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/
[email protected] / Maintenance
24 June 2015
Energy Efficiency & Loss Control
27 March 2015
HS&E 28 April 201524 August 2015
Operations Productivity
22 June 2015
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