Industrial Internet of Things (IIoT) – future proof plantJONAS BERGE – EMERSON PROCESS MANAGEMENT

Topics Covered

• What is IIoT• IIoT benefits• Getting started with IIoT

Industrial Internet of Things (IIoT)

Internet of Things

Internet of PeopleHuman interfaces• Computers• Tablets• Smart phones

Internet of ThingsNetworked autonomous devices• Refrigerator• Car• Aircon

Industrial Internet of Things (IIoT)

• Industrial thingsPressure transmitterIntelligent on-off valveSmart pumpRobot

• Using industrial networkingWirelessHARTFieldbus

FCG User Seminar | 10 June 2016 at Singapore

Industrial Internet of Things- ARC DescriptionDigital Transformation• Industrial products• Operations (run &

maintain)• Value chains

(business models)• Aftermarket services

(IoT linked maintenance)

Enablers• Expanded use of

sensors• Digitization (digital

from the first meter)• Networking (multiple

sensors, minimal wiring)

• Information systems

http://industrial‐iot.com/2016/02/killing‐the‐zombie‐meme‐iot‐is‐nothing‐new/

Internet Enables Remote Monitoring

• Enterprise levelGlobal technology center of excellence

• By equipment manufacturerPump, valve, ACHE, CT, etc.

• By third-party service provider

IIoT is a group of enabling technologies

FCG User Seminar | 10 June 2016 at Singapore

IIoT is Different from SCADA- Both Are Remote But There Are Differences• SCADA is about

process monitoring and operation

• SCADA typically use dedicated networks (not across the Internet)

• IIoT provides the ability to drill down into the ‘Things’

Into equipment and devices

» Monitor diagnostics» Configure» Update device firmware» etc.

IIoT Benefits

Benefits of IIoT and Pervasive Use of Sensors

• Every department in the plant benefits

• Shared infrastructure

Reliability Energy HS&E OperationsMaintenance IntegrityI&C•Improved reliability•Reduced downtime

•Greater energy efficiency•Lower energy and utility cost•Reduced flaring and venting•Reduced losses

•Reduced incidents•Faster incident response•Compliance•Reduced emissions

•Improved productivity

•Lower maintenance cost•Shorter turnarounds•Longer between turnarounds

•Improved integrity•Reduced corrosion control cost

•Improved reliability•Reduced downtime IIoT On‐

prem

Some plants are already reaping these benefits 

FCG User Seminar | 10 June 2016 at Singapore

System Architecture

• Traditional On-Premise Monitoring

• Remote Monitoring Service in the Cloud

HistorianHMIDCS

CTRL

RS485

JB

ReportReport

3G

SteamTrap

Management

Different IIoT Models

• Internal ExpertsPlants owns instrumentation and provides the remote expertise themselves

• Remote ExpertsPlants owns instrumentation, Service provider provides the remote expertise

• Remote Monitoring ServiceService provider owns instrumentation and provides the remote monitoring service and expertise

Getting Started with IIoTROADMAP

Digital Sensor 

Networks

Instrument Assets

On‐premise Analytics Software

Review Work 

Processes

IntRAnet of Things

IntERnet of Things 

Vision to Reality: Roadmap to IIoT

• Step 1 Plant-wide Digital Sensor Networks• Step 2 Instrumenting Assets• Step 3 Deploy Predictive Analytics Software On-

premise• Step 4 Review Work Processes• Step 5 Enable Private IntRAnet of Things• Step 6 IntERnet of Things Business Models

Pervasive Networking- Digital Sensor Network Infrastructure• Digital sensors with digital multi-device networking from

the very first meterPoint-to-point 4-20 mA or on-off signals not required

• Add wireless sensor networksCovering measurements left out in the original design» Energy efficiency» Reliability

Typically simple individual measurementsIntegrated with the control system or historianWireless technology is proven

• Modern plants built on Fieldbus can easily add sensors to existing networks

• Yet Fieldbus plants also deploy wireless sensor networks

All Devices Digitally Integrated;- Predictive Maintenance for All Devices

• With Fieldbus many more devices around the plant can benefit from device management: diagnostics

• No device left as an "isolated island“• More advanced diagnostics

Traditional Smart Devices

MOV

GCOn‐OffValves

Fieldbus

Missing Measurements Everywhere

• Today maintenance data and some operations data is collected manually

Not enough data for condition monitoringNot enough data for ISO 50001 energy managementMany other blind spots

• Hardwiring 4-20 mA and on-off sensors for all this would be impractical:

Very costlyRisk of damaging existing installation

Backwards Compatible with Existing Intelligent Devices and Networks• IIoT builds on existing digital network standards

FOUNDATION fieldbus (IEC 61784-1 profile 1)WirelessHART (IEC 62591)

• No need to bulldoze the existing automation• IIoT is a new extension of the existing digital

ecosystem in the plant

Deploy Sensors ‘At Will’

• The I&C department is responsible for the sensor network infrastructure

• Other departments deploy sensors as neededCurrent needsFuture needs

I&C

Reliability Energy HS&E OperationsMaintenance Integrity

•Condition monitoring•Data collection

•Energy management•performance monitoring

•Emissions monitoring•Situational awareness

•Data collection

•Maintenance scheduling

•Integrity monitoring

Build on the Fieldbus You’ve Got

• Fieldbuses usually not fully populated• Add sensors for condition monitoring

and energy management

Process Control & MonitoringCondition Monitoring & Energy Management etc.

Control SystemCondition Monitoring System & Energy Management System etc.

Technology with a Purpose- Not technology for technology’s sake• Conduct a plant modernization audit...• Collect needs from each department in the plant• Pervasive use of sensors• Each and every sensor has a purpose

Reliability Energy HS&E OperationsMaintenance Integrity•Manual data collection•Bearing failure•Mechanical seal failure

•Steam traps•Excess fan speed•Water balance •Compressed air balance•Steam balance•Pipe and flange leaks•Flare and vent reduction

•Safety showers•Manual valves•Hydrocarbon leaks

•Manual data collection

•Manual data collection•Heat exchanger fouling•Fouling in cooling towers•Cooling tower fouling•Fluid levels•Steam trap failure

•Manual data collection•Inhibitor injection

The Wireless Infrastructure Pays for Itself- Simple Single Measurements• Surprisingly many process equipment failures

detected immediately when the system is turned on

• The new data drives maintenance activities• Behavior and maintenance culture will change

from reactive to predictive

Reliability Energy HS&E OperationsMaintenance Integrity•Manual data collection•Bearing failure•Mechanical seal failure

•Flare and vent reduction

•Safety showers•Manual valves•Hydrocarbon leaks

•Manual data collection

•Manual data collection•Fluid levels

Software

• Advanced solutions use multiple measurements and analytics software:

Steam trap monitoringEquipment condition monitoringEquipment performance monitoringEnergy managementValve monitoringCorrosion monitoringVibration monitoring

Vibration is not sufficient for condition monitoring

T

A

V

T

A

V

P

DP

P

LL

LH

P

Smart Connected Equipment

• Sensors and software turn dumb equipment into smart connected equipment

DIKW: Analytics Software Distill Raw Data to Information and Knowledge

Wisdom

Knowledge

Information

Data•Vibration•Temperature•Pressure•Noise

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

•Root Cause Analysis

Collection

Real‐time Historizing

Remote Monitoring Service

Real‐time Analytics

•Heat transfer coefficient 

•Duty

Software Pays for Itself- Multiple Measurements• The new information drives maintenance activities

Reliability Energy HS&E OperationsMaintenance Integrity•Manual data collection•Bearing failure•Mechanical seal failure

•Excess fan speed•Water balance •Compressed air balance•Steam balance•Pipe and flange leaks•Flare and vent reduction

•Safety showers•Manual valves•Hydrocarbon leaks

•Manual data collection

•Manual data collection•Heat exchanger fouling•Fouling in cooling towers•Fluid levels•Steam trap failure

•Manual data collection•Inhibitor injection

Save Precious Time

• Automatic data collection reduces and eliminates:Field operator rounds to read mechanical gaugesMaintenance rounds with portable testersRetrieval and interpretation of recorder charts is drastically reduced saving time

• Alarms on abnormal conditionOperations and maintenance act on it

• Data-driven workflow

Check the Software First Mindset

• Incorporate the new data and information in the daily operation & maintenance activities

• Incentivize personnel to follow the new data-driven workflow

• Modify the Standard Operating Procedures (SOPs)

Include the new data and information

• Train staff to use the new data, software, and information

ExampleIf heat exchanger is not performing, the first course of action should not be to walk into the plant, but to check the software first

Remote Monitoring Service Architecture

• The site may not have staff with special skills• Difficult to attract and retain people at remote sites

away from their families for long periods of time

Site A Site B Site C Site D

Global Centre of Excellence

Pool of Experts•Rotating equipment (vibration)•Valves•Steam traps•Corrosion•Etc.

Global Centre of Operations

• City office with pool of experts• A second layer of intelligence and pool of experts

to guide the operators and maintenance in the company’s various plants

Maintenance Challenge

• The equipment manufacturer’s expert knows the equipment best

But is not at site• Not enough personnel to collect and analyze all

reliability and maintenance data

ST

ST

CompressorManufacturer

Steam TrapManufacturer

Heat ExchangerManufacturer

ValveManufacturer

PumpManufacturer

Fan/BlowerManufacturer

Cooling TowerManufacturer

Air Cooled Heat ExchangerManufacturer

Remote Monitoring Services

IIoT Architectures

Level 0Instruments

Level 1DCS

Level 2Historian and AMS

Level 3MES

Level 4ERP

I&C(“OT”)

ITDMZ DMZ

Level 0Instruments

Develop Your Company’s IIoT StrategyCONCLUSION

Summary

• IIoT transforms how plant is run and maintained

More proactiveLess reactive

• IIoT transform how personnel workLess time spent collecting dataMore time to act on the new information

• The standards and technologies are already in place

You can start todaySome plants have already taken the first few steps

Let’s Stay Connected

• Jonas Berge

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

jonas.berge@emerson.com

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