remote automation solutions iec62591 wireless interface
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Remote Automation Solutions IEC62591 Wireless Interface
Remote Automation Solutions IEC62591 Wireless Interface
Business ChallengesBusiness Challenges
CRITICALBUSINESS
CHALLENGES
Financial Results
Safety & Environment
Personnel & Resources
Efficiency & Throughput
Reliability &Access
Key Customer StakeholdersKey Customer Stakeholders
Oil & Gas Industry
Business Challenges by Functions
Asset Manager Reduced ProfitabilityHigh operating cost, low yield
Operations/SCADA Manager Rising Operating, Maintenance & Compliance Costs
Field Technicians/Engineers Rising WorkloadCostly frequent trips to remote sites
HSE Managers Rising RisksDetecting Safety & Environment problems
Production Manager Decreasing Productivity Difficulty optimizing production
New Oil / Gas Field Constructions (CAPEX)
High trenching, wiring, labor and Installation
Getting Online Faster
Shortage of Trained Workforce
Business & Operational Challenges Facing Oil & Gas ProducersBusiness & Operational Challenges Facing Oil & Gas Producers
Cost make automating prohibitive for at least 20% low point remote sites
“Per day production delay on a 50K bbl’s/day facility causes $2M revenue and opportunity loss”
“Shortage of O&G workforce will lead to critical impact on business”
Offshore Installations
Land Installations
Emerson’s Wireless Experience update:• ~8000 wireless Networks in operation
• Over 3000 SmartWireless installations
• ~100,000 wireless process devices installed
• ~950 million operating hours
Smart Wireless Vision Adopted at Over 3000 Customer Sites GloballySmart Wireless Vision Adopted at Over 3000 Customer Sites Globally
Time to first oil drives investment decisions
Declining Production rates for unconventionalwells
Operating and field maintenance cost inflation impacts margins
Need common standards that provide future architectural flexibility thru production development spectrum
Wellhead CustomerChallenge
60% faster installation and commissioning.
30% or more installed cost savings over wired alternatives
Most robust diagnostics eliminate false reading leading to bad operational and maintenance decisions.
Platform harmonization with tightest product integration from Emerson
Solution Value Drivers
Smart Wireless Field Link
NewInterfaceModules
FloBoss
ControlWave
ROC
IEC62591 Wireless Interface For Flow Computers and RTUsIEC62591 Wireless Interface For Flow Computers and RTUs
Proprietary & Confidential6
Time to first product delivery drives investment decisions
Difficulty adding additional measurement points
Operating and field maintenance cost inflation impacts margins
Need common standards that provide future architectural flexibility when replacing legacy station controls
Midstream CustomerChallenge
60% faster installation and commissioning.
30% or more installed cost savings over wired alternatives
Most robust diagnostics eliminate false reading leading to bad operational and maintenance decisions.
Platform harmonization with tightest product integration from Emerson
Solution Value Drivers
Smart Wireless Field Link
NewInterfaceModules
FloBoss
ControlWave
ROC
IEC62591 Wireless Interface For Flow Computers and RTUsIEC62591 Wireless Interface For Flow Computers and RTUs
Proprietary & Confidential7
IEC 62591 (WirelessHART) Global StandardIEC 62591 (WirelessHART) Global Standard
Global Standard An IEC standard-IEC 62591 (unanimously approved March 26, 2010)
• IEC 62591 is WirelessHART• HART 7 protocol• Adopted March 26, 2010
Simple – Reliable - SecureSimple – Reliable - Secure
SIMPLE
Self-Organizing Network
Auto-Recognition of New Devices
No Site Surveys
No Trenching
Finds Alternative Paths
RELIABLE
99% Field Proven Reliability
Self-Healing Network Repairs Itself
Coexists with other Wireless Networks
Robust and Tolerant to all Types of Interference
without any Site Survey
SECURE
Robust, Multi-tiered, Always-on Security
Industry Standard 128-bit AES Encryption
Unique Encryption Key for Each Message
Data Integrity and Device Authentication
Reports Message and Authentication Failures
Smart Wireless Portfolio is Large …and Getting LargerSmart Wireless Portfolio is Large …and Getting Larger
4300 Series Position Monitor
Smart Wireless THUM Adapter
Ovation Native Interface
DeltaV Native Interface
3051S SeriesPressure, Level & Flow
848T Multi Input Temperature648 Temperature
Smart Wireless Gateway
9420 Vibration
702 Discrete
6081 pH
6081C Conductivity
Current PortfolioCurrent Portfolio New ProductsNew Products
DeltaV S-series Wireless I/O
Smart Wireless Field Link
2160 Vibrating Fork Liquid
Level Switch
Video Integration with
DeltaV
702 Wireless Leak Detection
SOLUTION BENEFITSEasy to install
Low cost
Generic Modbus Gateway Interface
Supports legacy systems
DIAGNOSTICSTag ID
Device TypeStatusAlarm
RF FailureLow Battery
Traditional Wireless Architecture
Process Variable data
Pressure
temperature
Level
o Point-To-Multipointo Point-To-Point
IEC62591 STANDARD
Gateway integrates easily into legacy systems
PC, RTU, PLC, FCExtends PlantWeb®
SOLUTION BENEFITSOpen, easy-to-deploy
Secure & Reliable mesh network
Automatic re-routing
DIAGNOSTICS
Full access to Advanced HART diagnostics
Transparent pass-through to AMS
Smart Wireless Gateway Architecture
Pressure
Temperature Level
Process Variable data & full HART Diagnostics
Flow Computer
RTUPLC/RTU
AMS & SCADA
ONLY INTEGRATED WIRELESS SOLUTION
No Gateway
No Modbus mapping
IEC62591 Standard
SOLUTION BENEFITSEasy to install
Lower cost installation
Secure & Reliable mesh network
Automatic re-routing
Low power consumption
DIAGNOSTICS
Full access to Advanced HART diagnostics
Remote Automation Solutions Wireless Architecture
Pressure
temperature
Level
Process Variable data & full HART Diagnostics
Flow Computer
RTU
PLC/RTU
AMS & SCADA
New
Radio
RadioSerial, Ethernet or long haul wireless
Remote Automation SolutionsIEC62591
FeatureIEC62591 / Smart Wireless for RTU
RTU Functionality needed? Yes
Existing EMR RTU available Yes
Greenfield O&G Yes
Low Power <1.2 Watts
Number of Devices 20/60/100
Redundancy No
Mounting Requirements In the RTU
Support 1 sec Update Rate Yes, after November 2013
Discrete I/O Support 702, 4310, 4320, after Nov 2013
ROC, FloBoss & ControlWaveIEC 65591 Wireless TechnologyROC, FloBoss & ControlWaveIEC 65591 Wireless Technology Only truly integrated RTU/FC wireless
solution– One integrated configuration tool– Support built into firmware– Seamless integration from field to
back office– No third party gateways– No Modbus mapping
High reliability and low power consumption for remote installations– No site survey required– Auto re-routing mesh network– Smaller backup batteries &
enclosures
Integrated Solution BenefitsIntegrated Solution Benefits Distributes measurement & Control to
field locations– Not dependent on long haul reliability
for data integrity– Local Historical and Alarm logging– Local Control
Truly integrated configuration software tools
– One software to configure the RTU, flow computer and remote transmitters
RTUs & FCs provide local I/O, wired & wireless HART interfaces, interfaces to intelligent devices
Data available to SCADA host software
IEC62591 Seamless IntegrationIEC62591 Seamless Integration
FC, RTU, PLC Platform
IEC62591 Wireless I/O Module
Smart Wireless Field Link
IEC62591Interface
ControlWave MicroFB107
IEC62591Interface IEC62591
Interface
ROC800
ROC800 & FB107 IntegrationROC800 & FB107 Integration
Integrated into ROC800 & FB107 firmware
Integrated into ROCLINK configuration software
Integrated with OpenEnterprise™ Field Tools Device configurator
ControlWave IntegrationControlWave Integration
o Integrated into ControlWave firmware
o Integrated into ControlWave Designer configuration software
o Integrated with OpenEnterprise Field Tools Device configurator
Smart Wireless Field LinkSmart Wireless Field Link Smart Wireless Filed Link
– 4 wire connection to IEC62591 I/O module
– Powered by IEC62591 I/O module
No setup or configuration
Aluminum or Stainless Steel housing
Multiple FM, CSA & IS certifications
Antenna selection
– Standard range
– Extended range
Meter selection
750 ft (225 m)2600 ft (800 m) Extended range antenna
Smart Wireless Field Link
Wireless Field Devices
Field ToolsField Tools
Comm Manager
HART Server
Wired & WirelessHART
Device Configuration
Wireless SNAP-ON network analysis and device alerts
Field ToolsField Tools
Comm Manager
HART Server
Wired & WirelessHART
HART Modem
Use in place of 475 Handheld
Field Tools HART Device ConfiguratorField Tools HART Device Configurator
Wired & Wireless
HART configuration
Setup & Configuration
Process Variable Monitor
Device Diagnostics
HART is a mark owned by the HART Communication Foundation
AMS Wireless SNAP-ON Allows Users toEasily Plan and Manage Field NetworksAMS Wireless SNAP-ON Allows Users toEasily Plan and Manage Field NetworksNetwork Planning
– Easily validate / optimize network design against best practices
Network Monitoring– Status and communication
diagnostics
– Alerts
Advanced Reporting– Status and communication
diagnostics
Live Mode
Better Understanding the Health of the DeviceBetter Understanding the Health of the Device
Transmitter status log with time stamp
Pressure & temperature sensor log with time stamp- sensor excursions- max/min values
Set Maintenance RemindersSet Maintenance Reminders
Custom message & alert time
Receive alerts when time expires
IEC 62591 Production ApplicationsIEC 62591 Production Applications First only truly integrated WirelessHART Interface for RTUs and Flow
Computers Wireless Interface Significant Production Applications
Significant Customer Value– Up to 60% faster installation and commissioning. – 30% or more installed cost savings over wired alternatives– Easily add unmonitored points– Most robust diagnostics eliminate false readings and improves
operational and maintenance decisions.– Platform harmonization with tightest Emerson integration– High reliability wireless data network– Low power consumption for remote installations
STEAM INJECTIONHEAT EXCHANGER
WATER INJECTION FLOW
STEAM OR GASINJECTION FLOW
INJECTION WELLHEADMONITORING
Proprietary & Confidential27
WELLHEAD PRESSUREAND TEMPERATUREIndicates health of welland composition of fluids
WELL ANNULUS PRESSUREIndicates casing pressure – an increaseindicates fluid leakage and need to relieve pressure or kill well
WELLHEAD FLOWMeasures temperature for use as an indirect indication of flow
WELLHEAD FLOW LINEVALVE DIAGNOSTICSWireless THUM Adapter transmits Predictive diagnostics to aid maintenance
FLOW & NET OIL/WATERMEASUREMENT AT WELLTHUM Adapter transmitsdiagnostics for maintenanceuse and multiple processvariables for monitoring
OIL PRODUCTION VALVE POSITIONMonitors open / close status and position of choke valves, manifold valves, and manual valves
OIL PRODUCTIONTOTALIZED FLOWMultivariable transmitters efficiently calculate and provide totalized flow output
STEAM INJECTION HEATEXCHANGER MANAGEMENTMeasures pressure anddifferential pressureacross heat exchangersto monitor performance
WATER INJECTION FLOWMeasures and transmitswater flow data andpredictive diagnostics
STEAM OR GAS INJECTION FLOWMeasures and transmits steam or gas injection flow data and predictive diagnostics
GROSS OIL PRODUCTIONGauge pressure measuredat headers is sent to historian to capture production information
INJECTION WELLHEADMONITORINGPressure, temperature and DP flow Measurements provide better visibilityof injection process
WirelessHART Wellhead Monitoring Applications
First only truly integrated WirelessHART Interface for RTUs and Flow Computers Wireless Interface
Significant Transmission Applications
Significant Customer Value– Up to 60% faster installation and commissioning. – 30% or more installed cost savings over wired alternatives– Easily add unmonitored points– Most robust diagnostics eliminate false readings and improves
operational and maintenance decisions.– Platform harmonization with tightest Emerson integration– High reliability wireless data network– Low power consumption for remote installations
STATION PRESSURE &RUN TEMPERATURE
REMOTE TANK MONITORING
REMOTE PRESSURE MONITORING
COMPRESSOR VIBRATION MONITORING
IEC 62591 Transmission Applications IEC 62591 Transmission Applications
FLOW & NET OIL/WATERMEASUREMENT IN TESTSEPARATORTHUM Adapter transmitsdiagnostics for maintenanceand multiple variables for monitoring
VIBRATION IN INJECTION PUMPSMonitors vibration of basesand bearings, providing data for predictive maintenanceto improve availability
PLUGGED FILTER DETECTIONDifferential Pressure across line filters Indicate maintenance is needed
PIPELINE STATION PRESSUREMonitoring remotely located inlet and outlet pressures
TEST MANIFOLD & WELL MONITORINGMonitoring remote wells producing into a test manifold
SEPARATOR LEVEL MEASUREMENTMonitors separator interface level
OFFSHORE PLATFORM HEAT DETECTIONRemotely monitor heat exchanger’s inlet and outlet temps in harsh, difficult -to-reach areas indicate performance
SEPARATION PROCESSVALVE POSITIONMonitors open / closed statusand position of manual valves, relief valves, tank inlet and outlet valves, and shutdown valves
REMOTE TANK MONITORINGMonitoring low pressure points in a distribution system for efficient pressure management reducing leakage
DISTRIBUTION SYSTEM POINT MONITORGauge pressure measuredat headers is sent to historian to capture production information
WirelessHART General Upstream & Transmission Monitoring ApplicationsWirelessHART General Upstream & Transmission Monitoring Applications
WirelessHART Injection Well MonitoringWirelessHART Injection Well Monitoring
Producer Injector Water/Steam
InjectionFacility
RTU at the pump station, or in strategic field locations
RTU logs history, provides long range communications, local display, flow control, logic
At Injection wells Line pressure DP across meter Injection pressure Fluid temperature Valve/choke control
Use WirelessHART to Gather Required Data for ReportingUse WirelessHART to Gather Required Data for Reporting– Injection Well monitoring
• Injection wells are spread out, minimal IO at each point
• Information is not time critical
• Injection pressures, rates and totals are of high value– Main drivers include
governmental regulations and reservoir management needs
• RTUs to archive local histories and provide long range communication and data consolidation
Test System Manifold Well Testing with WirelessHARTTest System Manifold Well Testing with WirelessHART
Producer
Test Manifold
RTU/Flow Computer at test manifold
Automatic Well Testing Valve Control ( Fisher DVC) Measurement (Daniel Orifice,
Turbine, MMI) Pressure, Temperatures
(Rosemount) At producing wells
Casing, Flow Line Pressures
Line pressure Temperatures On/Off status Stuffing Box Leaks
WirelessHart Natural Gas WellheadWirelessHart Natural Gas Wellhead Well Optimization
Plunger Arrival Casing, Tubing, Bradenhead
Pressures Valve Position and Control (Future)
TestimonialsTestimonials
Where successful wireless networks have helped other customers achieve improved performance and financial results
CHALLENGE Manual collection of key process parameters Conventional methods require high
installation and maintenance costsSOLUTION Emerson Smart Wireless
– Proven measurement technology– Pressure, Temp, Level, Flow, Discrete– WirelessHART technology
RESULTS Decreased CAPEX & Operational Costs Lower Safety risks through online Casing
pressure monitoring
Smart Wireless Improves Wellhead Production AllocationOffshore Topsides Wireless Application
Smart Wireless Improves Wellhead Production AllocationOffshore Topsides Wireless Application
Production Manager Decreasing Productivity
Field Technicians/Engineers Rising Workload
HSE Managers Rising Risks
Emerson's Smart Wireless Improves Wellhead Monitoring at BP Wytch Farm Emerson's Smart Wireless Improves Wellhead Monitoring at BP Wytch Farm
CHALLENGE– Eliminate manual rounds to monitor wellhead pressure
reading– Respond to problems and rectify more quickly
SOLUTION– 40 wireless Rosemount® pressure transmitters total
• Two transmitters installed per wellhead• A single Smart Wireless gateway, mounted outside
process area, connects transmitters to control system• All devices on-line within 30 minutes
RESULTS – Improved operations– Automated wellhead pressure monitor– Real time information regarding well performance– Improved maintenance responsiveness to process problems
“The wireless instruments have performed without losing any data since they were installed in August …” - Chris Geen, BP Manager
Customers Are Solving Real Plant Problems: Chevron San Ardo, Calif.Customers Are Solving Real Plant Problems: Chevron San Ardo, Calif. Application:
– Pressure transmitters monitor steam injection on out-of-service wells Challenge: Over steaming caused lost production, increased wastewater
discharge; field visits required Solution: Smart Wireless network improves personnel safety, increases
production, reduces wastewater discharge Application:
– Pressure transmitters check down-hole well pressure Challenge: RTU network obsolete, required hard wired power Solution: Battery-powered transmitters collect reliable production strategy
data, less maintenance, installed for $60,000 savings
“It only took three hours to install all the instruments, configure and establish the network IP address, and make the Ethernet connection to the control room,” Kinne said. “We have eliminated the excess steam usage and now have a reliable steam injection measurement at eight stations.”
— Paul Kinne, Chevron head operator
Smart Wireless Improves Heat Exchanger performance at EnCana Oil Sands FacilitySmart Wireless Improves Heat Exchanger performance at EnCana Oil Sands Facility
CHALLENGE– Improve efficiency of heat exchangers in energy intensive
steam injection process, prevent downtime• Cost-effective way to measure heat transfer in HE’s for
boiler feedwater• Predict tube fouling to improve heat transfer and prevent
tube rupture SOLUTION
– Rosemount® wireless transmitters measure boiler feedwater inlet and outlet temperatures
– Wireless network installed and operating in 2 days RESULTS
– Improved efficiency of several key heat exchangers– Saved $40,000 versus wired installation– Optimized cleaning schedules to prevent tube ruptures– Boiler fuel consumption reduced
“We are now able to maximize heat exchanger operation and maintain the tubes more effectively to prevent heat losses and avoid devastating tube ruptures. We are pleased with the ease of installing the Smart Wireless network, which is working perfectly.” —Stephan Meerman, E&I Supervisor
Leveraging HART to Turn Field Insight into Actionable InformationLeveraging HART to Turn Field Insight into Actionable Information
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Statistical Process Monitoringvariable trending• Standard deviation• Coefficient of variation• Mean
Uncover opportunities byfingerprinting the process to know what "normal or good" looks like.
Decide on accurate alerts for abnormal situation management
Proactively correct abnormal conditions and improve process performance
