on the way to the smart plant safety technology in the digital age€¦ · hart®, the internet of...
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On the way to the smart plant
Safety technology in the digital age
ON THE WAY TO THE SMART PLANT
Connecting safety technology devices with industrial systems enhances the safety of industrial plants.
The key lies in smart solutions and the integration into existing safety concepts.
In the age of digitalization and Industry 4.0, companies face larger quantities of data to work with.The Industrial Internet of Things (IIoT) exemplifies the upward trend of devices interacting with industrial sytems. This also includes mobile and stationary gas detection systems.
Cutting-edge solutions begin where devices are integrated into a comprehensive safety concept. This enables companies to optimize processes and procedures, minimize downtime and stoppages, and aggregate and analyze safety-related data at a higher level.
Digital becomes smart
1.3 kilometers per day is the walking distance a gas analyst can save by using
the digitalized release measurement procedure.
The safety infrastructures of modern industrial plants are complex and highly sensitive. Legal requirements and standardized processes provide the basis for current safety concepts. At the same time, the digitalization of data provides new possibilities for optimizing processes and procedures, better assessing hazardous situations with more information and, by means of the aggregation and analysis of data, obtaining findings that were not even conceivable before.
Vision of a smart plantImagine a smart plant in which data is collected in real-time from diverse sources and combined centrally. One source of data might be a stationary gas sensor permanently installed in a system, or a device used for area monitoring. At the same time, a mobile single- gas detector carried by an industrial worker for personal protection can function as a data source as well. Such data can be combined with geodata, like GPS data, and other available data to create an entirely new situational overview, one that, for example, will provide an entirely new basis for assessment in an emergency scenario. What hazardous situations exist, and where in the plant are they located? Where is which employee? And who may have to be evacuated?
But there are opportunities for everyday applications as well, such as those that digitally replicate previously paper-based processes. In a field as heavily regulated as industrial safety, there is immense potential for accelerating processes while at the same time minimizing sources of error.
Industry 4.0: Safety technology in the smart plant
The age of Industry 4.0 has already begun – including the field of safety technology. Current safety concepts
incorporate the use of existing equipment and infrastructures, combining them with new technologies.
AN INNOVATION BOOST FROM NEW TECHNOLOGIES
Communication HART® The widely-used HART® communication standard enables digital communication between different detectors via a shared data bus.
GSM network The cellular network is used to transfer data to the cloud via a SIM card integrated into the devices or via a
smartphone connection.
Bluetooth With the Bluetooth industry standard, devices can communicate with each other over shorter distances of up to 25 meters.
LoRa LoRa stands for long-range wide-area network and is a new standard for the age of the Internet of Things.
Geodata GPS GPS, the standard for a global navigational satellite system, can be used to locate devices in a large industrial facility.
Beacon Beacon, a standard based on Bluetooth Low Energy (BLE), is a standard introduced by Apple in 2013 for locating in enclosed spaces.
IT infrastructure Software as a Service
SaaS is a software licensing and delivery model in which software is licensed on a subscription basis and is centrally hosted.
Different technological standardsIn terms of technology, this vision begins with the interaction of devices. In addition to established standards like Bluetooth or HART®, the Internet of Things (IoT) brings new infrastructures, such as low-power wide-area networks (LPWAN), into play. Wireless technologies such as LoRa reduce the cost of implementing a wireless infrastructure in partially EX-protected industrial areas. At the same time, these technologies are attractive solutions due to the limited need of battery power for connected devices. Combining different technological standards offers the opportunity to gradually implement parts of the vision of a smart plant in existing safety infrastructures.
Use Case: Digitalized release measurement procedure for confined spaces
Paper-based processes are yesterday’s news. In the digital age, the entire release measurement process
takes place digitally. For companies, this means a considerable gain in efficiency and safety.
In many industries, such as the chemical industry or the oil and gas sector, release measurements are an everyday activity. Before work is carried out on e.g. a tank or a pipeline, the confined space needs to be carefully checked with a release measurement (among other things). In a large industrial plant, gas analysts walk around all day for this purpose, but delays or errors can occur at any time. Oftentimes, the gas analysts is still taking care of the paperwork in the permit office, while the maintenance crew is already waiting to be deployed.
Today, the entire process can be replicated paperlessly with an EX- approved smartphone. With CSE Connect, job orders are sent directly to the gas analysts on site and the measurements are sent back to the permit office. Because job orders are available via a mobile device,
the gas analyst does not have to take time out to visit the permit office and can therefore optimize his/her routes. As a result, significantly more orders can be performed. Digitalizing the release measurement procedure thus yields considerable potential in cost savings. At the same time, CSE Connect guarantees reliable, easy to manage and complete documentation of all data.
In the Dräger solution, the smartphone and the Bluetooth-enabled Dräger X-am® 8000 multi-gas detector communicate directly with one another. Dräger is currently working on solutions that will integrate e.g. geodata or RFID scanning into CSE Connect. In the future, this data will make it easier for gas analysts to locate the right measurement point.
APPLICATION SCENARIOS IN A SMART PLANT
1. Digitalized release measurement procedure for confined spaces: A paperless release measurement procedure based on mobile availability of job orders and all relevant data in real-time.
2. Smart reporting: Creating useful insights through combining measurement records of stationary gas detection, area monitoring and portable gas detectors.
3. Asset & maintenance management: Collecting and combining data from stationary gas detection, area monitoring and portable gas detectors to increase maintenance efficiency.
4. Real-time situational awareness: A comprehensive overview of situations in case of on-site emergencies.
The smart plant merges economic, structural, logistical and safety-enhancing potentials. Dräger is working on a smart embedded safety concept. These are solutions that will be feasible tomorrow, not in the distant future, and which can be smartly embedded into existing infrastructures. Here are four examples:
ON THE WAY TO THE SMART PLANT
Dräger GS01Infrared gas detection transmitter: The Dräger GS01 detects flammable gases and vapors and relies entirely on wireless technology to transmit data.
Dräger Regard® 7000Modular analysis unit: The newly developed analysis unit is suitable for gas warning systems with various levels of complexity and works with the HART® and other standards.
Dräger X-am® 8000A modern multi-gas detector: The new Dräger X-am® 8000 is optimized for the release measurement procedure. From 2018, it will also be available with a Bluetooth module.
With solutions and products from Dräger, you can enter the age of the smart plant today.
Solutions and products
Dräger X-zone® 5500Mobile area monitor: The high-performance X-zone® 5500 automatically connects wirelessly with up to 25 devices. The data from the group of devices can be transmitted via the GSM network and can also be displayed via a cloud service.
Dräger X-pid® 9000/9500Ex-protected PID gas detection device: Release measuring for hazardous carcinogenic substances with miniaturized laboratory analytics down to the single-digit ppb range.
Dräger CSE ConnectThe digital solution of the future for a reliable and efficient releasemeasurement procedure.
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