Rfid Applications

RFID-BasedPlant Data Collection&Management Systems

Italteleco at a glance:

Employees: 95

Business Areas:

•Document Management•Management&Customization of Intergraph SmartPlantapplications

•High definition laser scanning•As-Built Surveys•Development of mobile plant data managementapplications

•Plant shutdown planning

•Design of pressure vessels

•Installation and maintenance of electrical/instrumentalplants

•Hardware&Software assistance and commercialization

RFID-Based applications developed by Italteleco:

Blinding Management

Scaffolding Management

SmartPlant P&ID Mobile

Software Requirements Specification

All the applications will be used in petrochemical plants during normalconstruction, operation and maintenance, they must therefore comply withthe following requirements:

1) It must be possible to install the applications on mobile devices2) It must be possible to use the applications in explosion risk areas3) Items identification must be univocal4) It must be possible to write information on the RFID tags5) Applications must be interfaceable with other DB-based applications6) It must be possible to access data from Intranet/Internet

Chosen Technology

1) It must be possible to install the applications on mobile devices2) It must be possible to use the applications in explosion risk areas

• Development Environment: Microsoft .NET Compact Framework

Palm Sized PC (PPC) characteristics :

• Operating System: Windows Mobile• RFID Scanner: 125 kHz• ATEX Certification

Chosen Technology

3) Items identification must be univocal4) It must be possible to write information on the RFID tags

RFID TAG characteristics :

• Operating Frequency: 125 kHz• Chip: HITAG S 2048 (read/write)• ATEX Certification• Easily identifiable (yellow colour)

Low operating frequency and RFID scanner’s characteristics require physicalcontact between RFID scanner and tag in order to complete any operation:It is therefore impossible either to operate on the wrong tag or to record wrongInformation.

Chosen Technology

5) Applications must be interfaceable with other DB-based applications6) It must be possible to access data from Intranet/Internet

A desktop application ensures data synchronization between PPCs and DBs used to manage the various processes.

Real-time access to information is ensured either by standard features of theinterfaced data management systems or by a dedicated web interface, devolopedaccording to the Customer’s requirements

Blinding Management

About 2000 blind flanges are involved in the shutdown of a medium-sized plant. Flanges are inserted and then removed in about 40 days.

This process must be correctly managed and controlled, in order toensure high safety levels and avoid problems that could lead tounwanted accidents and/or delays.

It is therefore necessary:

To verify the status (inserted/removed) of every blind flange.

To verify the status of every interference blind flange (common to severalblinding plans)

To verify the completion status of every blinding plan

To easily identify any potential problem

Blinding ManagementData Preparation

Blind positions are identified with a univocal code on the P&ID and on the blinding plan of each equipment/piperun: Interference blinds (common to several blinding plans) are identifiedin this phase.

Blind ManagementData Preparation

Blind positions are identified with a univocal code on the P&ID and on the blinding plan of each equipment/piperun: Interference blinds (common to several blinding plans) are identifiedin this phase.


Information relative to blinding plans and blinds positions are loaded into the DataBase (in this case: Intergraph Directa): Relations are created between objects.

Database data are daily synchronized with data from the field.


Properties shown in the figure are associated to every blind (fully customizable on request)

Blinding ManagementOperation

For every blind position, an RFID tag is initialized with the blind identification code and initialstatus: initial status is set to “To be identified”, meaning the blind position has to be identifiedon the field.

•Initialized tags are then mounted on a metallic support which is then placed in the correspondent blind position.

•User registers, with the PPC, the correct placement : status is set to “Identified”

•During the shutdown operations, users , using the PPC, register insertion/removal of blindflanges: Status is set to “Inserted”/”Removed”

•Removal of interference blinds can be registered on the system only when all the operationsconcerning the blinding plans on which the interference blind appears have been completed. Users are constantly reminded that they are working on interference blinds.


Application login (using an RFID tag) Main Menu


Blinding plans list Blinding plan: checking general status


RFID Tag Reading Setting status to “Identified”


Setting Status to “Inserted” Setting Status to “Removed”


Interference Blinds: setting status to “Inserted” and registering start of activities

Blinding ManagementAccessing information

Data from the field is synchronized daily (or at every shift change) with the main DB: userscan access information via the document management system (in this case: IntergraphDirecta)

Icons are coloured according to the blind status.

Blinding ManagementAccessing Information

Data from the field is synchronized daily (or at every shift change) with the main DB: userscan access information via the document management system (in this case: IntergraphDirecta)

Scaffolding Management

Scaffolding management software hasallows management of scaffoldinginformation such as position, volume, status (operable/not operable), work begin/end. A Google Earth interface allows visual check of space usage, operability, activities. About 1200 scaffoldings are involved in the shutdown of a medium-sized plant

Scaffolding ManagementData Preparation

According to the information extracted from the “scaffoldingrequirement form” and to the estimated position of the scaffolding, a database record is created.

Scaffolding ManagementData Preparation

RFID tags are initialized with the scaffolding univocal identification code and initial status;tags are then fastened to a signboard on the scaffolding.

Scaffolding ManagementOperation

Using the PPC operators can register and manage the followinginformation:

•Scaffolding Operability•Begin of activities•End of activities


Application login (using an RFID tag) Main Menu


Scaffolding data, operable/not operable status menu Assigning the “Operable” Status


Registering begin of activities Registering end of activities


Assigning the “Not Operable” Status Successful information registration confirmation

Scaffolding ManagementAccessing Information

All the information are accessible through a web interface based on Google Earth


Plant view on Google Earth: selected scaffoldings are highlighted


Plant detail view:plot plan, 3D Model, Scaffoldings: Operable scaffolding:green – not operable: red

SmartPlant P&ID Mobile

SmartPlant P&ID Mobile has been developed to allow plant operators, construction and maintenance personnel, to access, view and modifySmartPlant P&ID information using a Palm Sized PC (PPC) Using RFID tags to identify equipments, instruments, piperuns, piping components, etc. queries on the system are automatically performed.

SmartPlant P&ID MobileDescription of the system

SmartPlant P&ID mobile manages the followingSmartPlant P&ID objects:

•Equipments•Equipment Components•Instruments•Instrument Loops•Nozzles•Piperuns•Piping Components

Graphic P&ID can be visualized on the PPC:an intelligent zoom is performed on theselected object (not working, in this version onpiperuns)

SmartPlant P&ID MobileDescription of the system

A desktop application uses “Llama” libraries (Logical Model Automation) and SmartSketch libraries to connect to SPPID database and performs the following operations:

•Reads properties values of the various objects•Generates a mobile DB, which is transferred on the PPC•Converts graphic P&IDs from .pid to .dwg format•When properties are modified on the PPC, updates SmartPlant P&ID’s DB

SmartPlant P&ID MobileOperation

Unit Selection Queries can be performed manually or using an RFID TAG


Query Results Object visualizaton on the P&ID


Properties are categorized like on SPPID Modification of a property on a piperun

SmartPlant P&ID MobileSample applications

Adding appropriate values of “Construction Status” allows a simple work progress monitoring: In the above figure, piperuns with hydrotest completed are highlighted in blue (data registered with PPC). Every construction status can be traced from prefabrication to “Ready for Start-Up”

SmartPlant P&ID MobileSample Applications

Field data are written on the P&ID when data is synchronized: update time and cost is significantly reduced

SmartPlant P&ID MobileSample applications

Items for which field data are available are easily identified with an appropriate display set

Conclusions

Using RFID-based applications provides the following benefits:

• Process management improvement• Process monitoring is easier with consistent, verified data• Problems are easily identified and managed• Identification errors are not possible

• Easy and fast transition to the new system• Applications are designed to be as similar as possibile to the traditional working

procedures (applications are fully customizable according to the Customer’sspecifications

• Training time for a low-skilled user: 2 hours.

www.italteleco.it

Rfid Applications

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