Digital Transformation- for operational excellence

Topics Covered

The case for change: Operational excellence Digital transformation of operation and

maintenance Deploy digital operational infrastructure

Operational ExcellenceThe case for change

Plant Challenges: The Case for Change

HS&E

FewerIncidents

FasterResponse timeReducedNon-compliance

Production

HigherQuality/YieldGreaterThroughput

HigherProductivity

GreaterFlexibilityReducedOperation cost

Energy & Losses

ReducedEmissions and carbon footprint

LowerEnergy consumption and cost

Availability

Reliability & Maintenance

Maintenance costs

Equipment Life

Integrity

Digital TransformationThe new way of running and maintaining the plant

Digital Transformation: Reliability & Maintenance

ISO 55000 API 691 API 570

Digital testing Digital inspection Availability

Reliability & Maintenance

Maintenance costs

Equipment Life

Integrity

Digital Transformation: Health, Safety, and Environment

ISO 45001 ISO 14001 OHSAS 18001

Digital distress callsDigital safety checks

HS&E

FewerIncidents

FasterResponse timeReducedNon-compliance

Digital Transformation: Production

ISO 9001 ISO 29001

Digital operator rounds Digital milk run

Production

HigherQuality/YieldGreaterThroughput

HigherProductivity

GreaterFlexibilityReducedOperation cost

Digital Transformation: Energy Efficiency & Loss Control

ISO 55001

Digital energy management Digital loss control

Energy & Losses

ReducedEmissions and carbon footprint

LowerEnergy consumption and cost

Digital Operational InfrastructureA second layer of automation

Second Layer of Automation Integrated with Existing Operational Infrastructure and IT Infrastructure in a Digital Plant

Real Time

Analytics

Sensing

PervasiveNetworking

BI

Second Layer of Automation

ERP

MES

DCS

IO

Sensors & ActuatorsExisting Automation

L3.5 Integration

Digital Operational Infrastructure – Field Communications Key Role

DCS Hardware

DCS Software

Historian, CMMS

DMZ

ERP

Sensors & Actuators

BI Dashboards

Operational Dashboards

WirelessHARTFieldbus

Valve Analytics

Equipment Analytics

Vibration CorrosionAcoustics PowerPosition

FieldComm

Messaging OPC-UA

Vibration Analytics

Corrosion Analytics

Second Layer of Automation Existing

Can’t Diagnose Equipment Problems Using Existing Process Data

Operations need new information to run the plant better Condition monitoring only for turbomachinery is not enough Need sensors on other equipment as well I&C department must deploy and support these sensors

Reliability

Maintenance

Integrity

Quality

Energy HS&E

Production

Process

Data Driven Operations

Sensor data helps people do their work better and faster

Management Operations EnergyManager

Maintenance• Turn off• Reduce speed

• Clean• Repair• Replace

• KPI• KPI

Analytics

“Things”

Sensors

Solutions Determine Sensor Requirements

Each solution require different sensorsHealth, Safety, Environment Reliability & Maintenance

• Emergency Safety shower and eyewash• Manual valve position• Relief valve release• Shutdown valve position and performance• Hydrocarbon leak/spill detection• Storage tank breather valve• H2S• Independent tank overfill• Effluent temperature

• Pump & mechanical seal• Blower/fan• Air cooled heat exchanger• Non-process centrifugal compressor• Cooling tower• Pipe corrosion• Manual data collection rounds• Instrumentation and valves• Heat tracing system

Production Energy & Losses• Operator rounds• Offsite tank farm storage tank• Wellhead and control panel• Process troubleshooting • Control valve and damper position• Local control panels• Rotating kiln and reactor• Offsite pump• Consumables inventory• Non-wireless devices• Temperature profile

• Steam trap failure• Heat exchanger fouling• Cooling tower excess cooling• Air cooled heat exchanger excess cooling• Relief valve seat passing• Energy management

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

If it won’t break, don’t

sense it

Ubiquitous Sensors on the Equipment

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Lots of sensors are installed on plant equipment Faster data collection

o More predictive; act before outright failure Automatic the data collection

o Save timeo More time available to carry out fixes

T

A

V

T

A

V

P

DP

P

L

P

Equipment

Pressure

Temperature

Fluid Level

Vibration

Corrosion

Acoustic Noise

Software and Analytics Does Not Replace Everything You can’t detect equipment problem by

analyzing process data Example:

o A pump bearing problems has little effect on discharge pressure

o By the time changes in pressure is noticeable it is too late

The fastest way to detect a problem is by direct sensing

Must add new sensors By sensing directly, analytics becomes

very simple Correct issue early, before failure

Infrastructure to Handle Missing Measurements Today maintenance data and some operations data is collected manually

o Not enough data for condition monitoringo Not enough data for ISO 50001 energy managemento Many other blind spots

Hardwiring additional 4-20 mA and on-off sensors for all this would be impractical:o Very costlyo Risk of damaging existing installation

Pervasive Networking

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Hundreds or thousands of new sensors are required Not economical or practical to run a pair of wires for a 4-20 mA or

on-off signal for every measurement signal Need Digital Field Networks

o Wirelesso Fieldbus

The only practical way to connect these sensors using digital networking

Pervasive Networking

Digital sensors with digital multi-device networking from the very first metero Low costo Proven

Add wireless sensor networks; site-wideo Covering measurements left out in the original design Energy efficiency Reliability

o Typically simple individual measurementso Easy to integrate with the existing control system or historiano Wireless technology is proven

Sensors can easily be added to existing fieldbus networks Fieldbus sites also deploy wireless sensor networks

FOUNDATION Fieldbus for Digital Transformation- Build on the Fieldbus You’ve Got Add instruments for equipment condition and performance monitoring

o On premises or IIoT Fieldbuses usually not fully populated Add sensors for condition monitoring and energy management

Process Control & Monitoring

Control System

Condition Monitoring & Energy Management etc.

Condition Monitoring System & Energy Management System etc.

WirelessHART for Digital Transformation- Build on the Wireless Infrastructure You’ve Got Add instruments for equipment condition and performance monitoring

o On premises or IIoT Gateways usually not fully populated Add sensors for condition monitoring and energy management

Process Monitoring

Control System

Condition Monitoring & Energy Management etc.

Condition Monitoring System & Energy Management System etc.

Predictive Process Equipment Analytics

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Condition monitoring of pumps, cooling towers, compressors, blowers, heat exchangers, fans, and air cooled heat exchangers etc.

Detect developing equipment problems earlyo Servicing while it is still simple, fast and at low costo Before outright failure causes shutdowns and expensive repairs

Not All Applications Require Analytics Apps

Simple monitoring adequateo Vibrationo Corrosiono Temperatureo Pressureo Pressure drop

Analytics software required:o Pumpo Compressoro Heat exchangero Cooling towero Fan/blowero Air cooled heat exchangero Steam trapo Control valve

Historian is the Platform Middleware Historian is the Platform :

o Collects data from multiple sources; DCS, SIS, PLC, AMS, MHM...o Stores ito Makes it available to various applications such as analyticso Across the enterpriseo Displayo Reportingo Common security mechanismo etc.

Use existing historian for the architectureo Integrate new sensors and appso Through DCSo Or direct from WirelessHART and Fieldbus gateways

No need to rip and replace historian (big, costly, project) Protects the investment

Historian

Data Source

Data Source

Software App

Software App

Architecture

Use existing historiano Reduced complexityo Lower investment

costo Lower ongoing

support cost No second platform

system layer Analytics apps plug

directly into the historian

Historian

ReliabilityEngineer

Pump Health Heat Exchanger Performance

EnergyManager

Energy Management

DCS SIS PackagePLC

WirelessGateway Vibration

MaintenanceManager

No additional platform

ICS-CERTIndustrial Control System Cybersecurity

Department of Homeland Security (DHS)National Cybersecurity and

Communications Integration Center (NCCIC)

Industrial Control Systems Cyber Emergency Response Team (ICS-CERT)

Recommended Practice: Improving industrial Control System Cybersecurity

with Defense-in-Depth Strategies

Position Digital Transformation First, IIoT Follows

Digital transformation is mostly done on-premises No internet connection or cloud required IIoT can follow

Digital Transformation

IIoT(Internet, Cloud)

Delivering Device Diagnostics to Your Pocket

DCS PLC RTUGateway Multiplexer Linking Device

Provides device health and performance to E&I maintenance personnel

Anytime.Everywhere.All the time.

ConclusionSummary

Summary

The case for change: Operational excellence Digital transformation of operation and maintenance Deploy digital operational infrastructure

I’m Listening...

Jonas Berge

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

jonas.berge@emerson.com

https://www.emersonexchange365.com/members/jonas.berge

Copyright

Copyright © 2017 FieldComm Group™This document contains copyrighted material and may not be reproduced in any fashion without the written permission of the FieldComm Group™.

Trademark Information FieldComm Group™, FOUNDATION™ Fieldbus, HART-IP™ and FDI™ are trademarks, and HART®, WirelessHART®, ROM® and SIF® are registered trademarks of FieldComm Group, Austin, Texas, USA.

Any use of these terms hereafter in this document, or in any document referenced by this document, implies the trademark/registered trademark. All other trademarks used in this or referenced documents are trademarks of their respective companies. For more information, contact FieldComm Group at the address below.

Attention: FieldComm Group PresidentFieldComm Group9430 Research Blvd., Ste. 1-120Austin, TX 78759, USA Voice: (512) 792-2300 Fax: (512) 792-2310http://www.fieldcommgroup.org

Intellectual Property Rights The FieldComm Group (the Group) does not knowingly use or incorporate any information or data into the HART, FOUNDATION Fieldbus and FDI protocol standards, which the Group does not own or have lawful rights to use. Should the Group receive any notification regarding the existence of any conflicting private IPR, the Group will review the disclosure and either (A) determine there is no conflict; (B) resolve the conflict with the IPR owner; or (C) modify the standard to remove the conflicting requirement. In no case does the Group encourage implementers to infringe on any individual's or organization's IPR.

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