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Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
Wireless Retrofits for Enhanced Plant Asset ManagementJuly 07Vancouver, BCPaul Sereiko
Speaker Background
• Paul Sereiko– Professional
– President and CEO, AirSprite Technologies– Industrial wireless sensing software and infrastructure
– Founding CEO, Sensicast Systems, Inc.– Wireless sensor networking solutions
– EVP Marketing, PinPoint Corporation– Real-time wireless location systems
– Professional Affiliations– Co-chair, ISA-SP100 Marketing Working Group– HART Communication Foundation, Marketing Group
– Education– BC Computer Engineering, University of Illinois, Champaign– MBA, Northwestern University (Kellogg)
– Contact– [email protected]– 508.281.2720
Agenda
• 2008 – The Year of Industrial Wireless?• Plant Asset Management Baseline• Turbocharging PAM with Wireless Retrofits• Suggested Best Practices• Conclusions and Q&A
2008 – The Year of Industrial Wireless?
• Maybe …– Standards emerging:
– Wireless HART, spec approval by 2007 year end
– ISA100, spec approval during 2008
– Mesh networking reliability challenge resolved:– Dust SmartMesh >99.9% data throughput
– Early adopter products enjoying commercial success:– Emerson 1420, etc.
• Maybe not …– Security– Interoperability and compliance– Integration with existing business processes
Whatever the Year – Most Want Wireless for Monitoring and Alerting
Source: ISA SP100 Survey
Typical Wireless Deployment – ALL NEW!
• New wireless transmitters:– Expensive
– How do I provision these?
• New network:– Where do I put these repeaters?
– How do I know the signal is actually getting through?
– Can I trust the data on the other end?
– What if my control process gets all messed up?
• New software:– How do I integrate this stuff with
my existing systems?
– Is this really going to work with my DCS?
Gateway
DCS & Host Applications
Repeater
Repeater
An Alternative – Retrofit Your Wired Instrumentation
• Add wireless adapters to existing 4-20mA-only smart devices (e.g. HART)
• Continuously access smart device info– Device status
– Diagnostics
– Configuration
• Use standards (e.g. OPC) to connect data to enterprise systems … PAM, CBM, etc.
• Bypass the DCS
Existing HARTDevices
Wireless Adapters
Analog Only I/O
Gateway
Legacy DCS4-20 mA Signal
OPC & Host Applications
PV Data
HART Data
Why Retrofit? Continuously Use Valuable Data in Stranded HART Instruments
• 35-40 data items in every HART device– Device Identification– Basic Calibration data– Process Variables– Diagnostic Alerts
• Data is easily accessed by HART-enabled systems
• Continuous, real-time access enables operation and asset management improvements
• 35-40 data items in every HART device– Device identification
– Basic calibration data
– Process variables
– Diagnostic alerts
• Data is easily accessed by HART-enabled Systems
• Continuous, real-time access enables Operation and Asset Management improvements
Screen image source: HART Communication Foundation SDC625 software
More Valuable HART Data…
Quantity of Stranded Data is Huge
85%
15%
Stranded HART
Integrated HART
Source: ARC Advisory Group
3%
10%
12%
33%
42%
HARTFieldbusProprietary4-20mA +Pneumatic
~56 Million Devices in 2006(Press, Temp, Flow, Level, Valve Positioners, Analytical)
23.5M
1.7M
5.6M
18.5M
6.7M
20.0M
3.5M
OPC & Host Applications
(PAM, CBM, etc.)
WirelessHART Adapter Example
• Connects anywhere on 4-20 mA loop– Series connection
enables loop power option
– Parallel connection can simplify installation
• Sends/receives HART via wireless and wired transmission
• Enables direct path to host applications, bypassing legacy DCS
Existing HARTDevices
Gateway
To DCS
Series Adapter
Parallel Adapter
SEND HART
commands
Receive HART
digital data
Wireless Adapters Enable New, Low-Cost Monitoring Points
• Need transmitter to retrofit (can be dumb or smart)• Need field power supply• Need wireless adapter• Don’t need a new, expensive wired loop
+-
4-20 mA Transmitter (Smart or
Dumb)
Wireless Adapter
4-20 mA
and/or
Smart Data
24 V Field Powered
OPC & Host Applications
(CBM, Historians, PAM, Advanced Control,
etc.)
Gateway
Wireless Connects Directly to Plant and Enterprise Applications
Process Packaging, Warehouse
CIPCIP
Analog-only legacy control
Ethernet IP
Plant Control Network
Enterprise Network
ERP, MRP, Asset Mgmt
DCS
Wireless digital communication
Agenda
• 2008 – The Year of Industrial Wireless?• Plant Asset Management Baseline• Turbocharging PAM with Wireless Retrofits• Suggested Best Practices• Conclusions and Q&A
PAM Manages Performance, Availability, and Reliability of Plant Assets
Source: ARC Advisory Group
PAM
PAM Solutions Monitor, Predict, and Optimize
• Monitor asset health, typically sensing in real time• Assess to predict potential problems• Optimize maintenance and operations decisions
SenseAssess
Decide
Act
•Wired sensors•Wireless sensors•Virtual sensors•HART devices•Historians
•Predictive analytics•Condition monitoring•Trending
•Preventative maintenance•Predictive maintenance•Run to failure•Reliability-centered maintenance
•Enterprise Asset Management (EAM)•Computerized Maintenance Management Systems (CMMS)
Feedback / Improve
PAM Use Cases – Smart Valves
• Abnormal position vs. valve demand
• Automated detection of valve or positioner malfunctions
• Faster and control-room based troubleshooting and routine testing
• More accurate problem diagnosis– Fewer false positives and
needless valve teardowns– Fewer unnecessary
replacement parts• Valves operate closer to
rated performance– Possible results: Increased
plant capacity, higher yields, greater process efficiency
Screen image source: Emerson AMS ValveLink™ software
What’s Driving PAM?
More and more plant assets
Smaller size of field staff
Aging boomer workforce retiring
More loops per technician (500 to 2000)
Less expertiseper technician
Managing plant assets now takes more than just the workforce
PAM Use Case – Measurement Instruments
• Detect and resolve problems more quickly and efficiently– Alert operators and
maintenance before process degrades
– More efficiently schedule repairs
• Save labor on routine calibrations– Don’t need to be located– No handwritten reports– Results are digitized and
available as documents
PAM Benefits Go Beyond Maintenance
-60 -40 -20 0 20 40
Unplanned Breakdowns
Spare Parts Inventory Costs
Production Downtime
Product Defects
Plant Availability
Workforce Efficiency
Asset Performance
% Improvement Beyond Maintenance
Source: ARC Advisory Group
Huge Opportunity for Users to Improve
PAM is Growing Rapidly
Historical CAGR = 10.4%
749822
881920
11681230
0
200
400
600
800
1000
1200
1400
2000 2001 2002 2003 2004 2005
Source: ARC Advisory Group
Worldwide Sales($ millions)
Example Suppliers of PAM Systems
• ABB• Bently Nevada• Bruel Kjaer Vibro• Emerson Process
Management• FLIR Systems• Honeywell• Invensys• Rockwell Automation• SKF Condition Monitoring
PAM Enables Predictive Monitoring & Maintenance
• “Industry reports estimate that by changing 25% of all preventive maintenance to predictive maintenance, which is five times less costly than preventive maintenance, an organization could potentially realize an up to 60% reduction in maintenance expenses alone.”
Source: ‘Thar's Gold in That Plant-Floor Data'
By Howard Mars, InTech
• $50,000,000 /year in maintaining 40,000 points =$1,250 per point/per year
Source: Chemical Industry Plant Manager
Predictive monitoring & maintenance require field data that is often unavailable other than via manual surveys, if at all.
Agenda
• 2008 – The Year of Industrial Wireless?• Plant Asset Management Baseline• Turbocharging PAM with Wireless Retrofits• Suggested Best Practices• Conclusions and Q&A
Combine PAM and Wireless to Improve Operations and Maintenance
• Retrofit stranded HART devices to:– Better manage instrument assets
– Provide backup primary variable signals for operators
PAM Wireless
• Add measurement points via adapters to:– Better manage machinery and production
assets
– Cut costs of new monitoring points
– Enable process improvements
+-
4-20 mA Transmitter (Smart or
Dumb)
24 V Field Powered
HART Transmitter
Legacy DCS
Reaping the Benefits of Standards-Based Wireless and PAM
Problem Solution
Valuable information locked in smart field instruments.
Wirelessly access locked data via WirelessHART adapters for improved monitoring and PAM of automation assets.
Waiting for manual surveys to identify equipment problems is often too long.
WirelessHART adapters and new wireless measurement points enable continuous, predictive monitoring of assets.
Detecting and troubleshooting instrument problems is time consuming.
WirelessHART adapters cuts time-to-resolution by continuously enabling remote diagnostics and problem solving.
Manpower reductions, aging workforce.
Automate collection of field data to let staff focus on highest value activities.
Reaping the Benefits of Standards-Based Wireless and PAM
Problem Solution
New monitoring points for equipment assets involves costly runs of wire between DCS and field.
Field-powered wireless adapters add new PAM (or process) measurement points without long wire runs and use existing 4-20 mA instruments.
Incomplete field-data picture complicates time-sensitive decisions.
Broaden access to real-time data via retrofits of existing devices and addition of new points to improve decision making.
Extra costs of under (or over) maintaining assets.
Comprehensive picture of plant health cuts operating costs and improves plant productivity.
Getting data needed for PAM from plant through DCS is difficult.
Wireless networks bypass legacy DCS and integrate real-time monitoring data with plant management and enterprise systems.
Agenda
• 2008 – The Year of Industrial Wireless?• Plant Asset Management Baseline• Turbocharging PAM with Wireless• Suggested Best Practices• Conclusions and Q&A
Enter Learning Curve for Standard-based Wireless in ‘07
• Sessions like this• ISA 2007 exhibits (SP100, HART, vendors)• ISA SP100 involvement (users and vendors)• HART Communication Foundation involvement (mostly
vendors) • HART Communication Foundation events• Vendors
Accelerate Learning Curve by Piloting
• Start piloting now!– Certified standard-based products not available for at least a year – Learn how reliable and easy-to-use (or not) today's technology is– Learn about the RF nuances of your environment
• Stand-alone pilot– Do not integrate pilot with existing processes– Set up test processes for the stand-alone system
• Retrofit– Low-cost, low-risk piloting– No need to install new devices
Deployments in ’08 and Beyond
• Use standard-based products – Wait for availability– Extract upgrade commitment from vendor
• Understand use of data – Who are the human users of the information generated? – What systems do they rely on?
– DCS? – Historian? – PAM?
• Understand integration issues with existing processes – Single HMI or NOT? – Process modifications or NOT?
• View wireless’s ability to bypass the DCS as strategic for plant management and enterprise applications
Agenda
• 2008 – The Year of Industrial Wireless?• Plant Asset Management Baseline• Turbocharging PAM with Wireless• Suggested Best Practices for Wireless• Conclusions and Q&A
Conclusions and Q&A
• Retrofitting is the low-cost, low-risk first step into the world of standards-based industrial wireless networks
• Wireless extends the reach and value of PAM solutions– Enables economic monitoring of valuable field data– Enables bypass of DCS for integrating field data with plant
management and enterprise systems
• Start piloting in ’07 to get ready for standards-based products in ‘08