Modernizing Plants with Pervasive Sensing™ Infrastructure to Improve Reliability & MaintenanceWorld Reliability Day – 24/7

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Webinar LogisticsWebinar length– 45 min presentation– 15 min question and answer session in the end

This may be recorded– If you have any objection, disconnect/logout now

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Instructions for Audio Minimize dial-in– Audio is also provided over the

Internet:• Turn computer speakers on

You are in a “listen-only” mode the entire time– Press *6 to un-mute yourself

Submit questions any time during the webinar via the Internet, by typing them in.– Questions will be answered during

the Q&A session in the end

Sound Quality

Phone may be better than VoIP

Phone issues press *0

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Instructions for Questions

Submit questions any time via the Internet:– Click ‘Chat’ in Webex menu

bar– Type in your questions– Click ‘Send’

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The PresenterJonas BergeEducated in SwedenDirector of Applied Technology, Emerson Process Management, SingaporeSME– Wireless– Fieldbus– Device integration

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World Reliability Day24th July Dedicated to the pursuit of reliability

λ

24/7

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Everything Is Getting More SensorsOur Parents’ Car

Four sensorsHardwired

Modern Car60-100 sensorsDigitally networked– Bus– Wireless

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Pervasive Sensing for Smarter Cars- Dramatically More Sensors Everywhere

More reliableMore fuel efficient

Environmentally friendlierSafer

Telephone-CUSeat-CU, rear

Roof module

Climate panel backDoor-CU, rear right

Clock

Door-CU, passenger

Navigation-CU

ACC-CU

Motor –CU 1

Motor –CU 2

GearboxCU

Seat-CU,passenger

ACC-sensor

Power-CU

Airbag-CU

Park distance-CUCentral-CUComfort system

Hatchback-CU

TV tuner

Gas spring-CU

Tire pressure-CU

Trailer-CU

Battery-CU

Door-CU rear left

Steering column module

Door-CU driver

Instrument cluster

Seat-CU driver

Climate-CU driver

Wiper moduleHeater

ABS/ESP

Central locking-CU

CAN-Powertrain

CAN-Comfort

CAN-Infotainment

3 X

CAN bus. OBD-II

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Missing Measurements- Manual to Automatic Data Collection

Routine manual data collection

Continuous automatic data collection

TechnologyHuman Effort

ConditionMonitoring

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Topics CoveredNeed to Improve Reliability and Maintenance ProductivityMulti-variable Condition Monitoring– Pump– Fan/blower– Air cooled heat exchanger– Compressor– Cooling tower– Heat exchanger– Corrosion– Manual data collection

Modernize Plant with Pervasive Sensing™ Infrastructure

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“Beyond the Control Room”

HS&E Reliability Energy Efficiency

OpsSIS

Control Room

Process Control

Process Safety

Pervasive Sensing- More Data Beyond the Control Room

ProcessProcess Safety

HS&E Reliability Energy Efficiency

…Process Safety

Hardwired & FieldbusOn the P&ID

WirelessBeyond the P&ID

SIS DCS

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Need to Modernize- Missing Measurements

Plants are getting oldPlants were built with minimum instrumentation necessary for operationNow pushed to improve– Reliability – Energy efficiency– Reduced maintenance costs– Mitigate safety and

environmental incidents– Productivity

This requires more automation

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Modernize Existing Plants- Data Beyond the Control Room

More automation requires more sensors; missing measurements beyond the P&ID– Equipment monitoring, loss, HS&E, operator rounds,...

Laying cable has high risk of damaging the plant– 4-20 mA wiring for transmitters– On-Off wiring for switches

WirelessHART instrumentation drastically reduces risk: a “second layer” of automation– Self-organizing ‘full-mesh’ multi-hop multi-path

topology eliminates all cables– Pervasive sensing

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Common Solution – Shared InfrastructureReliability & Maintenance Energy Efficiency & Loss Control

• Pump & mechanical seal• Blower• Air cooled heat exchanger• Non-process compressor• Cooling tower• Pipe & vessel corrosion• Manual data collection: vibration,

temperature, acoustic

• Steam trap failure• Heat exchanger fouling• Cooling tower excess cooling• Air cooled heat exchanger excess

cooling• Relief valve seat passing• Energy management: water, air

(compressed), gas/fuel, electricity, and steam

Health, Safety, and Environmental (HS&E)

Process Operations Productivity

• Emergency Safety shower and eyewash• Manual and bypass valve position• Relief valve and rupture disk release• Shutdown valve position confirmation• Hydrocarbon leak/spill detection• Cooling water• Storage tank

• Operator rounds: gauge, sight glass, VA meter

• Offsite tank farm storage tank• Wellhead• Process troubleshooting • Valve and damper position

This not all you can do, just a small subset of common applications. Specific to each industry there are many applications possible. Users have discovered hundreds of unique applications.

Modernization

User Guide

Available

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Essential AssetsCritical equipments already have condition monitoring– Expensive turbines,

process compressors, and large pumps

Balance of equipments are not monitored– Many are still essential to

operationManual data collection– Not frequent enough

Also need condition monitoring

Critical

Essential

Non-essential

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Equipment Condition Dashboard- Focus Attention Where It Is Needed

Condition monitoring

software, not the DCS

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Raw Data Analyzed and Distilled- No Data Flooding

Wisdom

Knowledge

Information

Data•Vibration•Temperature•Pressure•Noise

•Duty

•Clean / not•Replace /not•Service / not

•Root Cause Analysis

Collection

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Multi Parameter

Inputs

Overall Pump Health

Status indicators

Raw Data and Diagnostic Information

Condition monitoring

software, not the DCS

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10 ms 100 ms 1 s 10 s 1 min 10 min 1 h 1 day 1 month 1 year

DaysWeeksMonths

MinutesHours

MillisecondsSeconds

Manual Data

Collection

WirelessVibration

Transmitter

MachineryProtection

SystemSecondsMinutes

WiredVibration

Transmitter

Vibration Monitoring

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Pump & Seal Condition Monitoring- Make the Pump Smart

Diagnostics able to detect:– Strainer plugging– Suction pressure drop– Discharge pressure– Vibration– Leak– Bearings overheating– Motor overheating– Mechanical seal failure

Result– Greater availability– Reduced manual data

collection– Lower maintenance cost– Shorter turnarounds

Vibration is a start but

not enough

API 682:2014

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Cooling Tower Condition Monitoring- Make the Cooling Tower Smart

Diagnostics able to detect:– High vibration– Bearing fault– Bearing temperature– Low head– Low discharge pressure– Low suction pressure– Strainer fault– Water temperature– Fouling– Corrosion– pH – Low flow– Windage/water loss

Result– Reduced manual data collection– Lower maintenance cost– Greater availability– Reduced fan power

Vibration is a start but

not enough

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Air Cooled Heat Exchanger Condition Monitoring- Make the ACHE Smart

Diagnostics able to detect:– High vibration– Bearing fault– Bearing temperature– Louver defect– Failed pitch actuator– Exchanger fouling– Excessive cooling

Result– Greater availability– Reduced manual data

collection– Lower maintenance cost– Shorter turnarounds

Vibration is a start but

not enough

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Blower Condition Monitoring- Make the Blower Smart

Diagnostics able to detect:– High vibration– Bearing fault– Louver defect– Bearing temperature– Plugged suction filter– Flowmeter defect

Result:– Greater availability– Lower maintenance cost– Lower electricity cost– Shorter turnarounds– Reduced manual data

collection

Vibration is a start but

not enough

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Compressor Condition Monitoring- Make the Compressor Smart

Diagnostics able to detect:– High vibration– Bearing fault– Plugged intake filter– Process instability– Low differential pressure– High differential temperature– Lube oil– Control vane defect– Gas composition change

Result– Greater availability– Lower maintenance cost– Shorter turnarounds– Reduced manual data

collection

Vibration is a start but

not enough

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Heat Exchanger Condition Monitoring- Make the Heat Exchanger Smart

Diagnostics able to detect (per bundle):– Fouling / inefficiency– Plugging– Duty

Result– Reduced manual data

collection– Lower maintenance cost– Lower utility/fuel cost– Shorter turnarounds

Start with heat exchangers in dirty service

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Pipe & Vessel Corrosion Monitoring- Make the Vessel

Diagnostics able to detect:– Corrosion

Result:– Ensure integrity: avoid

failures, spills, and fires

Start with pipes and

vessels in the most corrosive

service

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Substitute Maintenance Inspection Rounds for Manual Data Collection

Able to reduce field testing– Vibration– Temperature– Ultrasonic (valves)– Ultrasonic (steam traps)

Result– Fewer inspection rounds– Reduce exposure of people to hazards

Start with the more critical equipment

Infrastructure Integration with Existing Historian and DCSWirelessHART on Any System –No Need to Replace It

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Pervasive Sensing- Non-Intrusive Process Connection

Low installed cost– Clamp-on– Strap-on– Bolt-on– Stick-on– Stud– Magnetic– Slip-in

Low risk– No cut– No drill– No weld

Clamp-on

Strap-on

Stick-onScrew-onMagnetic

Bolt-on

Bolt-on

LaySlip-in

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Does Not Need Huge Expensive Infrastructure

Do not need huge expensive infrastructureGateway for each plant unitDevices create their own infrastructure

System

FAR FAR

FAR

FAR

FARFAR

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Architecture: Separate “Second System” for Asset Management

EAMSIS EMISEAM HMI MHM STMDCS

Safety Control

LS

CTRL

Separate Second System: Asset Management

•Steam traps

ReliabilityEnergy HS&EReliability Steam Traps

•Valve•Cooling tower•air cooled heat exchanger•Blower•Pump

•Energy consumption•Heat exchanger fouling•PRV leaks

•Eyewash stations•Safety showers•Relief valve•Bypass valves•Hand valves

RS485Ethernet

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Architecture: Separate PIMS/Historian

SIS

Reliability

Energy HS&EReliability

Steam Traps

MHM STMDCS

Safety Control

LS

CTRL

PIMS/Historian

OPC OPC

•Valves•Cooling tower•air cooled heat exchanger•Blower•Pump

•Energy consumption•Heat exchanger fouling•PRV leaks

•Eyewash stations•Safety showers•Relief valve•Bypass valves•Hand valves

•Steam traps

RS485

Ethernet

Beyond the P&IDDon’t build your new plant old

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Don't Build Your New Plant OldNew designs also do not make provisions for automation beyond operation and safety per P&ID– Not included in process licensor's design

These missing measurements must be added– But the project may have passed the FEED stage...

No redesign– With WirelessHART additional measurement points do

not affect DCS I/O count, cable layout, or junction boxes etc. Why build an

ordinary plant when you can

build an extraordinary

plant?

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Don’t Operate New Plants the Old WayDon’t design-in clipboard rounds and manual labor in a new plant– Labor cost will go up – I promise

Points not on the P&ID– Manual data collection:

• Vibration and temperature test• Steam trap and valve passing test• Gauges, dipsticks, and clipboard rounds• Temperature checks

– Missing measurements:• Valve position feedback (hand operated, On-Off, control...)• Grab samples of product or effluent for lab analysis

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Beyond the P&ID: A Second Layer of Automation for Missing MeasurementsOn the P&ID:Primary layer of Automation

Process Control System– Closed loop control– Process alarms

Process Safety System– Functional safety

Core Business and Data

Beyond the P&ID:Second layer of Automation

Second system beyond the control roomMissing measurements– Reliability and maintenance

productivity– Energy efficiency– HS&E– Operator productivity

Non-core Business and Data

Process ControlHundreds of Milliseconds

Missing MeasurementsSeconds-minutes-hours

ConclusionBeyond the P&ID

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Plant Modernization Deployment Work Process

Justify

Audit

Define

Assign

Plan

Detail Design

Implement

FAT

Installation

Commissioning

Site Integration

Develop Procedures

Training

Handover

User guide for plant-wide deployment of modernization solutions

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Results for Everyone: Modernization / Pervasive Sensing Value

Reliability & Maintenance• Improved equipment reliability• Reduced scheduled plant downtime• Reduced unscheduled plant

downtime• Reduced preventive maintenance• Shorter turnarounds• Longer between turnarounds

Energy Efficiency & Loss• Reduced loss and consumption of

WAGES (Water, Air, Gas, Electricity, and Steam)

• Reduced loss of product• Improved energy efficiency

Health, Safety, and Environmental (HS&E)

• Reduced incidents• Faster incident response time• Regulatory compliance• Greater situational awareness

Process Operations Productivity• Greater productivity• Greater situational awareness• Greater well recovery factor

λη

ϕReliability

EfficiencyIncidents

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SummaryNeed to Improve Reliability and Maintenance ProductivityMulti-variable Condition Monitoring– Pump– Fan/blower– Air cooled heat exchanger– Compressor– Cooling tower– Heat exchanger– Corrosion– Manual data collection

Modernize Plant with Pervasive Sensing™ Infrastructure

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Instructions for Questions

Submit questions any time via the Internet:– Click ‘Chat’ in Webex menu

bar– Type in your questions– Click ‘Send’

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Let’s Stay ConnectedJonas Berge

http://www.linkedin.com/in/smartdigital

http://community.emerson.com/members/jonas.berge/

jonas.berge@emerson.comReliability / Maintenance

24 June 2015

Energy Efficiency & Loss Control

27 March 2015

HS&E 28 April 201524 August 2015

Operations Productivity

22 June 2015