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Wireless Retrofits for Enhanced Plant Asset ManagementJuly 07Vancouver, BCPaul Sereiko

Speaker Background

• Paul Sereiko– Professional

– President and CEO, AirSprite Technologies– Industrial wireless sensing software and infrastructure

– Founding CEO, Sensicast Systems, Inc.– Wireless sensor networking solutions

– EVP Marketing, PinPoint Corporation– Real-time wireless location systems

– Professional Affiliations– Co-chair, ISA-SP100 Marketing Working Group– HART Communication Foundation, Marketing Group

– Education– BC Computer Engineering, University of Illinois, Champaign– MBA, Northwestern University (Kellogg)

– Contact– psereiko@airsprite.com– 508.281.2720

Agenda

• 2008 – The Year of Industrial Wireless?• Plant Asset Management Baseline• Turbocharging PAM with Wireless Retrofits• Suggested Best Practices• Conclusions and Q&A

2008 – The Year of Industrial Wireless?

• Maybe …– Standards emerging:

– Wireless HART, spec approval by 2007 year end

– ISA100, spec approval during 2008

– Mesh networking reliability challenge resolved:– Dust SmartMesh >99.9% data throughput

– Early adopter products enjoying commercial success:– Emerson 1420, etc.

• Maybe not …– Security– Interoperability and compliance– Integration with existing business processes

Whatever the Year – Most Want Wireless for Monitoring and Alerting

Source: ISA SP100 Survey

Typical Wireless Deployment – ALL NEW!

• New wireless transmitters:– Expensive

– How do I provision these?

• New network:– Where do I put these repeaters?

– How do I know the signal is actually getting through?

– Can I trust the data on the other end?

– What if my control process gets all messed up?

• New software:– How do I integrate this stuff with

my existing systems?

– Is this really going to work with my DCS?

Gateway

DCS & Host Applications

Repeater

Repeater

An Alternative – Retrofit Your Wired Instrumentation

• Add wireless adapters to existing 4-20mA-only smart devices (e.g. HART)

• Continuously access smart device info– Device status

– Diagnostics

– Configuration

• Use standards (e.g. OPC) to connect data to enterprise systems … PAM, CBM, etc.

• Bypass the DCS

Existing HARTDevices

Wireless Adapters

Analog Only I/O

Gateway

Legacy DCS4-20 mA Signal

OPC & Host Applications

PV Data

HART Data

Why Retrofit? Continuously Use Valuable Data in Stranded HART Instruments

• 35-40 data items in every HART device– Device Identification– Basic Calibration data– Process Variables– Diagnostic Alerts

• Data is easily accessed by HART-enabled systems

• Continuous, real-time access enables operation and asset management improvements

• 35-40 data items in every HART device– Device identification

– Basic calibration data

– Process variables

– Diagnostic alerts

• Data is easily accessed by HART-enabled Systems

• Continuous, real-time access enables Operation and Asset Management improvements

Screen image source: HART Communication Foundation SDC625 software

More Valuable HART Data…

Quantity of Stranded Data is Huge

85%

15%

Stranded HART

Integrated HART

Source: ARC Advisory Group

3%

10%

12%

33%

42%

HARTFieldbusProprietary4-20mA +Pneumatic

~56 Million Devices in 2006(Press, Temp, Flow, Level, Valve Positioners, Analytical)

23.5M

1.7M

5.6M

18.5M

6.7M

20.0M

3.5M

OPC & Host Applications

(PAM, CBM, etc.)

WirelessHART Adapter Example

• Connects anywhere on 4-20 mA loop– Series connection

enables loop power option

– Parallel connection can simplify installation

• Sends/receives HART via wireless and wired transmission

• Enables direct path to host applications, bypassing legacy DCS

Existing HARTDevices

Gateway

To DCS

Series Adapter

Parallel Adapter

SEND HART

commands

Receive HART

digital data

Wireless Adapters Enable New, Low-Cost Monitoring Points

• Need transmitter to retrofit (can be dumb or smart)• Need field power supply• Need wireless adapter• Don’t need a new, expensive wired loop

+-

4-20 mA Transmitter (Smart or

Dumb)

Wireless Adapter

4-20 mA

and/or

Smart Data

24 V Field Powered

OPC & Host Applications

(CBM, Historians, PAM, Advanced Control,

etc.)

Gateway

Wireless Connects Directly to Plant and Enterprise Applications

Process Packaging, Warehouse

CIPCIP

Analog-only legacy control

Ethernet IP

Plant Control Network

Enterprise Network

ERP, MRP, Asset Mgmt

DCS

Wireless digital communication

Agenda

• 2008 – The Year of Industrial Wireless?• Plant Asset Management Baseline• Turbocharging PAM with Wireless Retrofits• Suggested Best Practices• Conclusions and Q&A

PAM Manages Performance, Availability, and Reliability of Plant Assets

Source: ARC Advisory Group

PAM

PAM Solutions Monitor, Predict, and Optimize

• Monitor asset health, typically sensing in real time• Assess to predict potential problems• Optimize maintenance and operations decisions

SenseAssess

Decide

Act

•Wired sensors•Wireless sensors•Virtual sensors•HART devices•Historians

•Predictive analytics•Condition monitoring•Trending

•Preventative maintenance•Predictive maintenance•Run to failure•Reliability-centered maintenance

•Enterprise Asset Management (EAM)•Computerized Maintenance Management Systems (CMMS)

Feedback / Improve

PAM Use Cases – Smart Valves

• Abnormal position vs. valve demand

• Automated detection of valve or positioner malfunctions

• Faster and control-room based troubleshooting and routine testing

• More accurate problem diagnosis– Fewer false positives and

needless valve teardowns– Fewer unnecessary

replacement parts• Valves operate closer to

rated performance– Possible results: Increased

plant capacity, higher yields, greater process efficiency

Screen image source: Emerson AMS ValveLink™ software

What’s Driving PAM?

More and more plant assets

Smaller size of field staff

Aging boomer workforce retiring

More loops per technician (500 to 2000)

Less expertiseper technician

Managing plant assets now takes more than just the workforce

PAM Use Case – Measurement Instruments

• Detect and resolve problems more quickly and efficiently– Alert operators and

maintenance before process degrades

– More efficiently schedule repairs

• Save labor on routine calibrations– Don’t need to be located– No handwritten reports– Results are digitized and

available as documents

PAM Benefits Go Beyond Maintenance

-60 -40 -20 0 20 40

Unplanned Breakdowns

Spare Parts Inventory Costs

Production Downtime

Product Defects

Plant Availability

Workforce Efficiency

Asset Performance

% Improvement Beyond Maintenance

Source: ARC Advisory Group

Huge Opportunity for Users to Improve

PAM is Growing Rapidly

Historical CAGR = 10.4%

749822

881920

11681230

0

200

400

600

800

1000

1200

1400

2000 2001 2002 2003 2004 2005

Source: ARC Advisory Group

Worldwide Sales($ millions)

Example Suppliers of PAM Systems

• ABB• Bently Nevada• Bruel Kjaer Vibro• Emerson Process

Management• FLIR Systems• Honeywell• Invensys• Rockwell Automation• SKF Condition Monitoring

PAM Enables Predictive Monitoring & Maintenance

• “Industry reports estimate that by changing 25% of all preventive maintenance to predictive maintenance, which is five times less costly than preventive maintenance, an organization could potentially realize an up to 60% reduction in maintenance expenses alone.”

Source: ‘Thar's Gold in That Plant-Floor Data'

By Howard Mars, InTech

• $50,000,000 /year in maintaining 40,000 points =$1,250 per point/per year

Source: Chemical Industry Plant Manager

Predictive monitoring & maintenance require field data that is often unavailable other than via manual surveys, if at all.

Agenda

• 2008 – The Year of Industrial Wireless?• Plant Asset Management Baseline• Turbocharging PAM with Wireless Retrofits• Suggested Best Practices• Conclusions and Q&A

Combine PAM and Wireless to Improve Operations and Maintenance

• Retrofit stranded HART devices to:– Better manage instrument assets

– Provide backup primary variable signals for operators

PAM Wireless

• Add measurement points via adapters to:– Better manage machinery and production

assets

– Cut costs of new monitoring points

– Enable process improvements

+-

4-20 mA Transmitter (Smart or

Dumb)

24 V Field Powered

HART Transmitter

Legacy DCS

Reaping the Benefits of Standards-Based Wireless and PAM

Problem Solution

Valuable information locked in smart field instruments.

Wirelessly access locked data via WirelessHART adapters for improved monitoring and PAM of automation assets.

Waiting for manual surveys to identify equipment problems is often too long.

WirelessHART adapters and new wireless measurement points enable continuous, predictive monitoring of assets.

Detecting and troubleshooting instrument problems is time consuming.

WirelessHART adapters cuts time-to-resolution by continuously enabling remote diagnostics and problem solving.

Manpower reductions, aging workforce.

Automate collection of field data to let staff focus on highest value activities.

Reaping the Benefits of Standards-Based Wireless and PAM

Problem Solution

New monitoring points for equipment assets involves costly runs of wire between DCS and field.

Field-powered wireless adapters add new PAM (or process) measurement points without long wire runs and use existing 4-20 mA instruments.

Incomplete field-data picture complicates time-sensitive decisions.

Broaden access to real-time data via retrofits of existing devices and addition of new points to improve decision making.

Extra costs of under (or over) maintaining assets.

Comprehensive picture of plant health cuts operating costs and improves plant productivity.

Getting data needed for PAM from plant through DCS is difficult.

Wireless networks bypass legacy DCS and integrate real-time monitoring data with plant management and enterprise systems.

Agenda

• 2008 – The Year of Industrial Wireless?• Plant Asset Management Baseline• Turbocharging PAM with Wireless• Suggested Best Practices• Conclusions and Q&A

Enter Learning Curve for Standard-based Wireless in ‘07

• Sessions like this• ISA 2007 exhibits (SP100, HART, vendors)• ISA SP100 involvement (users and vendors)• HART Communication Foundation involvement (mostly

vendors) • HART Communication Foundation events• Vendors

Accelerate Learning Curve by Piloting

• Start piloting now!– Certified standard-based products not available for at least a year – Learn how reliable and easy-to-use (or not) today's technology is– Learn about the RF nuances of your environment

• Stand-alone pilot– Do not integrate pilot with existing processes– Set up test processes for the stand-alone system

• Retrofit– Low-cost, low-risk piloting– No need to install new devices

Deployments in ’08 and Beyond

• Use standard-based products – Wait for availability– Extract upgrade commitment from vendor

• Understand use of data – Who are the human users of the information generated? – What systems do they rely on?

– DCS? – Historian? – PAM?

• Understand integration issues with existing processes – Single HMI or NOT? – Process modifications or NOT?

• View wireless’s ability to bypass the DCS as strategic for plant management and enterprise applications

Agenda

• 2008 – The Year of Industrial Wireless?• Plant Asset Management Baseline• Turbocharging PAM with Wireless• Suggested Best Practices for Wireless• Conclusions and Q&A

Conclusions and Q&A

• Retrofitting is the low-cost, low-risk first step into the world of standards-based industrial wireless networks

• Wireless extends the reach and value of PAM solutions– Enables economic monitoring of valuable field data– Enables bypass of DCS for integrating field data with plant

management and enterprise systems

• Start piloting in ’07 to get ready for standards-based products in ‘08