smart wireless - enabling process manufacturers to tackle their biggest challenges

Smart WirelessEnabling Process Manufacturers to Tackle Their Biggest

Challenges

Bob Karschnia Vice President Wireless

[File Name or Event] • Emerson Confidential • 04/13/2023 • Slide 2

• What is Pervasive Sensing– Strategy: The more you sense, the more you solve– Easily improve: Process – Reliability – Energy – HSSE– Using familiar devices in new ways

• Applying these strategies – Available today with immediate payback – Scale your growth without scaling your problems– Become more competitive

• How wireless works • Top concerns about implementation

Agenda


Key Challenges Facing Manufacturers

Amount of a typical refinerymaintenance budget that is

spent on corrosionremediation and repairs

36%Potential improvement in the

indutrial sector’s lifecycle energy use

50%Annual investment in safety,

health and environment by U.S. chemical industry

$16BEnvironmental expenditures

toward remediation and spills spent annually.

$1.5B


Advanced Sensors Enable Manufacturers to Tackle Their Biggest Challenges

• Immediate response• Plant shutdown• Maximum focus• Already automated

• Information overload

PROCESS-CRITICAL

Process Safety

PROCESS SENSINGCritical to Core Operations

Process Control• SIL• ESD• Fire & Gas• Compliance

• PID• Optimization• Alarm• Batch



• Immediate response• Plant shutdown• Maximum focus• Already automated

• Information overload

PROCESS-CRITICAL

Process Safety


Process Control



PERVASIVE SENSINGExpanded View of Business

• Process Safety• Process Control

• Reliability• HSSE• Energy




HSSE

ENERGY RELIABILITY

PROCESS


Advanced Sensing for Your Biggest Challenges

• per·va·sive; adjective [per-vey-siv]• Existing in every part of something : spreading to all parts of

something : lots of, spread everywhere

PervasiveSensing =

Definition of Pervasive

StrategicInterpretation

Actionable Information

Strategic Interpretation

Innovative SensingWireless Non-intrusiveSelf-powered Maintenance freeCalibration free



• per·va·sive• adjective [per-vey-siv]• Existing in every part of something : spreading to all parts

of something : lots of, spread everywhere

PervasiveSensing

ActionableInformation

Innovative Sensing

=

Definition of Pervasive

StrategicInterpretation

Wireless Non-intrusiveSelf-powered Maintenance freeCalibration free


Internet of Things (IoT)

• Have you heard of

• Development of the Internet in which everyday objects have network connectivity, allowing them to send and receive data.

Internet of EverythingSmarter PlanetInternet of Your ThingsThe Next NetworkIndustrial InternetPervasive Sensing

http://youtu.be/Be3lQnldOIM?list=PLFT-9JpKjRTBUHKODoxHdGhV2GlaMBru5

http://youtu.be/Be3lQnldOIM?list=PLFT-9JpKjRTBUHKODoxHdGhV2GlaMBru5


• Emerson is the IoT leader in the Process industry and it’s:– ….here today– ….about connectivity– ….using devices you use today– ….letting automation work for you

Pervasive Sensing is Emerson’s IoT

Lack capability of selling sensors or implementing industrial sensing technology

Lack domain expertise critical to effectively analyzing data and recommending actions

Primary interest is in selling consulting hours

Supplier Barriers


The More You Sense, the More You Solve

Enhance the focus. Expand the strategy. Enjoy the impact.

SAFETY

ENERGYENVIRONMENTAL

REGULATION

RELIABILITYHSSE

ENERGY RELIABILITY

PROCESS

Improving your Operational Excellence by using the power of advanced sensing everywhere to gather data and transform it into actionable information.


Industry Leaders Recognize the Valueof the Pervasive Sensing Strategy

A next-gen process plant is currently deploying wireless infrastructure to grow measurements by 60%

Site Safety+2,000

Reliability+8,000

Energy Efficiency+2,000

20,000 wired I/O points Including additional 12,000 pervasive sensors

$ 5M Greenfield Expansion Project 14 Month Payback!


Process

Pressure

Temperature

Level

Flow

Analytical


ENERGYRELIABILITY

PROCESSHSSE

PROCESS

Mobility

Mobile maintenance

Mobile operations


Wireless Mobile Worker Improves Efficiency

Checkout time was reduced by half. 2 weeks from four. Required manpower was reduced by half. Virtually no loop troubleshooting during startup.

Ergon executed a turnaround and DeltaV migration that required loop checking 300 loops and indicators and verification of approximately 100 DVC valve actuators. Ergon targeted 10, 24 HR shifts.

Ergon Refining

“Mobile Worker with Emerson’s Wireless Plant Network gave Ergon flexibility and increased efficiency on our turnaround. It allowed us significant cost savings, and may be used a tool by Engineering and Operations in the future. We cut way back on the communication form the field to the control room. We used to have to ask the console operator to run the valves up and down to prove the connection, now we do it all outside from the Toughbook”. Steve Elwert, Ergon Refining

PROCESS

CHALLENGE

2 Mobile worker equipped checkout crews were deployed. Cabinets were staged in advanced and hardware checked with Mobile Worker.

SOLUTION RESULTS



PROCESS HSSE

ENERGY RELIABILITY

Essential Asset Monitoring

Heat exchangers

Pumps

Blowers

Cooling towers

Compressors

Air cooled heat exchangers

RELIABILITY


RESULTS

Heat Exchanger Monitoring

Efficiency gained in energy savings was estimated at $55K per heat exchanger, per year. Investment payed back under 90 days for each exchanger.

CHALLENGECrude unit was subject to preheat train fouling.

No data to quantify how much energy was being lost, or when (and which) exchangers to clean.

Conoco Philips

“Due to monitoring, customer can now able to maximize heat exchanger operation and maintain the tubes more effectively to prevent costly heat losses and avoid disruptive tube ruptures. In addition, they created a safer work environment for all.” - Randy Stout, Emerson

Analyze the efficiency of heat exchangers using heat duty calculations through wireless temperature and flow measurements. Installed without any interruption to process.

SOLUTION

RELIABILITY


RESULTS

Pump Monitoring

• No fires in 5 years due to early detection on three pump failures 1st year. Avoided shut downs!

• Monitor 158 pumps at 1/10th the cost of the manual process of just a few pumps.

CHALLENGE

Need to prevent a vapor cloud release when pumps fail to protect staff and environment.

Only able to monitor a few essential pumps, but now sure which pumps need service.

Flint Hills Pine Bend

““Today, I’m happy to report that FHR Pine Bend has not had a single pump fire in more than 5 years!. Now that we can monitor all our pumps we can plan preventive maintenance instead of being reactive. - Flint Hills Pine Bend, Emerson Exchange 2013

Utilize Essential Asset Monitoring to measure the seal for gas leaks of essential pumps throughout their operation. Use monitoring to know which pumps need service.

SOLUTION

RELIABILITY


Safety shower monitoring

Gas detection

Leak detection

PRV release

Hydrocarbon detection


Tank overfill/spill detection

Corrosion

Effluent discharge

Interlocks on gates/doors

Access Awareness

Personnel location tracking ENERGY

RELIABILITY

PROCESS HSSE

Health, Safety, Security & Environment


Detecting Hydrocarbon Leaks

Tanks spills monitored to improve employee safety and avoid environmental incident. Demonstrates regulation compliance.

Detecting and monitoring hydrocarbon leaks around tanks, valves and pipe flanges. Level fluctuates a lot due to process demand.

BP

“Wireless breaks the cost paradigm by reducing maintenance visits, time-consuming physical monitoring, and injury-related occurrences. Furthermore Wireless was easy to install. Minimizing the engineering department efforts by allowing members of maintenance to install and maintain the equipment.” Tom Kenis, E&I, BP Geel (Belgium)

CHALLENGENon-intrusive solution to detect liquids leak around the tanks, sump wells, and curbs of pump skids.

SOLUTION RESULTS

HSSE


Energy and Utilities

Steam trap monitoring

Instrument air monitoring

Compressed air monitoring

Natural gas monitoring

Water/Wastewater consumption and discharge

EMIS Energy Advisor

Remote monitoring


ENVIRONMENTAL

RELIABILITY HSSE

ENERGY


Steam Trap Monitoring

The steam lost calculated for 1 year is 40k€ for the 6bar steam system. High pressure ROI would be shorter.

Tanatex to expand wireless network due to quick payback.

.

Unable to find cold or leaking steam traps early to reduce energy use.

Need to demonstrate compliance with Energy Efficiency directive

.

Tanatex Chemicals

“Monitoring of steam traps with WirelessHART acoustic devices is a successful solution. The ROI (Return on investment) is shorter than 2 years for 6 bar system. (For higher pressure the ROI time would be shorter). Due to our experience Tanatex will expand the WirelessHART network with additional measurement to optimise the plant.” Jörg Hamacher, Tanatex Deutschland GmbH

CHALLENGESteam Trap monitoring installed to give real-time visibility to all critical steam traps, early detection of boiler tube and pressure relief valve leaks.

SOLUTION RESULTS

ENERGY


INF

OR

MA

TIO

N C

OS

T

INFORMATION BENEFIT

HIGH

LOW

Now is the Time

HSSEReliability

EnergyProcess Control

Process Safety

LOW HIGH

Previously:• cost was high• info benefit was low • previously immeasurable• data was raw• technology complex to install

Now:• innovative sensors• wireless communications • non-intrusive installation • mobile and location technology• advanced analytic capabilities• embedded expertise• power technology


Pervasive Sensing a Reality, Not a Trend

Home Car Retail Plant





Agenda


IEC 62591 (WirelessHART) is HART Without the Wires


IEC 62591 (WirelessHART) is HART Without the Wires

Advantages of Self-Organizing Mesh over Other Mesh

• Self-Forms• Adding Device• Remove Device

• Self-Mitigates Obstacles• Standard Instrument Locations

• No RF Survey• No Manual Link Configuration

• Native Redundancy• Self-Heals to Environment

• Weather• Infrastructure Changes

• Device Location Changes• RF Engineer Embedded in the

WirelessHART Instrument instead of your organization


• Control and redundancy • Batteries • Security • Ease of Use • Environment • Coexistence

Top Concerns About New Wireless Technology


Thinking through Wireless: Control and Redundancy

• 90% of Control Applications have a time constant greater than 16 seconds, requiring a minimum of 4 second updates.– WirelessHART supports 1 second

updates and is proven reliable

• Need self-organizing connections – RF Engineer embedded in the technology to ensure reliability

• Redundancy from the field device to the control system

• Mesh technology is very robust –made simple for the end user with self-organizing technology

Shared IP Address

Shared IP Address

WirelessHART is used for control today. FACT.

The biggest value is extending automation to solve problems with health, safety, environmental, and

efficiency where costs of wire and engineering have been prohibitive – monitoring AND control

applications.


Thinking Through Wireless: Batteries

Batteries– Battery “pack: may be removed in IS

environment– Do NOT change batteries in

hazardous atmosphere– Ensure 2 new batteries are used to

prevent “…a risk of fire or chemical burn”

– Dropping the battery may cause damage

– Only approved batteries can be used – not standard lithium cells

Example: Batteries

Example: power module

Ultra-low power radios in WirelessHART devices enable battery lives up to 10 years and self-organizing mesh.

For safety and ease of use, use power modules instead of off the shelf batteries.

Power Modules– Enclosed battery cells with additional

short circuit protection– Can be removed in IS environments– No risk of mismatched or wrong

batteries– No risk due to dropping– Keyed to ensure proper insertion


AES128 Message Encryption01100110011011001100101001111100101100110110011001001011001001001010110100100101101001001101010110

101010110000110110110001011010

Thinking Through Wireless: Security

Administrative Lockdown


Day 1 Life

Add Devices Remove Devices Personnel Change

Secure


Managed Connections with SSL Encryption

Integrate into any host just like HART.

Embedded security into any host from any WirelessHART vendor.

Unique Join Keys for Network AccessA3DC9E2D-7F3A1ED4-B4FWA2A1-CDA82FDB

Full Spectrum Use

FACT: Recommended by U.S. Homeland Security,

Idaho National Labs, Carnegie Mellon

University, and End-User Corporate IT leaders.

This also prevents an instrument engineer from

needing IT approval to add another wireless device.

NO TCP/IP Address in Field Devices10.4.0.10


Thinking Through Wireless: Ease of Use

Design and Monitoring Tools

Integrate Data just like Wired

Example: Operator saving $2M preventing a shutdown, did not even know it was wireless, just another data point.

Install where you need them, not where wireless

needs them

Manage WirelessHART Instruments just like HART

Instruments


Thinking Through Wireless: Environment

• 2.4GHz wavelength = 4.9” • Rain: 0.02-.33”, 0.5db/miles• Fog: 10-100x smaller than rain• Snow: 0.1db/mile• Snow cover: 1 db/ft: 6” on both

device and gateway• Sand: .007”, 0.12db/mile

Yes, still works.

High Magnetic Field


Coexistence

=

Reliability

Global Standard

Interoperable

Secure

Easy to Use

ABB – E+H – Emerson – MacTek – Pepperl+Fuchs – Rohrback Coscaso – Siemens – Softing – Tyco – 200+ Vendors

HART Communication Foundation 7.1IEC 62951

• Self Organizing Mesh• Low Power

• Channel Hopping• DSSS

• Monitoring Applications• Control Applications

• RF Engineer Embedded in Technology to ensure reliability

Based on 30M HART Devices• Tools

• Training• Installation

• Work Practices• Asset Management• System Integration

End-to-End Protection• Encryption

• Authentication• Verification

• Anti-Jamming• Key Management

Designed for the Process Industry


3.4+ billion hoursoperating experience

Tens of thousands of smart wireless field devices

19,500+ networks

Proven Technology

Offshore OnshoreFACT: In the time it takes to give this presentation, Emerson Smart Wireless has gained another 50,000+ hours of operating experience reliably solving

end-user problems.





Summary


Pervasive Sensing Opportunities in Your Business

Gas Leak

Blower Monitoring

Natural Gas Monitoring

Compressed Air

Steam Trap Monitoring Air Cooled Heat Exchanger

Hydrocarbon Detection

Heat Exchanger

Gas Detection

Effluent Discharge

Corrosion

CompressorCooling Tower Monitoring

PRV ReleaseMobile Operations

Leak detection Interlocks gates/doors

Tank overfill/spill detectionRemote MonitoringSafety Shower

Pump

And Many More…

smart wireless - enabling process manufacturers to tackle their biggest challenges

Engineering

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power of advanced sensing

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