Adoption of IIoT Technology for Superior Maintenance Practice of Plant AssetsJonas Berge, Emerson Automation Solutions

A Digital Plant... An Intelligent Plant...

Manual dyke valve open

Close manual transfer valve

Fuel gas over-

consumption

Schedule relief valve overhaul

Schedule bearing

replacementInject more

corrosion inhibitor

High-risk area

intrusion

Non-uniform temperature

profile

Topics Covered

Operational ExcellenceThe case for change

Plant Challenges: Achieve Operational Excellence- The Case for Change

HS&E

FewerIncidents

FasterResponse timeReducedNon-compliance

Production

ReducedOff-specGreaterThroughput

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 of Tasks- Of How the Plant is Run and Maintained

ManualPaper-based

Tasks

AutomaticDigital

Software-basedData-drivenWays of Working

Transformation

Digital Transformation: Reliability & Maintenancel ISO 55000l API 691l API 570

Digital inspection Digital testing Availability

Reliability & Maintenance

Maintenance costs

Equipment Life

Integrity

Digital Transformation: Health, Safety, and Environmentl ISO 45001l ISO 14001l OHSAS 18001

Digital distress callsDigital safety checks

HS&E

FewerIncidentsFasterResponse timeReducedNon-compliance

Digital Transformation: Productionl ISO 9001l ISO 29001

Digital operator rounds Digital milk run

Production

HigherQuality/YieldGreaterThroughput

HigherProductivity

GreaterFlexibilityReducedOperation cost

Digital Transformation: Energy Efficiency & Loss Controll ISO 50001

Digital energy management Digital loss control

Energy & Losses

ReducedEmissions and carbon footprint

LowerEnergy consumption and cost

Emerson Connected ServicesEmerson experts. IIoT

Your Fleet Management CenterUsing experts in your own center or integrated operations. IIoT.

On-premisesUsing experts within the plant. No Internet. No cloud

Digital Transformation for Operational Excellence in Digital Plants- Internet and Cloud are Not a Must

Diagnosis or Work

Instructions

Site Personnel

Data

Data

Data

Analytics

AnalyticsAnalytics

Edge

Clou

d

Digital Operational InfrastructureA second layer of automation

NAMUR Open Architecture

Digital Operational Infrastructurel Second Layer of Automationl Integrated with Existing Operational Infrastructure and IT Infrastructure

Business Intelligence

Real Time

Analytics

PervasiveSensing

PervasiveNetworking

BI

DigitalOperational

Infrastructure(DOI)

ERP

MES

DCS

IO

Sensors & Actuators

L3.5 Integration

IT Infrastructure

OperationalInfrastructure

IT departmentresponsibility

I&C departmentresponsibility

L0

L1

L2

L3

L4

ST

Digital Operational Infrastructure – Field Communications Key Role

DCS Hardware

DCS Software

Historian, CMMS

DMZ

ERP

Sensors & Actuators

FieldComm

OPC-UA

Second Layer of Automation Existing

BI Reports

Operational Dashboards

WirelessHARTFieldbusWi-Fi

Valve Analytics

Equipment Analytics

Vibration CorrosionAcoustics PowerPosition

Operational Notifications

Vibration Analytics

Corrosion Analytics

Data Diode Historian Cloud Connection

Physically Independent

Mobility: Operations Dashboards- Putting Historian to Good Use

l KPIs based on roles and responsibilitiesl Displays anywhere: on smartphone, tablet, laptop, and desktop...l From underlying analytics; using historian as single platform

Quality Manager

Production Manager

Plant Manager

Maintenance Manager HS&E Manager

Energy Manager Reliability Manager

Mobility: Notifications

l Notifications based on roles and responsibilitiesl Displays anywhere: on smartphone, tablet, laptop, and desktop...l Based on underlying analytics

QualityManager

PlantManager

Maintenance Manager

HS&EManager

EnergyManager

Reliability Manager

Integrity Manager

ProductionManager

Catalytic cracker unit

trip

Boiler fuel gas over-

consumption

Isolation valve left

open

Quality going off-

spec

Pump pre-cavitation

Motor bearing

wearing out

Pipe wall thickness

thinning fast

Catalytic cracker unit

trip

Platform Independent Equipment Analytics

Improve Safety and Compliance

• Comply with regulations• Identify leaking and sticking

situations• Gain real-time visibility• Avoid potential safety hazards• Reduce fines and

environmental impact

Improve Reliability and Energy Efficiency

• Spot abnormal situations• Recognize optimum

maintenance times• Reduce energy costs• Identify and prevent failures

before they occur• Track asset health ISO 55000

Predict Problems in Process Equipmentl Easy to use, platform agnostic, web-based, predictivel Aggregates data from existing systems and additional sensors

Existing Systems

& Historians

Mobile

Edge

Gateway

Virtual

Machine

Web UI

Deploy Anywhere

Connect to Anything

Sense Everything Visualize Anywhere

Existing Systems

& Historians

Aggregate from Everywhere

OPC-UA OPC-UA

Readymade Analytics That Require No Custom Programming

Purpose-Built - Easy Diagnostics Drives Maintenance Tasksl Actionable information

Severity Priority Problem

Ubiquitous Sensors on the Equipment

23

Vibration is a start but not enough

Discharge Pressure (existing)

Strainer DP

Mechanical Seal Flush

Fluid Reservoir Pressure Mechanical

Seal Flush Fluid

Reservoir Level

Mechanical Seal Flush Fluid

Temperature

Vibration x 2

(Flow)

Bearing Temperature

x 2

Leak Detection

(Suction Pressure)

Up to

12Sensors

Infrastructure to Handle Missing Measurements

Vibration

Valve Pass.

Corrosion

Trap Failure

Temperature

Power

Pressure

Temperature

Level

Flow

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

o On premises or IIoTl Fieldbuses usually not fully populatedl 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 Gotl Add instruments for equipment condition and performance

monitoringo On premises or IIoT

l Gateways usually not fully populatedl Add sensors for condition monitoring and energy

management

Process Monitoring

Control System

Condition Monitoring & Energy Management etc.

Condition Monitoring System & Energy Management System etc.

ConclusionSummary

Summary

Experience the New Digital Ways of Working in a Digital Plant in the Emerson Solutions Center in Singapore

Digital plant visioning, Mobile notifications, KPI dashboards on tablets

Industrial Internet of Things (IIoT), Fleet management, remote collaboration, and expert support , Cloud

Digital Twin, Digital logbook, Equipment Performance Analytics, Digital integrity management, Location Awareness (RTLS), Digital mustering and rescue locating, geofencing, Digital energy management, Predictive analytics, batch analytics, Big Data

Digital reporting, Digital inspection, Mobile operator, RFID, Wearable video conferencing, Wireless Infrastructure, Augmented Reality (AR), Non-intrusive wireless sensors, Edge Analytics

Virtual Reality (VR), Success sharing

Operational Certainty Discovery Session, Design Thinking

I’m Listening...l Jonas Berge

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

jonas.berge@emerson.com

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