industrial internet of things (iiot) – future proof plant · industrial internet of things (iiot)...
TRANSCRIPT
Industrial Internet of Things (IIoT) – future proof plantJONAS BERGE – EMERSON PROCESS MANAGEMENT
Topics Covered
• What is IIoT• IIoT benefits• Getting started with IIoT
Industrial Internet of Things (IIoT)
Internet of Things
Internet of PeopleHuman interfaces• Computers• Tablets• Smart phones
Internet of ThingsNetworked autonomous devices• Refrigerator• Car• Aircon
Industrial Internet of Things (IIoT)
• Industrial thingsPressure transmitterIntelligent on-off valveSmart pumpRobot
• Using industrial networkingWirelessHARTFieldbus
FCG User Seminar | 10 June 2016 at Singapore
Industrial Internet of Things- ARC DescriptionDigital Transformation• Industrial products• Operations (run &
maintain)• Value chains
(business models)• Aftermarket services
(IoT linked maintenance)
Enablers• Expanded use of
sensors• Digitization (digital
from the first meter)• Networking (multiple
sensors, minimal wiring)
• Information systems
http://industrial‐iot.com/2016/02/killing‐the‐zombie‐meme‐iot‐is‐nothing‐new/
Internet Enables Remote Monitoring
• Enterprise levelGlobal technology center of excellence
• By equipment manufacturerPump, valve, ACHE, CT, etc.
• By third-party service provider
IIoT is a group of enabling technologies
FCG User Seminar | 10 June 2016 at Singapore
IIoT is Different from SCADA- Both Are Remote But There Are Differences• SCADA is about
process monitoring and operation
• SCADA typically use dedicated networks (not across the Internet)
• IIoT provides the ability to drill down into the ‘Things’
Into equipment and devices
» Monitor diagnostics» Configure» Update device firmware» etc.
IIoT Benefits
Benefits of IIoT and Pervasive Use of Sensors
• Every department in the plant benefits
• Shared infrastructure
Reliability Energy HS&E OperationsMaintenance IntegrityI&C•Improved reliability•Reduced downtime
•Greater energy efficiency•Lower energy and utility cost•Reduced flaring and venting•Reduced losses
•Reduced incidents•Faster incident response•Compliance•Reduced emissions
•Improved productivity
•Lower maintenance cost•Shorter turnarounds•Longer between turnarounds
•Improved integrity•Reduced corrosion control cost
•Improved reliability•Reduced downtime IIoT On‐
prem
Some plants are already reaping these benefits
FCG User Seminar | 10 June 2016 at Singapore
System Architecture
• Traditional On-Premise Monitoring
• Remote Monitoring Service in the Cloud
HistorianHMIDCS
CTRL
RS485
JB
ReportReport
3G
SteamTrap
Management
Different IIoT Models
• Internal ExpertsPlants owns instrumentation and provides the remote expertise themselves
• Remote ExpertsPlants owns instrumentation, Service provider provides the remote expertise
• Remote Monitoring ServiceService provider owns instrumentation and provides the remote monitoring service and expertise
Getting Started with IIoTROADMAP
Digital Sensor
Networks
Instrument Assets
On‐premise Analytics Software
Review Work
Processes
IntRAnet of Things
IntERnet of Things
Vision to Reality: Roadmap to IIoT
• Step 1 Plant-wide Digital Sensor Networks• Step 2 Instrumenting Assets• Step 3 Deploy Predictive Analytics Software On-
premise• Step 4 Review Work Processes• Step 5 Enable Private IntRAnet of Things• Step 6 IntERnet of Things Business Models
Pervasive Networking- Digital Sensor Network Infrastructure• Digital sensors with digital multi-device networking from
the very first meterPoint-to-point 4-20 mA or on-off signals not required
• Add wireless sensor networksCovering measurements left out in the original design» Energy efficiency» Reliability
Typically simple individual measurementsIntegrated with the control system or historianWireless technology is proven
• Modern plants built on Fieldbus can easily add sensors to existing networks
• Yet Fieldbus plants also deploy wireless sensor networks
All Devices Digitally Integrated;- Predictive Maintenance for All Devices
• With Fieldbus many more devices around the plant can benefit from device management: diagnostics
• No device left as an "isolated island“• More advanced diagnostics
Traditional Smart Devices
MOV
GCOn‐OffValves
Fieldbus
Missing Measurements Everywhere
• Today maintenance data and some operations data is collected manually
Not enough data for condition monitoringNot enough data for ISO 50001 energy managementMany other blind spots
• Hardwiring 4-20 mA and on-off sensors for all this would be impractical:
Very costlyRisk of damaging existing installation
Backwards Compatible with Existing Intelligent Devices and Networks• IIoT builds on existing digital network standards
FOUNDATION fieldbus (IEC 61784-1 profile 1)WirelessHART (IEC 62591)
• No need to bulldoze the existing automation• IIoT is a new extension of the existing digital
ecosystem in the plant
Deploy Sensors ‘At Will’
• The I&C department is responsible for the sensor network infrastructure
• Other departments deploy sensors as neededCurrent needsFuture needs
I&C
Reliability Energy HS&E OperationsMaintenance Integrity
•Condition monitoring•Data collection
•Energy management•performance monitoring
•Emissions monitoring•Situational awareness
•Data collection
•Maintenance scheduling
•Integrity monitoring
Build on the Fieldbus You’ve Got
• Fieldbuses usually not fully populated• Add sensors for condition monitoring
and energy management
Process Control & MonitoringCondition Monitoring & Energy Management etc.
Control SystemCondition Monitoring System & Energy Management System etc.
Technology with a Purpose- Not technology for technology’s sake• Conduct a plant modernization audit...• Collect needs from each department in the plant• Pervasive use of sensors• Each and every sensor has a purpose
Reliability Energy HS&E OperationsMaintenance Integrity•Manual data collection•Bearing failure•Mechanical seal failure
•Steam traps•Excess fan speed•Water balance •Compressed air balance•Steam balance•Pipe and flange leaks•Flare and vent reduction
•Safety showers•Manual valves•Hydrocarbon leaks
•Manual data collection
•Manual data collection•Heat exchanger fouling•Fouling in cooling towers•Cooling tower fouling•Fluid levels•Steam trap failure
•Manual data collection•Inhibitor injection
The Wireless Infrastructure Pays for Itself- Simple Single Measurements• Surprisingly many process equipment failures
detected immediately when the system is turned on
• The new data drives maintenance activities• Behavior and maintenance culture will change
from reactive to predictive
Reliability Energy HS&E OperationsMaintenance Integrity•Manual data collection•Bearing failure•Mechanical seal failure
•Flare and vent reduction
•Safety showers•Manual valves•Hydrocarbon leaks
•Manual data collection
•Manual data collection•Fluid levels
Software
• Advanced solutions use multiple measurements and analytics software:
Steam trap monitoringEquipment condition monitoringEquipment performance monitoringEnergy managementValve monitoringCorrosion monitoringVibration monitoring
Vibration is not sufficient for condition monitoring
T
A
V
T
A
V
P
DP
P
LL
LH
P
Smart Connected Equipment
• Sensors and software turn dumb equipment into smart connected equipment
DIKW: Analytics Software Distill Raw Data to Information and Knowledge
Wisdom
Knowledge
Information
Data•Vibration•Temperature•Pressure•Noise
•Clean / not•Replace /not•Service / not
•Root Cause Analysis
Collection
Real‐time Historizing
Remote Monitoring Service
Real‐time Analytics
•Heat transfer coefficient
•Duty
Software Pays for Itself- Multiple Measurements• The new information drives maintenance activities
Reliability Energy HS&E OperationsMaintenance Integrity•Manual data collection•Bearing failure•Mechanical seal failure
•Excess fan speed•Water balance •Compressed air balance•Steam balance•Pipe and flange leaks•Flare and vent reduction
•Safety showers•Manual valves•Hydrocarbon leaks
•Manual data collection
•Manual data collection•Heat exchanger fouling•Fouling in cooling towers•Fluid levels•Steam trap failure
•Manual data collection•Inhibitor injection
Save Precious Time
• Automatic data collection reduces and eliminates:Field operator rounds to read mechanical gaugesMaintenance rounds with portable testersRetrieval and interpretation of recorder charts is drastically reduced saving time
• Alarms on abnormal conditionOperations and maintenance act on it
• Data-driven workflow
Check the Software First Mindset
• Incorporate the new data and information in the daily operation & maintenance activities
• Incentivize personnel to follow the new data-driven workflow
• Modify the Standard Operating Procedures (SOPs)
Include the new data and information
• Train staff to use the new data, software, and information
ExampleIf heat exchanger is not performing, the first course of action should not be to walk into the plant, but to check the software first
Remote Monitoring Service Architecture
• The site may not have staff with special skills• Difficult to attract and retain people at remote sites
away from their families for long periods of time
Site A Site B Site C Site D
Global Centre of Excellence
Pool of Experts•Rotating equipment (vibration)•Valves•Steam traps•Corrosion•Etc.
Global Centre of Operations
• City office with pool of experts• A second layer of intelligence and pool of experts
to guide the operators and maintenance in the company’s various plants
Maintenance Challenge
• The equipment manufacturer’s expert knows the equipment best
But is not at site• Not enough personnel to collect and analyze all
reliability and maintenance data
ST
ST
CompressorManufacturer
Steam TrapManufacturer
Heat ExchangerManufacturer
ValveManufacturer
PumpManufacturer
Fan/BlowerManufacturer
Cooling TowerManufacturer
Air Cooled Heat ExchangerManufacturer
Remote Monitoring Services
IIoT Architectures
Level 0Instruments
Level 1DCS
Level 2Historian and AMS
Level 3MES
Level 4ERP
I&C(“OT”)
ITDMZ DMZ
Level 0Instruments
Develop Your Company’s IIoT StrategyCONCLUSION
Summary
• IIoT transforms how plant is run and maintained
More proactiveLess reactive
• IIoT transform how personnel workLess time spent collecting dataMore time to act on the new information
• The standards and technologies are already in place
You can start todaySome plants have already taken the first few steps
Let’s Stay Connected
• Jonas Berge
http://www.linkedin.com/in/smartdigital
https://www.emersonexchange365.com/members/jonas.berge