The Gauge Report - Making the case for intelligent instrumentation

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How do you measure upThe Gauge Report - Making the case for intelligent instrumentation

White paper

How do you measure up | White Paper 2

Contents

1.0 Executive Summary2.0 Introduction3.0 How was the survey carried out? 3.1 Rationale4.0 The results 4.1 How old are the majority of your plant’s assets? 4.2 How old is your control system? 4.3 How much of your process control instrumentation (including analysers) is

intelligent i.e. HART/Fieldbus/Profibus 4.4 Do you use intelligence? 4.5 If so, in which of the following areas 4.6 Thinking about your safety systems, which parts are certified

i.e. TUV/Exida 4.7 How often does your organisation formally review impending

environmental legislation? 4.8 What do you see as the future legislation technology you will be using? 4.9 Do you envisage significant investment for the following? 4.9.1 Safety first 4.9.2 Process efficiency 4.9.3 Environmental compliance 4.9.4 Reduced energy consumption 4.9.5 Business management information 4.10 Considering the legacy instrumentation in your plant, in most cases, how

do you procure MRO requirements? 4.11 Due to limited engineering skills in the industry, how do you think you’ll be

addressing future procurement of the majority if instrumentation products and services?

5.0 Summary


1.0 Executive summaryRising costs, the need to stay competitive and a growing raft of environmental and health & safety legislation, are just some of the key challenges facing today’s industrial operators. The ability to be able to respond quickly to changing circumstances and minimise unplanned production stoppages caused by downtime makes it more important than ever for operators to have a comprehensive and informed grip on their processes.

Developments in intelligent instrumentation technology have opened up new possibilities for gathering data from industrial processes. Today, high-quality, real-time data can be collected for a wide variety of parameters, which can be relayed in a variety of ways, either to the operator in the field or to a control room where it will be to use inform automated decision-making systems.

The ‘How do you measure up’ campaign is an attempt both to quantify and qualify the current level of adoption of intelligent instrumentation in industry to obtain a snapshot against which future performance can be measured.

The campaign is divided into two distinct phases. The first phase, already carried out, provides a set of answers to specific questions presented to users in the UK oil, gas and chemical sectors. These answers have been used to establish an industry standard for the second phase of the campaign. This White Paper is concerned with analysing the results from this first phase.

The second phase of the campaign uses the same set of questions as the basis of an on-going survey exercise, the results of which can be compared to the established industry standard. These results are available instantly to the survey respondent in the form of an infographic, which shows how they compare against the norm and encourages them to learn more about improving their performance through the deployment of modern instrumentation technology.

From the results of the first phase of the campaign, it can already been seen that there is still much work to do in promoting the benefits of intelligent instrumentation and in securing a greater adoption of the technology in industrial applications. However, factors such as tightening safety and environmental legislation and the need to improve performance and reduce production costs, do appear to already be driving greater investment in the technology.

Evidence in the results also shows that the need to plug a widening skills gap is likely to change the way that many operators specify, purchase and even install their instrumentation in future, with greater reliance on providers of integrated systems already apparent.

Taken together, the results from the survey highlight a need for manufacturers and suppliers in particular to help educate the market and to encourage greater take-up of intelligent instrumentation.

The Gauge Report


2.0 IntroductionThere are thousands of instruments from various manufacturers currently in use in industrial applications throughout the UK. When it comes to criteria such as age, functionality and intelligence, the composition of this installed base is as diverse as the parameters the instruments are used to measure.

ABB’s ‘How do you measure up?’ campaign aims to take a snapshot of this installed base in the chemical, oil and gas industry and to identify ways to educate users about how they could be putting their instruments to better use.

As such, the campaign is comprised of two main stages.

The first stage of the campaign uses a survey to ascertain the current level of sophistication in the purchase and use of industrial instrumentation. The results from this survey are then used to create a benchmark for the industry.

The Gauge Report

The second stage of the campaign is on-going and enables operators from multiple industry sectors to compare their performance against the benchmark set by the survey.

In this way, the campaign provides an evolving picture of the way in which instrumentation is being used in the UK today and how it could be used to greater effect in the future.

This paper explains how the benchmark has been achieved. It describes how the survey was carried out and provides details of the questions and responses achieved.

It also looks at some of the key findings from the survey and identifies and suggests ways in which users could be deriving greater value from their instrumentation.


6. Thinking about your safety systems, which parts are certified, i.e. TUV / Exida? (If more than one answer applies, please tick the relevant boxes)

– Fire and gas – ESD (Emergency Shutdown) – Associated instrumentation – Associated analysers and environmental monitoring

7. How often does your organisation formally review impending environmental legislation? – Monthly – Quarterly – Half yearly – Yearly – Never

8. What do you see as the future instrumentation technology you will be using?

– HART (4-20mA) – FF – PROFIBUS – Ethernet IP – Wireless

9. Do you envisage significant investment in instrumentation for the following? (If more than one answer applies, please tick the relevant boxes)

– Reduced energy consumption – Environmental compliance – Health and safety legislation – Process efficiency – Business management information – None

10. Considering the legacy instrumentation in your plant, in most cases, how do you procure MRO requirements?

– Replace like with like product – From equivalent vendor limited list – Look for best available technology from all suppliers – Use external consultant / contractor to advise

11. Due to limited engineering skills in the industry, how do you think you’ll be addressing future procurement of the majority of instrumentation products and services?

– Single instruments – Instrumentation package from a systems integrator – Instrumentation package including engineering – Instrumentation package including engineering and

control system – Outsource all instrumentation, procurement,

management, maintenance and support

3.0 How was the survey carried out?The survey was carried out over the course of 8 weeks, with respondents invited to complete an anonymous online survey. To eliminate the possibility of bias or prejudice during the exercise, no ABB branding was contained in the survey and no mention of the company or its products was made.

The survey was aimed at key organisations located in the UK operating in the chemical, oil and gas sectors. Responses came from 43 individuals, from 17 organisations.

A breakdown of the questions contained in the survey is detailed below:

1. How old are the majority of your plant’s assets? 0-10 years 11-20 years 21-30 years 30+ years

2. How old is your control system? 0-10 years 11-20 years 21-30 years 30+ years 3. How much of your process control instrumentation

(including analysers) is intelligent (i.e. HART, Foundation Fieldbus, Profibus, etc?

0-20% 21-40% 41-60% 60%+

4. Do you use this intelligence? – Yes – No

5. If so, in which of the following areas? (If more than one answer applies, please tick the relevant boxes)

– Instrument maintenance – Plant optimisation – Early event warning (to avoid unplanned shutdowns) – Preventive maintenance – Environmental compliance


The Gauge Report

3.1 RationaleThe questions in the above survey were guided by a desire to ascertain the overall understanding and take-up of intelligent instrumentation by companies operating in the oil and gas sector and to assess which factors are driving users to install the technology.

Other factors such as age and the likely capabilities of a user’s control system were also considered.

As mentioned in the introduction, the ‘How do you measure up’ campaign is divided into two key stages. The first stage uses the results from the above survey to establish a benchmark for the industry. As such, it provides a distinct snapshot of the performance of a set of known users at a set period of time against which future performance can be assessed.

The second stage of the campaign features an on-going survey, which is open to users throughout the oil, gas and chemical markets. Users are invited to complete the survey, after which they are able to view an infographic comparing their performance against the benchmarked norm. A copy of part of this infographic is shown below, where the respondent’s answers are shown in blue. The benchmark average is shown in bold type.

The purpose of the survey is two-fold. Firstly, it provides ABB itself with a useful barometer for its own work in the area of intelligent instrumentation, highlighting potential opportunities and identifying areas where greater education is needed to convince users of the merits of intelligent instrumentation.

Secondly, by enabling users to assess their own performance against that of their peers, the survey will also help to build greater awareness of the scope for improvement in terms of the way that plants are instrumented and operated.

Extract from an infographic based on a completed How do you measure up survey response


4.0 The resultsThe results of the initial survey have been used to create the benchmarked norm against which respondents involved in the second stage of the ‘How do you measure up campaign’ can compare themselves.

Carried out in the opening months of 2012, the initial survey produced a variety of interesting data, which is presented and discussed in this section.

4.1 How old are the majority of your plant’s assets?

The aim of this question was to establish whether there is a likely connection between the average age of a plant’s assets and the level of sophistication offered by its installed instruments. An older plant is less likely to use the latest equipment and communication standards, revealing a potential need either to upgrade currently installed instruments or to find ways to better optimise the level of intelligence within those instruments.

As can be seen from the results, the majority of those surveyed (46.5%) reported the average age of their plant assets as being between 11 and 20 years. This finding explains other results throughout the survey, such as the popularity of HART communications over other communications protocols and also other areas, such as the overall take-up of intelligent instrumentation, which reveals that there is still much to do in terms of educating users.

4.2 How old is your control system?

The aim of this question was to establish a link between the level of sophistication offered by a user’s control system and their take-up of intelligent instrumentation. The latest control system technology, such as ABB’s System 800Xa Extended Automation system, for example, offers a wealth of possibilities for real-time supervision and control of industrial processes. The ability of these systems to offer optimum performance relies on the quality, frequency and currency of data that is fed to them.

There is therefore an obvious link between the level of intelligence offered by an instrument and the overall intelligence of a control system.

The results of the survey show that 46.5% of respondents are operating a control system that is between 0 to 10 years old. However, this is closely followed by 39.5% of respondents reporting a control system in the 11-20 year band. With studies showing that modern control systems can greatly enhance both operator and process performance, the results to this question highlight a potential need for site operators to re-examine the technologies they are currently using to control their processes.

0-10 years

1.

2.

3.

4.

5.

ResponsePercent

answered question 43

skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless

Instrument maintenance

ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation

Early event warning (to avoid unplanned shutdowns)

Preventative maintenance

Environmental compliance

0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount

ESD (Emergency shutdown)

Associated instrumentation

Associated analysers and environmental monitoring

Replace like with like product

10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount

From equivalent vendor limited list

Look for best available technology from all suppliers

Use external consultant/contractor to advise

Reduced energy consumption

9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount


Health and safety legislation

Process efficiency

1135.5%Business management information

26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount

Instrumentation package from a systems integrator

Instrumention package including engineering

Instrumentation package including engineering and control system

412.9%Outsource all instrumentation,

procurement, management, maintenance and support

0-10 years

1.

2.

3.

4.

5.

ResponsePercent


skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless


ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation




0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount





10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount





9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount



Process efficiency


26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount







The Gauge Report

4.3 How much of your process control instrumentation (including analysers) is intelligent i.e. Hart/Fieldbus/ Profibus?

This question, together with questions four and five, is aimed at discovering the overall extent of use of intelligent instrumentation on oil, gas and chemical sites. The results to the question ‘How much of your process control instrumentation is intelligent?’ show that there is still a lot of work to be done in promoting the benefits of site-wide deployment of intelligent devices. The vast majority of respondents (51.2%) report that less than a quarter of their installed instruments use HART, Foundation Fieldbus or Profibus communications.

4.4 Do you use this intelligence?

The response to this question again shows the considerable scope for educating users about the benefits of utilising the intelligence within their instruments. Of those who reported the use of intelligent instrumentation on their site to some extent, 56.8% said that they used it in some way. More information about exactly how this intelligence is used is shown in the answers to question five.

4.5 If so, in which of the following areas?

The intelligence within a device can be used in a variety of ways to help operators both to improve the efficiency of their processes and to ensure compliance in areas such as environmental legislation.

The above response breakdown shows the main ways in which survey respondents are using their data. The most popular use for instrument data is for instrument maintenance purposes (77.3%), with other high scoring areas including the closely related requirements for plant optimisation (54.5%), preventive maintenance (63.6%) and early event warning to avoid unplanned shutdowns (54.5%).

Data from an instrument can be used both to monitor its performance and to diagnose potential problems before they occur. As such, it can help organisations not only to reduce unplanned plant downtime, but also to create and operate a proactive preventive maintenance schedule which will further help to minimise the risk of instrument failure.

With health and safety being a major concern on any oil, gas or chemical site, the ability to diagnose faulty equipment and systems before a problem can escalate can make a major contribution to boosting site safety.

0-10 years

1.

2.

3.

4.

5.

ResponsePercent


skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless


ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation




0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount





10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount





9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount



Process efficiency


26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount






0-10 years

1.

2.

3.

4.

5.

ResponsePercent


skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless


ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation




0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount





10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount





9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount



Process efficiency


26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount






0-10 years

1.

2.

3.

4.

5.

ResponsePercent


skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless


ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation




0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount





10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount





9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount



Process efficiency


26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount







4.6 Thinking about your safety systems, which parts are certified i.e. TUV/Exida?

Another key use for intelligent data from instruments is ensuring compliance with environmental legislation. Tightening restrictions on pollution are placing an onus on industrial companies to closely monitor their emissions to air, land and water. Using analytical instrumentation with inbuilt intelligence can deliver significant benefits for industrial operators by providing a wealth of operational data that can be used to prove compliance with environmental legislation.

Defined as ‘the ability of a safety instrumented system to carry out the actions needed to achieve or maintain a safe state’, functional safety is a vital factor that should be considered when selecting and using an instrument in any potentially hazardous application.

Certification by bodies such as TüV and Exida help to provide proof of an instrument’s suitability for safety-related applications.

TüV and Exida certification demonstrate that an instrument meets the standards set down by IEC61508, which provides a structure for the quantitative and qualitative assessment of risk associated with the use of Electrical, Electronic and Programmable Electronic (E/E/PE) equipment in industry.

IEC61508 also provides measures to be taken to reduce risks to “as low as reasonably practical” (ALARP). These risks include minimising the probability of failure and ensuring there is adequate protection within the device or system in the event of a failure.

Though IEC61508 is not a mandatory standard, the measures within it are nevertheless widely construed as constituting best practice, such that conformity with its requirements could provide a defence in the event of a process incident.

The results of this question show that around two-thirds of respondents are using safety systems certified by TüV or Exida for purposes including fire and gas (64.9%), emergency shutdown (67.6%) and associated instrumentation (64.9%).

With the recent spate of high profile incidents, such as Texas City, Buncefield and Deepwater Horizon, the results to this question demonstrate a need for improved safety systems with the need for certified safety systems to be more widely adopted.

4.7 How often does your organisation formally review impending environmental legislation?

The data from the survey shows that 35% of those surveyed are now carrying out a monthly review of impending environmental legislation, followed by 21.6% of respondents who carry out a quarterly check.

Increasingly stringent controls on emissions to land, air and water have placed the onus on industrial plant operators to keep abreast of the latest legislative requirements affecting the generation, monitoring and discharge of pollutants.

The complexity and extent of legislation relating to environmental performance in the oil, gas and chemical industries means it is important for operators to keep pace.

Oil and gas companies are already obliged to observe strict procedures and reporting requirements, including the preparation of environmental statements, where their activities are likely to have potentially detrimental effect on the environment.

An example is where an oil, gas or chemical company wishes to construct a combustion plant as part of their operation. Under the Environmental Permitting Regulations (EPR), these companies must first apply to obtain a permit to operate.

0-10 years

1.

2.

3.

4.

5.

ResponsePercent


skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless


ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation




0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount





10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount





9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount



Process efficiency


26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount






0-10 years

1.

2.

3.

4.

5.

ResponsePercent


skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless


ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation




0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount





10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount





9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount



Process efficiency


26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount







The Gauge Report

Any permit application has to include details of which equipment and techniques will be used to prevent and/or reduce emissions to the environment. A permit application must also include information about any technologies that will be used to monitor the emissions, which should represent the Best Available Technique (BAT) available on the market. These applications must be submitted in addition to any environmental statement documentation.

Accurate measurement over the life of an oil or gas well is especially important as emissions will fluctuate as the well’s output declines. The information collected will therefore provide a useful foundation for negotiating the overall mass emissions for the operation.

4.8 What do you see as the future communications technology you will be using?

In the last 30 years, developments in industrial automation communications technology have opened up new possibilities for plant operators. Starting with the development of HART (Highway Addressable Remote Transducer Protocol) in the early 1980s, a range of new automation protocol technologies have emerged offering expanded possibilities for extracting increasingly detailed data from a site’s installed instrumentation.

Collectively known as ‘fieldbus’, these technologies are now rapidly becoming the method of choice for communication between process control systems and field instrumentation. Of the fieldbus technologies on offer, two in particular have emerged as the leaders, namely FOUNDATION Fieldbus and Profibus DP / Profibus PA. Both these technologies offer a number of benefits, including the ability to transmit multiple parameters per device as opposed to HART which can only transmit data on one parameter at a time.

Fieldbus has found its greatest success in Greenfield projects, where it has increasingly been chosen ahead of HART as the preferred method of communication. With the ability to specify and install fieldbus systems from the start and take full advantage of the lower cabling requirements and number of connections that the technology needs, greenfield projects have offered the ideal proving ground for fieldbus. In these projects, commissioning time is being cut through the use of technicians familiar with the protocol, saving on CAPEX, whilst OPEX savings are also being derived from making best use of the increased maintenance and performance data that the protocol makes available.

Despite the increasing prevalence of fieldbus, HART protocol remains the preferred way to convey digital signals from traditional field instrumentation while preserving the 4-20 mA signal. Installed in over thirty million devices worldwide, HART remains the most widely used of all the communication protocols available today. By overlaying a small digital signal over the 4-20 A current, it gives access to instrument status and allows for parameterization and set-up of device characteristics. In comparison to more sophisticated fieldbus technologies, HART is much simpler and less costly to install, operate and maintain.

The possibilities open to operators through the HART protocol have been further augmented by the arrival of WirelessHART. It is estimated that around 85% of all installed HART devices are not being used to their full potential, with valuable device diagnostic data remaining locked away. In many cases, the main reason for this can be attributed to the device being installed in a hard to reach or hazardous area which makes collecting data from the device either impractical or dangerous.

With the arrival of WirelessHART, this data can now be accessed remotely, providing a simple, effective and secure means of obtaining process data without the associated cost of wiring.

The popularity of HART over other communications protocols is demonstrated by the findings of the How do you measure up survey, with 12 respondents (38.7%) seeing themselves continuing to use HART into the future. In second place with seven respondents each (22.6%) are Profibus and, perhaps surprisingly given its relatively recent entrance into the market, WirelessHART.

0-10 years

1.

2.

3.

4.

5.

ResponsePercent


skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless


ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation




0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount





10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount





9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount



Process efficiency


26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount







Despite the double digit growth reported by the ARC Advisory Group in 2008, FOUNDATION Fieldbus appears to lag behind in the survey, with just three respondents (9.7%) seeing the protocol as being likely to be adopted by their organisation.

Just two respondents (6.5%) saw their organisation as being likely to adopt EtherNet IP (Industrial Protocol) technology, despite its popularity in oil and gas applications, where it is widely deployed to run networks for supervising a variety of tasks, including extraction and production, distribution and refining.

4.9 Do you envisage significant investment in instrumentation for the following?

As a means of gathering vital measurement data, instrumentation plays a vital role in any industrial process. This question was aimed at discovering the key factors driving organisations to invest in instrumentation, with respondents given a range of choices covering some of the key issues prevalent in modern industrial applications.

The findings reveal a close split between environmental compliance (71%), safety (77.4%) and process efficiency (74.2%) as the top three drivers. Reduced energy consumption also scored highly, demonstrating the desire amongst operators to find ways to tackle rising energy prices by measuring their processes more carefully.

4.9.1 Safety firstAs stated earlier in this report, safety has become a major concern for oil, gas and chemical process operators. In recent years, companies have had to interpret and implement a raft of health and safety legislation in order to minimise the impact of their operations both on staff and the wider community.

Various high-profile incidents in recent years show that there is still considerable room for improvement, spanning everything from correctly identifying potential risks through to reducing the chance of catastrophic failure through investment in the right equipment.

As the front line in every industrial process, instrumentation can play a vital role in protecting against the risk of a catastrophic failure. Not surprisingly therefore, 24 respondents (77.4%) in the How do you measure up survey see it as the major driver for investment in instrumentation within their organisation.

Choosing the right equipment for a safety application is not a straightforward task, particularly as different processes will have different requirements. For example, when it comes to choosing equipment with the appropriate Safety Integrity Level (SIL) rating for an application, many operators frequently over-specify, opting for higher rated equipment when in fact a lower-rate device would provide an adequate, and more cost effective, option.

The potential complexity involved in correctly matching equipment against the inherent risks on a site also makes it likely that operators will increasingly be looking either to their equipment supplier(s) or a specialist for help.

0-10 years

1.

2.

3.

4.

5.

ResponsePercent


skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless


ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation




0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount





10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount





9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount



Process efficiency


26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount






0-10 years

1.

2.

3.

4.

5.

ResponsePercent


skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless


ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation




0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount





10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount





9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount



Process efficiency


26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount







The Gauge Report

4.9.2 Process efficiencyGaining a greater understanding of what’s happening across a plant is vital in helping to ensure that production processes are performing at optimum efficiency. Data from the process can be used either locally, or relayed to a control system to automatically address any variations in performance that could affect both efficiency and final product quality. By providing accurate, real-time measurement of a wide variety of process parameters, instrumentation can play a key role in boosting process efficiency.

In many cases, particularly in oil, gas and chemical applications, operators will be faced with selecting a variety of instruments for a process, which, when used together, can have a major impact on the efficiency of that process. An example is an ethylene cracking process, where close control of the cracking process is essential. If the feedstock is over-cracked, excessive coke can form in the furnace, causing it to deactivate. If the feed is under-cracked, the quantity of olefins produced will be reduced.

This process alone will use a wide variety of instruments. Temperature and pressure sensors and transmitters, for example, will help to achieve the 850°C needed for the cracking process. Flue gas measurement using a zirconia oxygen probe will help to optimise combustion efficiency through the correct air/fuel ratios. Additional improvements in performance can also be achieved by using process gas analysers to measure the output gases at various points and the feedstock quality.

4.9.3 Environmental compliance Growing awareness of the impact of industry on the environment has led to a steadily increasing raft of legislation aimed at curbing emissions in recent years. Globally, oil, gas and chemical companies are subject to rules and regulations governing key areas such as combustion plant and production process emissions, discharges to watercourses and chemical treatment and disposal, to name but a few. Failure to comply can lead to severe penalties, which can include the cost of damages and any resulting clean-up operation, potentially running into billions.

Environmental data from production processes is also increasingly required to be reported on a regular basis. Operators must therefore be able to record and collect up to the minute details on their processes.

Again, instrumentation can play a vital role in helping operators to gather the data required for environmental compliance purposes, a process which can be greatly simplified by using the latest generation of intelligent devices. Using these devices, operators are able to collect a wide variety of data, covering everything from key parameters through to diagnostic and alarm information that could be used to help trace the root of a particular problem.


4.9.4 Reduced energy consumptionThe cost of energy is a pressing issue for operators in many countries worldwide, and particularly in the UK, having a major impact on competitiveness and profitability. Consequently, it is in the interest of operators to look for new ways to minimise energy consumption wherever possible.

As a means of gathering up-to-the-minute data on process performance, instrumentation can form the front line in any energy saving programme.

In a steam system, using a flowmeter to measure steam consumption to one or more processes can help to assess efficiency and identify the steps needed to improve performance. Steam metering throughout the entire distribution system is crucial for good energy management. Proper metering allows operators to see exactly what’s going on. For example, meters can track the consumption of individual user processes across a site. This enables energy managers to encourage efficiency by introducing separate billing, or target energy saving measures where they will have the most effect. Trend information also enables operators to spot malfunctioning equipment or other problems as they develop.

Flowmeters can be supplemented with data recorders to collect energy data such as consumption and trend patterns, which can then be easily transferred to a PC or relayed to a control system for subsequent analysis.

4.9.5 Business management informationAlthough it scores low in the survey (35.5%), the use of instrumentation to supply business management information systems is another area of key importance that should be considered in any drive to improve overall operational performance.

In many respects, the heading of business management information actually incorporates the higher scoring choices in the question, with data on the environment, energy consumption and process efficiency in particular all being vital to business management decisions in today’s organisations.

4.10 Considering the legacy instrumentation in your plant, in most cases, how do you procure MRO requirements?

The onus on operators to find new ways to meet the challenges of today’s production environment is apparent in the response to this question. Changes in areas such as environmental and safety legislation, for example, are obliging many operators to upgrade their installed instruments. The digital technology now widely incorporated in modern instruments is offering new levels of sophistication and intelligence for helping solve the legislative, financial and environmental challenges facing today’s industrial companies.

The persuasive, rather than mandatory nature of key standards, such as MCERTS and IEC61508, means that there is no prescriptive guidance on exact makes and models of products to use for specific applications. Instead, it is deemed sufficient if an operator can be proven to have used the best available technology, or technique, for their application.

This is supported by the results of the survey, with 45.2% of respondents either procuring, or likely to procure, their maintenance, repair and operations requirements from suppliers offering the best available technology.

This may denote a shift away from the tendency to simply replace an existing device with an identical, like-for-like product. Alternatively, it may indicate that certain equipment may be deemed to be more important than others, with devices handling specialised roles more likely to be chosen more carefully.

0-10 years

1.

2.

3.

4.

5.

ResponsePercent


skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless


ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation




0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount





10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount





9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount



Process efficiency


26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount







A shortage of skilled engineers is a problem affecting many countries around the world, including the UK. A recent statistic for the UK has shown that only around 12,000 engineers graduate every year, some 18,000 short of the number required. Furthermore, of this 12,000, around half are being lost to other professions.

This shortfall has resulted in those engineers who do go on to work in industry being expected to handle multiple roles, rather than specialising in specific disciplines as would previously have been the case. The impact of this is being seen especially in roles concerning energy management and functional safety, where many engineers lack either the time or the training to properly perform their duties.

In the area of functional safety, for example, many engineers now lack the skills or the knowledge to carry out Safety Requirements Specifications (SRS), leading to a mismatch between the risks identified on a site and the equipment used to help address them.

Systems integrators, including manufacturers offering integrated control and instrumentation systems, are well-placed to assist throughout the lifecycle of a system or product, encompassing all stages from specification through to replacement and upgrade.

The Gauge Report

4.11 Due to limited engineering skills in the industry, how do you think you’ll be addressing future procurement of the majority of instrumentation products and services?

The results to this question show that respondents are increasingly looking towards packaged instrumentation systems. Of the 31 respondents who answered the question, 17 (54.8%) are looking for some form of packaged instrumentation solution, either with or without associated engineering expertise. Of the remainder, 10 respondents (32.3%) believe that their procurement strategy will be on a single instrument-by-instrument basis.

With constraints on the availability of skilled resources in UK industry, the shift towards procuring packaged instrumentation is an ideal means of reducing some of the time, effort and expertise involved in specifying individual equipment. Especially where matched systems are required, opting for a packaged instrumentation system is a good way of helping to minimise on-site configuration and commissioning work. It can also reduce the amount of work in checking issues such as certification, as packaged systems, particularly those for specific duties, will already have been pre-certified.

0-10 years

1.

2.

3.

4.

5.

ResponsePercent


skipped question 0

11.6% 5

20

10

8

46.5%

23.3%

18.6%

ResponseCount

11-20 years

21-30 years

30+ years

Monthly

7.ResponsePercent


skipped question 6

35.1% 13

8

6

9

21.6%

16.2%

24.3%

ResponseCount

Quarterly

Half yearly

Yearly

12.7%Never

HART (4-20mA)

8.ResponsePercent


skipped question 12

38.7% 12

3

7

2

9.7%

22.6%

6.5%

ResponseCount

FF

PROFIBUS

Ethernet IP

722.6%Wireless


ResponsePercent


skipped question 21

77.3% 17

12

12

14

54.5%

54.5%

63.6%

1463.6%

ResponseCount

Plant optimisation




0-10 years

ResponsePercent


skipped question 0

46.6% 20

17

4

2

39.5%

9.3%

4.7%

ResponseCount

11-20 years

21-30 years

30+ years

0-10%

ResponsePercent


skipped question 0

51.2% 22

7

7

7

16.3%

16.3%

16.3%

ResponseCount

21-40%

41-60%

60%+

Yes

ResponsePercent


skipped question 0

56.8% 21

1643.2%

ResponseCount

No

6.

Fire and gas

ResponsePercent


skipped question 6

64.9% 24

25

24

16

67.6%

64.9%

43.2%

ResponseCount





10.ResponsePercent


skipped question 12

29.0% 9

7

14

1

22.6%

45.2%

3.2%

ResponseCount





9.ResponsePercent


skipped question 12

61.3% 19

22

24

23

71.0%

77.4%

74.2%

ResponseCount



Process efficiency


26.5%None

Single instruments

11.ResponsePercent


skipped question 12

32.3% 10

11

2

4

35.5%

6.5%

12.9%

ResponseCount







5.0 Summary

The How do you measure up survey provides a valuable snapshot of how instrumentation products are currently being specified and deployed in oil, gas and chemical applications. As such, it identifies a number of areas where operators could be enhancing their performance, efficiency and cost effectiveness when it comes to specifying, operating and maintaining their instruments.

The survey provides a useful indication for manufacturers such as ABB of where their future efforts should be aimed, particularly when it comes to building awareness of the benefits that intelligent instruments can bring in industrial processes.

The survey also emphasises the increasing role that will be played by manufacturers and suppliers of instrumentation and control equipment in the future, with these companies likely to be plugging the skills gap caused by a shortage of engineers. As such, these companies have an opportunity to develop their offering to address not only the full lifecycle of an instrument, but also to work in closer partnership with customers over and above just the supply of equipment.

Power and productivityfor a better world TM

Contact us

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GermanyABB Automation Products GmbHBorsigstr. 263755 AlzenauTel: +49 551 905 534Fax: +49 551 905 555

Italy ABB S.p.A. ABB SACE DivisionVia Statale 113 22016 Lenno (CO) Tel: +39 0344 58111Fax: +39 0344 56278

China ABB Engineering (Shanghai) Ltd. No.5, Lane 369, Chuangye Road Kangqiao Town, Nanhui District Shanghai, 201319, P.R. China Tel: +86(0) 21 61056666 Fax: +86(0) 21 61056677

www.abb.com/instrumentation

UKABB LimitedOldends LaneStonehouseGloucestershire GL10 3TATel: +44 1453 826 661 Fax: +44 1453 829 671

USAABB Inc.125 E. County Line RoadWarminster, PA 18974-4995 Tel: +1 215 674 6000 Fax: +1 215 674 7183

Notes: We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents – in whole or in parts – is forbidden without prior written consent of ABB.

Copyright© 2012 ABB

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Printed in UK (09.2012)

Documents

The Gauge Report - Making the case for intelligent instrumentation