IoT in the Valve and Actuator Industry · What is the Internet of Things (IoT)? 3 •In 2010 Ericsson’s former CEO Hans Vestburg predicted 50 billion connected devices by 2020 •In

IoT in the Valve and Actuator Industry3rd March 2017

Presented by:Mike Devrell

Image source: Adapted from original by Wilgengebroed

Agenda

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• What is the Internet of Things (IoT)?

• The Internet of Things is not about things!

• 6 Technology Buzzwords

• Smart Asset Management

• Improving Site Performance

• Existing Technology in the Valve Industry

• What might we see in the future?

• Security and Implementation Challenges

What is the Internet of Things (IoT)?

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• The world will have 21 billion connected devices by 2020, predicted by Gartner.

• Isn’t IoT just connecting things to the Internet? For the consumer this may be their air conditioning, fridge, toaster, mirror…

What is the Internet of Things (IoT)?

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• In 2010 Ericsson’s former CEO Hans Vestburg predicted 50 billion connected devices by 2020

• In 2011 Cisco also predicted 50 billion by 2020

• In 2012 IBM predicted 1 trillion connected devices (The world’s population is 7.5 billion people, so 133 devices each!?)

• Where are we now? In 2016 we had:

• Gartner: 6.4 billion

• International Data Corporation: 9 billion

• HIS: 18 billion, including smart phones and tablets

• These early predictions generated a lot of investment

The Internet of Things is not about Things!

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• Where are my 1 trillion devices?

• The majority will be consumer devices, but IoT technology has a growing adoption in industry too

• IoT is not about things, or even the internet, it’s about data

• Specifically real-time data, combining multiple data sources together to make smart, timely decisions that save money, save time, increase safety and improve performance


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• Moved into the IoT world in 2012 when Belkin’s WeMo was integrated.

If This Then That

Technology Buzzwords

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Smart Factory / Industry 4.0 / Industrial IoT

• All terms for the same thing:

• A merger of IT and manufacturing; interconnectedand intelligent machines using software applicationsto make smart, timely and data-driven decisions

Virtualisation

• Creation of a virtual resources such as an operatingsystem, a server, a storage device or network

• Similar to partitioning a physical hard drive into twovirtual drives for better organization, but scaled up

• Allows scalability and resource sharing


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Data Fusion• Combining diverse data sets from multiple sources

with different sample rates to give a new data set

• Example: Sea temperature, weather patterns, fish geo location

Big Data• Data sets so large or complex that traditional data processing is inadequate

• Volume, Variety, Velocity, Variability of data

• Often related predictive analytics to extract value from data

• Example: eBay uses 7.5PB and 40PB data warehouses for search,consumer recommendations and merchandising

• Already old, real-time data is the new thing!


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Hyperconvergence

• An architecture that tightly integrates storage, computing, networking and virtualization in a commodity hardware box – all in one place

• The terms has come from ‘converged infrastructure’ – theidea of a pre-configured bundle of hardware and softwareinside a single box

• Hyperconvergence means the integration is sotight, it cannot be broken down in to individual components

• All system parts managed though a single toolset

Augmented Reality

• Virtual reality meets actual reality

Smart Asset Management

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• IoT in industry has most value in improving asset management

• Several sources define Asset Management as the"coordinated activity of an organisation to realise value from assets”

• The art and science of making the right decisions and optimising the delivery of value


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• ISO 55000 - Set of 3 standards (from BSI PAS 55:2008)


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Image source: ISO 55000

Improving Site Performance

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• Devices are getting smarter

• The data is not always used

• IIoT helps to gather data


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Why doesn’t existing device data get used?

• Difficult to collect

• Legacy fieldbus and control systems

• Hazardous areas: FM, IECEx, ATEX, CSA, etc.

• Confined spaces

• Environmental challenges

• Cost of tools and software

• Different methods for different equipment

• System required to record data

• Time consuming with little perceived business benefit


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Operational Stability

IIoT based Asset Management system installed

Existing Technology in the Valve Industry

• Netbiter is small module that allows remote access

• Connects to equipment using

• Ethernet

• Modbus (RS485 and 232)

• Digital & Analogue I/O

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• Ethernet or 3G connection to the internet

• It has GPS location – good for mobile fleet use

• ~ $440 for Ethernet only

• ~ $750 for Ethernet & 3G


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Image source: Modified from HMS


• Remote monitoring

• Remote control

• Logging

• Usage

• Alarms

• Produces graphs that can help customers better understand their process

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Use Cases

• Can be added to a wide variety of existing equipment

• Useful for small sites, even down to 1 pump or tank

• Remote monitoring

• Leek, fault and theft protection

• Example - License requirement to obtain consent to store anti-freeze rather than food products


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Pipeline valve diagnostics

Pump starts


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Actuator rated torque was above calculated required value including 1.5x safety factor

Effect of starting pump was underestimated, able to control pump using VFD to prevent tripping


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Gearbox diagnostics


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Actuator ejection


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We have increasingly smart devices

We can use IIoT to gather this data

Data analysis is the next key step

• Difficult to process large data sets manually

• Requires specialist knowledge

Automated analysis is required

• Simple rule based analysis

• Big data / machine learning models


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What might we see in the future?

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Increased device intelligence – more sensors

More connected devices, more data, easier connection

Data collection and analysis across sites, countries and processes

Nomura say this could make oil and gas companies more profitable at $70pb than they were previously at $100pb

McKinsey say the effective use of IIoT could reduce capital expenditures by up to 20 percent

Processes and oil fields that are not viable today could be brought back into play

Wireless may have a large role – however standardisation required!


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GPRS / 3G / 4G

• Good coverage

• Good range: 35km max for GSM200km max for HSPA

• Worldwide coverage & use

• Frequencies: 900/1800/1900/2100MHz

• Fast data rates: 35-170kps (GPRS) 384Kbps-3Mbps (3G), 3-20Mbps (LTE)

• Power consumption relatively high

• Suitable for main link to the internet, not idea for individual sensors


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WiFi

• Well known technology

• Based on 802.11n/ac standard

• Frequencies: 2.4/5GHz

• Short range: Approximately 50m

• Data rates: Upto 1Gbps, 150-200Mbps is more typical

• Worldwide coverage & use

• High data throughput, but short range and high power requirements

• Suitable for manufacturing environments, less so for oilfields


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Zigbee

• Large industrial installed base

• ZigBee 3.0 based on IEEE 802.15.4

• Frequency: 2.4GHz

• Short range: 10m – 100m

• Data rates: 250 kbps

• Low power operation, high security, robustness and high scalability

• Ideal for battery powered sensors requiring relatively infrequent data exchanges at low data rates

• 5 year battery life possible


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Z-Wave

• Primarily home automation use

• Z-Wave Alliance ZAD12837 / ITU-T G.9959

• Frequency: 900MHz

• Short range: 30m

• Data rates: 9.6 / 40 / 100 kbps

• Avoids busy 2.4GHz range

• Optimised for reliable low-latency communication of small data packets


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LoRaWAN

• Designed for IoT applications

• Long range: 2 – 15km

• Data rates: 0.3-50 kbps

• Avoids busy 2.4GHz range

• Designed to provide low cost, low power consumption, mobile, secure, bi-directional communication

• Ideal for sensor networks reporting small amounts of data

• Large networks with millions of devices supported


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Sigfox

• Primarily home automation use

• Long range: 3 – 50km

• Frequency: 900MHz

• Data rates: 0.01-1 kbps

• Extremely low power, 10+ year battery life possible

• Robust and scalable

• Idea for large networks supporting millions of devices

• Currently being rolled out in cities across Europe, including ten cities in the UK

Security and Implementation Challenges

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Acceptance is a challenge

Some customers are actively connecting their sites to internet based services

Large companies saying “wireless communication will become more secure than wired”

• Wireless protocols are generally recent with high levels of security

• Wired networks such as Modbus, Profibus have no security

• Once you have broken into a wired network, you have full control

Many customers are saying “no way”


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Security is extremely important

• Consequences of an attack could range from industrial espionage, DoS, ransomware and causing process, environmental or physical loss or damage

• Security cannot be added, must be built in from design stage

Examples

• Electricity Smart Meters venerable to attack

• Not allowed to name manufacturer!

• Meters used same encryption key for all devices

• Weak encryption

• Default, weak passwords


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Examples

• 2015 Chrysler recall of 1.4 million vehicles

• Stuxnet, specific targeting of industrial control systems

• Code is now ‘in the wild’

• Global Ping

• In 2013 the entire Internet was pinged by a single operator

• Revealing about 114,000 manufacturing control systems vulnerable for attack

• About 13,000 could be accessed without inputting a single password


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Solutions

• Secure design, don’t assume an attack won’t be attempted

• Turn on security

• Use certificates

• Use strong passwords

• Solution appropriate for use case

• Data Diodes to securelyexport process data

• Laser transmitter andoptical receiver


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There can be risks associated with connecting a site to the internet

There are also risk associated with not connecting and missing the valuable data that may predict a failure, leak, malfunction, etc

The risks associated with each need to be balanced

E: [email protected]: +44 1225 733200

www.rotork.com

Brassmill LaneBath BA1 3JQUK

Thank you!

E: [email protected]

Documents

IoT in the Valve and Actuator Industry · What is the Internet of Things (IoT)? 3 •In 2010 Ericsson’s former CEO Hans Vestburg predicted 50 billion connected devices by 2020 •In