eric milavickas: pervasive sensing, a strategy that’s changing the fundamentals of automation

Pervasive Sensing

Eric Milavickas

Emerson Proces

Management

www.360mn.org

Pervasive Sensing A Strategy That’s Changing the Fundamentals of Automation

NAME: Eric Milavickas

TITLE: Director, Emerson Smart Wireless

[File Name or Event] • Emerson Confidential • 11/19/2014 • Slide 3

• 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

Agenda


Key Challenges Facing Manufacturers

Amount of a typical refinery

maintenance budget that is

spent on corrosion

remediation and repairs

36% Potential improvement in the

industrial sector’s lifecycle

energy use

50% Annual investment in safety,

health and environment by U.S.

chemical industry

$16B Environmental 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 SENSING Critical to Core Operations

• SIL

• ESD

• Fire & Gas

• Compliance

• PID

• Optimization

• Alarm

• Batch

Process Control Process Safety



PERVASIVE SENSING Expanded View of Business

Reliability

Energy

HSSE

Process Safety

Process Control


PERVASIVE SENSING


PROCESS RELIABILITY

HSSE ENERGY


Advanced Sensing for Your Biggest Challenges

Pervasive

Sensing =

Definition of Pervasive

• per·va·sive; adjective [per-vey-siv]

• Existing in every part of something : lots of, spread everywhere : spreading

to all parts of something

Strategic

Interpretation

Strategic

Interpretation Actionable

Information

Advanced

Sensing Wireless

Non-intrusive

Self-powered

Maintenance free

Calibration free


Internet of Things (IoT)

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

Internet of Everything = CISCO

Smarter Planet = IBM

Internet of Your Things = Microsoft

The Next Network = Siemens

Industrial Internet = GE


• Emerson is the IoT leader in the Process industry and it’s:

– here today

– about connectivity

– using devices you already have 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

ENERGY ENVIRONMENTAL

REGULATION

RELIABILITY

SAFETY

ENERGY

RELIABILITY PROCESS

HSSE

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 Value of Implementing Pervasive Sensing Strategies

Deploying wireless infrastructure to grow measurements by 60% 32,000

Points!

Site Safety

+2,000 Reliability

+8,000 Energy Efficiency

+2,000

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

…..industry leaders and the

facilities around the world

are already using the

pervasive sensing strategy

to get results, and they are

doing it in a big way.


Process

Pressure

Temperature

Level

Flow

Analytical


PROCESS

Mobility

Mobile maintenance

Mobile operations

PROCESS

PROCESS


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



RELIABILITY

Essential Asset Monitoring

Heat exchangers

Pumps

Blowers

Cooling towers

Compressors

Air cooled heat exchangers

RELIABILITY

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.

CHALLENGE

Crude 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 not 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

HSSE

Health, Safety, Security & Environment

HSSE HSSE

HSSE


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 because level continuously fluctuates due to changing process demands.

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)

CHALLENGE

Non-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

Energy Advisor

Remote monitoring


ENERGY

ENERGY


Pressure Relief Valve & Steam Trap Monitoring

The first audit showed 25% of

steam traps were failing, that

were unknown.

Payback in one year in energy

savings by correcting issue.

Continually reduce environmental impact by reducing energy usage, but unable to determine how much energy they were wasting.

Fluor Global Services

“A simple cost analysis based only on energy savings, the installation of the steam trap monitoring was easily

justified, because the solution paid for itself within one year. Not to mention the savings from avoiding

equipment damage, and avoiding safety or environmental incidents”

- Fluor Global Services , Emerson Exchange 2013

CHALLENGE

Monitoring of 187 steam traps and 63 pressure relief valves to ensure proper operation, avoiding equipment damage and wasted energy via lost steam.

SOLUTION RESULTS

ENERGY


INF

OR

MA

TIO

N C

OS

T

INFORMATION BENEFIT

HIGH

LOW

Now is the Time

HSSE Reliability

Energy

Process

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


• 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

Summary


Pervasive Sensing Opportunities in Your Business

Gas Leak

Blower Monitoring

Natural Gas Monitoring

Compressed Air

Air Cooled Heat Exchanger

Hydrocarbon Detection Gas Detection

Effluent Discharge

Corrosion

Compressor

Mobile Operations

Leak detection Interlocks gates/doors

Tank overfill/spill detection Remote Monitoring

And Many More…

PRV Release

Steam Trap Monitoring

Pump Health Monitoring

Heat Exchanger Monitoring

Cooling Tower Monitoring

Measure Utilities

Safety Shower Monitoring

Mobile Maintenance

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