© Tata Consultancy Services ltd. 7 June 2006 1

RFID for Oil and Gas

T.S.Rangarajan (ts.rangarajan@tcs.com)Head, RFID SolutionsTata Consultancy Services Ltd. (http://www.tcs.com/rfid)

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Agenda

What is RFID and how does it work?RFID Tags and their classificationRFID readersRFID MiddlewareRFID applications and value chainTCS in RFIDRFID case profiles from TCSDetailed case study – Virgin AtlanticQuestions from Petrofed members

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RFID identifies individual itemsAircraft assembliesAircraft sub assembliesAircraft components

RFID tags consist ofIntegrated chipIntegrated antennaVarieties: Passive tags, active tags with (battery) power source, etc

RFID readers can “read” many tagsLine of sight not required Anti-collision prevents interference

RFID readers may beHandheld or stationary

RFID equipment has its own allotted frequency band

What is RFID and how does it work?

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Antenna

Reader

• Uses radio waves or micro waves for quick & automatic identification • Detection/data transfer is contact-less and doesn’t need line of sight• Tags can store data and help maintain historical information

TagTag

Chip

Polyethylene Media

Copper coil antenna

Tag receives signal and gets charged

Antenna reads the data and sends to reader Reader sends data/info to

computer for processing

Computer sends event based data to be stored on tag

Reader broadcasts signal through antenna

The Charged tag sends identifying response back to the reader

RFID Middleware

EnterpriseApplications

RFID - a bird’s eye view

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125 kHz 13.56 MHz

UHF 902-928 MHz2.45 GHz

RFID tags

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Classification of RFID tags

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Low ( 125-134 kHz)

Read range – 2 meters Great penetration Slow data rate Costlier tag antennas Multiple tags cannot be read together

High Frequency (13.56 MHz)

Read range – 1 meter Good penetration Simultaneous read capability @ 50 tags Most progress on standard setting

UHF (868, 902-928 MHz)

Read range –10 meters. Fast data rate Simultaneous read capability @ 50 tags

2.45 GHz Read range – 1 meter Very fast data rate

• Spectrum use is often regulated by governments (13.56MHz designated for ISM applications in most countries)

• UHF frequencies (850 - 960 MHz) for RFID vary from country to country • Read range is greater with battery powered tags (active/semi passive)

RFID tags and their frequencies

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Basic readersProvide serial port interfaceHost initiated Request-Response protocolBasic commands includes reading a block, writing a block and locking

Advanced readersProvide serial and ethernet interface TCP/IP stack included - provide Telnet and http interface Provide command line and web interface Advanced command setProvide advanced digital inputs and outputsAutonomous mode - response on user defined triggersHeartbeat messagesAdvanced outputs formats - text, XML

RFID readers

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Readability and range depend upon the design of readers and anteReadability and range depend upon the design of readers and antennaennae

RFID readers and antennae

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RFID Data CharacteristicsHigh Volume - some applications may have > 100,000 readers generating terabytes of dataFast rate - several reads / secondMultiple redundant reads of same tag data Reader health monitoring and management

RFID MiddlewareConnects data from RFID readers to Enterprise applications Device monitoring and management

Middleware featuresDevice driver / control, diagnostics, remote maintenance, upgradesData aggregation Data filtering and smoothingEvent monitoringConnectivity

RFID middleware

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Airlines baggage handling•Boarding pass•Package Tracking•Container Tracking•Yard Management•Toll collection•Fleet tracking •Rail car ID

Chips Inlays Antenna Middle ware

Systems Integration EAI

Analytics/ Process

RedesignTags Reader Reader

Network

Silicon companies – TI, Philips , Siemens, HitachiTag manufacturers –EMS, TI, Matrics, Alien

RFID Reader / Antenna makers – EMS, TI, Matrics, Alien, Hitachi

RFID Software providers – OAT, Sun, ORACLE, SAP, Globeranger, Matrics, ConnecTerra Savi

IT Solutions & Services providersTata Consultancy ServicesAccenture, IBM GS, CGEYWipro

Supply chain management & distributionProduction

managementFactory

AutomationMaintenance /

condition monitoringAsset

management

•Inventory management•Warehouse operation•Supply Chain Management•Interactive Kiosk•Self check out at POS•Electronic Article Surveillance

•Asset Tracking and Management• Contact less Payment solutions using mobile phones• Billing solutions• Various Value Added Services

Manufacturing Transportation Retail Telecom

•Asset Tracking•Patient tracking•Personnel tracking•Sterile Equipment management•Blood bags tracking•Anti counterfeiting of pharmaceutical products•Medicine dispensing

Healthcare

RFID applications and value chain

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Domain experience

Technology expertise

RFID Technology expertise

TCS RFID Solutions

Differentiation by synergy

• Pharmaceuticals & Healthcare • Transportation & Logistics • Retail & CPG• Manufacturing• Government• Utilities

RFID expertise & Assets• RFID Lab since 2001• RFID Center in Chicago• Presence in Oracle Sensorworld,

UK• Hardware & middleware expertise• Tools & assets

•Hospital Management system •Architecture

• ERP / SCM / WMS•Application development

•Application integration (EAI)•Business Intelligence & DWH

Strategic alliances• Oracle• Texas Instruments• Hitachi• Sun Microsystems• EMS

Member of

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Process consultingData and event utilization Strategy & Business case developEPC / GTIN consulting

Application DevelopmentCustom Modifications

Reader Interfaces, Reader Adapters,Filters and logger, Reader management RFID integration with EAI

Site Surveys Reader and Tag SelectionRF Engineering,Antenna placement & design ,

MIDDLEWARE

Business ProcessesBusiness Processes

Enterprise ApplicationsEnterprise Applications

Application / Integration Servers

Application / Integration Servers

Edge Processing LayerEdge Processing Layer

Hardware Interface Layer

Hardware Interface Layer

RFID HardwareRFID Hardware

TCS’ RFID StackTCS’ RFID Stack

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• Established in 2001; approx. 20 researchers • Hardware: HF, UHF and MW from TI, EMS, Hitachi

and Alien• Middleware: Sun, Oracle and Auto-Id Center• Antenna footprint Analysis, Power Spectrum analysis,

Tag placement and readability tests

• Demonstrate industry specific RFID applications.• RFID physics related testing: Product evaluation and

benchmarking.• Integrate RFID hardware and middleware

RFID Center of Excellence

Kolkata

• Readers, antennas and tags: HF and UHF• Middleware from Sun, Oracle

Site Simulation Facility for Dock doors, smart shelf, conveyors

• Demonstration and piloting of solutions in numerous industry segments

• Access to leading RFID tech• Performance testing, analysis and benchmarking of

RFID hardware and middleware products.• Facilitate end-to-end integration testing

RFID Technology

Center, Chicago

Running real life scenarios for:• Asset Management Zone• Customer Experience Zone• Supply Chain Zone• Product Zone• Management Zone

• Ability to run pilots and test full scale implementation projects with our customers.

• Presentation and demonstration facility for TCS-Oracle RFID solutions

• To enable business mangers to see tangible evidence of the potential of RFID technologies to deliver business value

Sensor World, UK

DetailsObjectives

TCS RFID expertise centersTCS RFID expertise centers

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Enhancing airline MRO OperationsClient: Scope

High value rotable parts at Heathrow warehouseIntegration with Enterprise MRO application

ObjectivesTo improve performance and reduce costTo improve the visibility of critical partsTo provide clear measurement of the impact of the pilotTo improve the service provided by the warehouse

BenefitsReduction of cost of labor associated with managing goods/business processesImprove visibility into the incremental steps that are part of complex business processesImprove visibility into customer (Internal and External) demandBetter forecastingEnhanced product visibility in the stores Eliminating the possibility of misplacement of high value assetsAutomatic recording of items’ entry and exit from the storage areaReduction of manual errors in data recording & data entry

Case Study

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Engagement with a leading CROScope:

Specimen receipt management from investigator sitesSample management

ModeRFID tagged Tubes

Pain points addressedLack of end-to-end visibility for sponsorLong trial times for sponsorLong lead-times for patients

Expected benefits: Error Reduction at Investigator site Reduction in shipment and stability related issuesReduction in data management issues (automatic scanning)Chain of custody and effort reduction within central labsAdvanced Capacity planning/forecasting and allocation

Increased stakeholder SatisfactionReduced loss of data points for clientsReduced re-testing with patients (human aspect)

Unique ID linkedto back end systemfor automated Kitproduction line

Visit Scheduling

PackageReception

Sample Draw

Lab Testingand Results

Accessioning,Routing,

Aliquoting

During Transportation

CourierPickup

PackagingKit Samples

Visit Scheduling

PackageReception

Sample Draw

Lab Testingand Results

Accessioning,Routing,

Aliquoting

During Transportation

CourierPickup

PackagingKit Samples

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Authentication client

Authentication client

Authentication client

TI Reader

TI Reader

TI Reader

Product authentication serverWindows 2000 server

Oracle server

Oracle 10g server

RFID enabled product authentication scenario: a prototype

Technology

Microwave RFID tagsHandheld readersWeb based authentication application

Features Extremely small size of productTag is injection molded into productHandheld RFID reader used for readsTags commissioned and ids are registered in database Central authentication server Thin authentication client Web service based communication

Benefits

Impossible to duplicate product idsCounterfeits can be easily detectedNo other technology allows embedded idsFlexible and scalable architecture

Metallicpart

Plastic“Nose”

Data cable

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RFID based inventory management for Kansas DOTClient: Department of transportation, Kansas state, US of AmericaScope: Identify how RFID can provide an optimum level of information for

Capital Inventory trackingThese assets are dispersed over the entire State of Kansas and their value is $307,057,000+. The number of physical locations of the Capital Inventory is approximately 28 headquarters offices in Topeka and 159 statewide field offices

Consumable Inventory trackingKDOT manages between $12 and $15 million in consumable inventory at any given time. There are 41 manned stock locations and approximately 420 unmanned locations statewide

Materials TestingDeliverables:

Study ReportImpact on existing databases and applicationsImpact on existing processesAnalysis of costs and benefitsSuggested roadmap

Technology Recommendation ReportIncludes hardware and software required for interfacing RFID systemDetails of suitable RFID tags and readersMiddleware requiredNetwork requirement

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RFID based inventory management

Client: A leading medical equipment manufacturer.Pain Areas

Inaccurate inventory records Data inconsistencies between the ERP and actual bin level

statusEvery month, 2-3 days production is lost for cycle counting

SolutionManual bin cards replaced by re-writeable RFID tags Reader applications developed to reduce errorsData integration was done with the ERP

BenefitsInstant visibility of stock due to real-time updationElimination of error due to manual entryAutomatic checking of parts being pickedCycle counting eliminated

TechnologyPassive tags HF tags on Warehouse binsHandheld readerIntegration with Oracle Apps

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ClientIndian defense division

ScopeDocument and file tracking

FeaturesHandheld RFID reader integrated to PDAAutomated document inventory and tracking applicationSynchronized with desktop document management application Document issue history available in document itself

BenefitsImproved document inventory visibilityReduction in misplaced documentsReduced effort in tracking classified documents

TechnologyHigh Frequency RFID tags from TIHandheld RFID reader

RFID based document tracking

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ClientA leading auto auction house, US

Pain AreasDifficulty in locating individual cars in an area spread across 80 acresManual identification and tracking process extremely time consuming, error proneMandatory verification of buyer ID and vehicle ID at exit cumbersome

SolutionRFID tags fitted to each vehicleIdentify and track vehicles at entry, parking lot, detail shop, run lines and exitIntegration with existing auctioning applicationMetrics collection on vehicle sales and cycle timesStatus reports and dashboard Verification of buyer id and vehicle Id at exit

TechnologyActive tags on vehicles to be identified and trackedFixed and Handheld readers

BenefitsEnsure complete up to date inventoryReplace labor intensive bar code systemAutomatic billingEnhanced securityMarket intelligence

RFID based car tracking

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Client: A premier Electrical equipment manufacturer

Scope: Asset and equipment tracking at power plants

TechnologyPassive tags on equipment /asset to be tracked and maintainedActive tags in case assets may move over a wide areaGate and Handheld readers

FeaturesIdentify location of equipment / assetsAsset / Equipment identifies itselfData storage capabilities - update equipment history on tagHandheld displays equipment details to field workerAutomatic upload of field data to servers after field work is completed Integration with Asset Management application ( Oracle database)

BenefitsAccurate identificationSuperior performance in harsh environmentLocal data storage and availability without need of data networksReduced workload and increase in efficiency

RFID based asset management

RFID Reader

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RFID based management of quality tests on tobacco samples in a cigarette factoryObjectives

Reduce time required for testing lab samplesReduction of manual effort in data recording & data entryReduce data entry errors

Features Identification and Tracking of tobacco samplesAutomatic data capture at sample collection site and laboratoryRFID tags metallic tobacco containersSpecially designed tags to withstand high temperature cyclesIntegration of RFID reader with weigh scalesAutomated capture of tag id and weight from weighing scaleData logging to QMS databaseReports and query support

TechnologyPassive HF Tags ( TI)HF Fixed Reader ( Custom designed)Handheld Readers ( Psion Teklogix)MySQL database.Net application

RFID Based Tobacco Quality Management

RFID based quality system for tobacco

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Salient Features of Lorry tracking System ApplicationZonal tracking of lorries inside the facilityApplication developed on MS DOTNET platformIntegrated with photo-pass systemIntegration with SAP ERPAccessible through Mobile platform

Scope of work Hardware:

Procurement from NEDAP, NetherlandsInstallation at siteTesting and system configuration

Application development: Requirements gathering and SRS preparationSoftware development

Integration: Interfacing various hardware components like RFID, photo pass camera, etc, Providing an interface for integration with SAP systems at multiple instances

Support: Training and implementation support

BenefitsHigher customer satisfaction: as real-time status of the location of the lorry will be communicated to the owner of the lorry as well as the consignee.Better queue management: as the information of the movement of traffic is available at the entry point.Responsiveness: of the system to manage any changes in the filling orderReduction in administrative effortArresting discrepancies in scheduled orders

RFID based lorry tracking inside a refinery

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Body shell tracking in an automobile paint shopTechnology

Low Frequency ( 134 KHz) RFID tags from TIHigh temperature tags capable of withstanding 350 deg CFixed RFID reader

Features RFID tags used for identifying and tracking body parts in paint shopFixed RFID readers placed at 7 locations in paint shopTags placed on skids that carry the body shellReaders integrated with plant automation system ( PLC) Body Serial number, colour code, model description code etc. is associated with RFID tag and used at different locations

BenefitsAutomated identification of body shellDecentralized control of manufacturing based on RFID tag

RFID based body shell tracking in automobile paint shop

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Virgin Atlantic and RFIDWhat are the expected benefits of using RFID

technologies?Process efficiencies – Data capture;Data accuracy Improved turn around performance of components through stores.Increased visibility of parts and materials within the maintenance environmentMore accurate inventory control at the point of entry to the aircraft storesConsequential benefits – process control

In addition to these benefits, the wider benefits include:

Greater ability to comply with expected guidelines from EASA (European Aviation Safety Agency) concerning traceability and authenticity of aircraft componentsIntegration with the RFID specifications proposed by Boeing and Airbus for use within the aircraft supply chain

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The Pilot StudyThe high level scope of the pilot was:

To RFID tag all rotable parts within the Heathrow warehouseTo integrate with Ultramain processTo provide automated tag printing to work in line with existing Goods inwards process

The objectives of the pilot were:

To demonstrate the potential savings of using RFID tagsTo improve the visibility of critical partsTo provide clear measurement of the impact of the pilotTo improve the service provided by the warehouseTo test the technology

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The Pilot Study - architecture

M id d le w a re la ye r

U ltra m a in In te rfa c e

D a ta h u b in te rfa c e

P rin te r In te rfa c e

K P I in te rfa c e A p p lic a tio n

E d g e A p p lica tio n

R e a d e r S e rve r E d g e S e rve r

P re s e n ta tio n la y e r D a ta la y e r

D a ta h u b

K P I A n a lys is

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Pilot Environment

First Stage Inspection

BinningArea

Quarantine Back Office

Preload / Bulk Deferred Defect

Back Office

Component Repair Section /

Dispatch

Bulk Racking

Bins

Printer Handheld

Wireless network

Location Barcode

RFID Label

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KPI measurement

Each stage of process is measured

•Average times

•Data accuracy –compare Ultramain with data hub

•Identify supply blockages

•Identify fast track items

•Item life cycle

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Questions from responses

LPG Cylinder tracking – cost, availabilityOil Tanker trackingDocument trackingAsset trackingAccess controlOil retail outletsHandsfree RFID based payments at pumpsTag life cycle managementSafety in inplant use?Hazardous useReading accuracy and inteferenceIntegration with backendPreventing adulteration and pilferage

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