Enhanced Plant Asset

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18 Νοε 2013 (πριν από 3 χρόνια και 6 μήνες)

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Standards

Certification

Education & Training

Publishing

Conferences & Exhibits

Wireless Retrofits for
Enhanced Plant Asset
Management

July 07

Vancouver, BC

Paul 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


psereiko@airsprite.com


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 HART

Devices

Wireless
Adapters

Analog
Only I/O

Gateway

Legacy DCS

4
-
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%
HART
Fieldbus
Proprietary
4-20mA +
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 HART

Devices

Gateway

To DCS

Series Adapter

Parallel Adapter

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

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

CIP

CIP

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

Field
Devices

Control
Valves &
Positioners

PAM

Process &
Mechanical
Equipment

Motors,
Rotating,
Reciprocating
Equipment

Electrical
Equipment

Analyzers

Automation Assets

Machinery &
Production Assets

Wiring

Networks

Rest of
Plant

PAM Solutions Monitor,

Predict, and Optimize


Monitor asset health, typically sensing in real time


Assess to predict potential problems


Optimize maintenance and operations decisions




Sense

Assess

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 expertise

per 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%

749
822
881
920
1168
1230
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