessGateway Vibration
MaintenanceManager
No additional platform
ICS-CERTIndustrial Control System Cybersecurity
Department of Homeland Security (DHS)National Cybersecurity and
Communications Integration Center (NCCIC)
Industrial Control Systems Cyber Emergency Response Team (ICS-CERT)
Recommended Practice: Improving industrial Control System Cybersecurity
with Defense-in-Depth Strategies
Position Digital Transformation First, IIoT Follows
Digital transformation is mostly done on-premises No internet connection or cloud required IIoT can follow
Digital Transformation
IIoT(Internet, Cloud)
Delivering Device Diagnostics to Your Pocket
DCS PLC RTUGateway Multiplexer Linking Device
Provides device health and performance to E&I maintenance personnel
Anytime.Everywhere.All the time.
ConclusionSummary
Summary
The case for change: Operational excellence Digital transformation of operation and maintenance Deploy digital operational infrastructure
I’m Listening...
Jonas Berge
http://www.linkedin.com/in/smartdigital
https://www.emersonexchange365.com/members/jonas.berge
Copyright
Copyright © 2017 FieldComm Group™This document contains copyrighted material and may not be reproduced in any fashion without the written permission of the FieldComm Group™.
Trademark Information FieldComm Group™, FOUNDATION™ Fieldbus, HART-IP™ and FDI™ are trademarks, and HART®, WirelessHART®, ROM® and SIF® are registered trademarks of FieldComm Group, Austin, Texas, USA.
Any use of these terms hereafter in this document, or in any document referenced by this document, implies the trademark/registered trademark. All other trademarks used in this or referenced documents are trademarks of their respective companies. For more information, contact FieldComm Group at the address below.
Attention: FieldComm Group PresidentFieldComm Group9430 Research Blvd., Ste. 1-120Austin, TX 78759, USA Voice: (512) 792-2300 Fax: (512) 792-2310http://www.fieldcommgroup.org
Intellectual Property Rights The FieldComm Group (the Group) does not knowingly use or incorporate any information or data into the HART, FOUNDATION Fieldbus and FDI protocol standards, which the Group does not own or have lawful rights to use. Should the Group receive any notification regarding the existence of any conflicting private IPR, the Group will review the disclosure and either (A) determine there is no conflict; (B) resolve the conflict with the IPR owner; or (C) modify the standard to remove the conflicting requirement. In no case does the Group encourage implementers to infringe on any individual's or organization's IPR.
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