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Remote Automation Solutions IEC62591 Wireless Interface.

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Presentation on theme: "Remote Automation Solutions IEC62591 Wireless Interface."— Presentation transcript:

1 Remote Automation Solutions IEC62591 Wireless Interface

2 Business Challenges CRITICAL BUSINESS CHALLENGES Financial Results Safety & Environment Personnel & Resources Efficiency & Throughput Reliability & Access

3 Key Customer Stakeholders Oil & Gas Industry Business Challenges by Functions Asset Manager  Reduced Profitability High operating cost, low yield Operations/SCADA Manager  Rising Operating, Maintenance & Compliance Costs Field Technicians/Engineers  Rising Workload Costly frequent trips to remote sites HSE Managers  Rising Risks Detecting Safety & Environment problems Production Manager  Decreasing Productivity Difficulty optimizing production

4 New Oil / Gas Field Constructions (CAPEX) High trenching, wiring, labor and Installation Getting Online Faster Shortage of Trained Workforce Business & Operational Challenges Facing Oil & Gas Producers Cost make automating prohibitive for at least 20% low point remote sites “Per day production delay on a 50K bbl’s/day facility causes $2M revenue and opportunity loss” “Shortage of O&G workforce will lead to critical impact on business”

5 Emerson’s Wireless Experience update: ~8000 wireless Networks in operation Over 3000 SmartWireless installations ~100,000 wireless process devices installed ~950 million operating hours Smart Wireless Vision Adopted at Over 3000 Customer Sites Globally

6 Time to first oil drives investment decisions Declining Production rates for unconventional wells Operating and field maintenance cost inflation impacts margins Need common standards that provide future architectural flexibility thru production development spectrum Wellhead Customer Challenge 60% faster installation and commissioning. 30% or more installed cost savings over wired alternatives Most robust diagnostics eliminate false reading leading to bad operational and maintenance decisions. Platform harmonization with tightest product integration from Emerson Solution Value Drivers Smart Wireless Field Link New Interface Modules FloBoss ControlWave ROC IEC62591 Wireless Interface For Flow Computers and RTUs Proprietary & Confidential 6

7 Time to first product delivery drives investment decisions Difficulty adding additional measurement points Operating and field maintenance cost inflation impacts margins Need common standards that provide future architectural flexibility when replacing legacy station controls Midstream Customer Challenge 60% faster installation and commissioning. 30% or more installed cost savings over wired alternatives Most robust diagnostics eliminate false reading leading to bad operational and maintenance decisions. Platform harmonization with tightest product integration from Emerson Solution Value Drivers Smart Wireless Field Link New Interface Modules FloBoss ControlWave ROC IEC62591 Wireless Interface For Flow Computers and RTUs Proprietary & Confidential 7

8 IEC 62591 (WirelessHART) Global Standard Global Standard An IEC standard-IEC 62591 (unanimously approved March 26, 2010) IEC 62591 is WirelessHART HART 7 protocol Adopted March 26, 2010

9 Simple – Reliable - Secure Self-Organizing Network Auto-Recognition of New Devices No Site SurveysNo TrenchingFinds Alternative Paths 99% Field Proven Reliability Self-Healing Network Repairs Itself Coexists with other Wireless Networks Robust and Tolerant to all Types of Interference without any Site Survey Robust, Multi-tiered, Always-on Security Industry Standard 128-bit AES Encryption Unique Encryption Key for Each Message Data Integrity and Device Authentication Reports Message and Authentication Failures

10 New Wireless Products Expand Served Market Products Launched in 2013 7 Products To Be Launched in 2014 8 Products/Applications 31 Conductivity pH Vibration Tank Gauging Temperature Discrete Radar Acoustic Position Corrosion Pressure Gas/Flame Detection THUM Power Module Field Instruments WPN AMS Wireless SnapOn RTU WIOC Gateway PFN Network Management WiFi Solutions Mobile Operations Asset Tracking Video Safety Mustering Wearable Video/Voice Network Infrastructure DP Flow DP Level LevelFlow 2051 3051 3051S Tiered Wireless Pressure Guided Wave Radar Smart Wireless Gateway 1410 Smart Wireless Navigator 702 w/GO Switch Turbine Totalizer Fire & Gas Detection Integrated WIFI Pressure/dP Explosion Proof THUM Adapter High Temperature Acoustic Transmitter Cold Temperature Discrete Transmitter Power over Ethernet Gateway 1420 Integrated Wireless Pneumatic Actuator Control

11 Proven with Customers

12 Billions of hours of operating experience Hundreds of Thousands of Smart Wireless field devices Tens of Thousands of Wireless Field Networks Proven Technology

13 A B C D G1 E F G H I J K L M N O P Q R S T U V Frequency hopping, time synchronized, mesh to the edge, self-organizing network

14 A B C D G1 E F G H I J K L M N O P Q R S T U V Automatic Rerouting

15 Traditional Wireless Architecture Process Variable data Pressure temperature Level o Point-To-Multipoint o Point-To-Point o Point-To-Multipoint o Point-To-Point

16 Smart Wireless Gateway Architecture Pressure TemperatureLevel Process Variable data & full HART Diagnostics Flow Computer RTU PLC/RTU AMS & SCADA

17 Remote Automation Solutions Wireless Architecture Pressure temperature Level Process Variable data & full HART Diagnostics Flow Computer RTU PLC/RTU AMS & SCADA New Radio Serial, Ethernet or long haul wireless

18 Remote Automation Solutions IEC62591 Feature IEC62591 / Smart Wireless for RTU RTU Functionality needed?Yes Existing EMR RTU availableYes Greenfield O&GYes Low Power<1.2 Watts Number of Devices20/60/100 RedundancyNo Mounting RequirementsIn the RTU Support 1 sec Update RateYes, after March 2013 Discrete I/O Support702, 4310, 4320, after Mar 2013

19 IEC62591 Supported Devices Supported by IEC62591 Initial Release DeviceMfr CW MicroROC800FB107 248RMTTemp deviceVerified 648RMTTemp deviceVerified 3051RMTPressureVerified 775 THUM w/3051RMTPressureVerified 2051RMTPressureVerified 708RMTSteam TrapVerified 9420CSIVibrationVerified 2160RMTVibrating fork level gaugeVerified 3308RMTRadar gauge levelVerified Supported by IEC62591, DI/DO Release - March 702RMTDiscrete TransmitterMar. Release 4310FisherValve positionerMar. Release 4320FisherValve positionerMar. Release Returns the four process variables(PV, SV, TV, QV) and dynamic (slot) variables (0,1,2,3).

20 IEC62591 Supported Devices Returns the four process variables (PV, SV, TV, QV) and dynamic (slot) variables (0,1,2,3). Analog Support until Discrete Release (Spring 2014) RTU does not support Machinery Health Manager nor Device Descriptors. RTU does not support AMS Pass Through. HART-Pass through on a single RTU connection basis will be supported via Field Tools AMS Device Configurator (for configuration), will be available in March 2014. Enterprise-wide Asset Management (for remote diagnostics application) will be supported via AMS Device Manager v12 Service Pack along with OE 3.2 in August 2014.

21 ROC, FloBoss & ControlWave IEC 65591 Wireless Technology Only truly integrated RTU/FC wireless solution –One integrated configuration tool –Support built into firmware –Seamless integration from field to back office –No third party gateways –No Modbus mapping High reliability and low power consumption for remote installations –No site survey required –Auto re-routing mesh network –Smaller backup batteries & enclosures

22 Integrated Solution Benefits Distributes measurement & Control to field locations –Not dependent on long haul reliability for data integrity –Local Historical and Alarm logging –Local Control Truly integrated configuration software tools –One software to configure the RTU, flow computer and remote transmitters RTUs & FCs provide local I/O, wired & wireless HART interfaces, interfaces to intelligent devices Data available to SCADA host software

23 IEC62591 Seamless Integration FC, RTU, PLC Platform IEC62591 Wireless I/O Module Smart Wireless Field Link IEC62591 Interface ControlWave Micro FB107 IEC62591 Interface IEC62591 Interface ROC800

24 ROC800 & FB107 Integration Integrated into ROC800 & FB107 firmware Integrated into ROCLINK configuration software Will be integrated with OpenEnterprise™ Field Tools Device configurator Integrated into ROC800 & FB107 firmware Integrated into ROCLINK configuration software Will be integrated with OpenEnterprise™ Field Tools Device configurator

25 ControlWave Integration o Integrated into ControlWave firmware o Integrated into ControlWave Designer configuration software o Will be integrated with OpenEnterprise Field Tools Device configurator o Integrated into ControlWave firmware o Integrated into ControlWave Designer configuration software o Will be integrated with OpenEnterprise Field Tools Device configurator

26 Smart Wireless Field Link Smart Wireless Filed Link –4 wire connection to IEC62591 I/O module –Powered by IEC62591 I/O module No setup or configuration Aluminum or Stainless Steel housing Multiple FM, CSA & IS certifications Antenna selection –Standard range –Extended range Meter selection 750 ft (225 m) 2600 ft (800 m) Extended range antenna Smart Wireless Field Link Wireless Field Devices

27 OpenEnterprise Field Tools Comm Manager HART Server Wired & WirelessHART AMS Device Configurator Wireless SNAP-ON network analysis and device alerts (available in Mar 2014)

28 OE Field Tools* Comm Manager HART Server Wired & WirelessHART HART Modem Use in place of 475 Handheld *coming soon

29 Field Tools HART Device Configurator* HART is a mark owned by the HART Communication Foundation * Excepted Availability March 2014

30 AMS Wireless SNAP-ON Allows Users to Easily Plan and Manage Field Networks Network Planning –Easily validate / optimize network design against best practices Network Monitoring –Status and communication diagnostics –Alerts Advanced Reporting –Status and communication diagnostics Live Mode

31 Better Understanding the Health of the Device Transmitter status log with time stamp Pressure & temperature sensor log with time stamp - sensor excursions - max/min values

32 Set Maintenance Reminders Custom message & alert time Receive alerts when time expires

33 IEC 62591 Production Applications First only truly integrated WirelessHART Interface for RTUs and Flow Computers Wireless Interface Significant Production Applications Significant Customer Value –Up to 60% faster installation and commissioning. –30% or more installed cost savings over wired alternatives –Easily add unmonitored points –Most robust diagnostics eliminate false readings and improves operational and maintenance decisions. –Platform harmonization with tightest Emerson integration –High reliability wireless data network –Low power consumption for remote installations STEAM INJECTION HEAT EXCHANGER WATER INJECTION FLOW STEAM OR GAS INJECTION FLOW INJECTION WELLHEAD MONITORING Proprietary & Confidential 33

34 WELLHEAD PRESSURE AND TEMPERATURE Indicates health of well and composition of fluids WELL ANNULUS PRESSURE Indicates casing pressure – an increase indicates fluid leakage and need to relieve pressure or kill well WELLHEAD FLOW Measures temperature for use as an indirect indication of flow WELLHEAD FLOW LINE VALVE DIAGNOSTICS Wireless THUM Adapter transmits Predictive diagnostics to aid maintenance FLOW & NET OIL/WATER MEASUREMENT AT WELL THUM Adapter transmits diagnostics for maintenance use and multiple process variables for monitoring OIL PRODUCTION VALVE POSITION Monitors open / close status and position of choke valves, manifold valves, and manual valves OIL PRODUCTION TOTALIZED FLOW Multivariable transmitters efficiently calculate and provide totalized flow output STEAM INJECTION HEAT EXCHANGER MANAGEMENT Measures pressure and differential pressure across heat exchangers to monitor performance WATER INJECTION FLOW Measures and transmits water flow data and predictive diagnostics STEAM OR GAS INJECTION FLOW Measures and transmits steam or gas injection flow data and predictive diagnostics GROSS OIL PRODUCTION Gauge pressure measured at headers is sent to historian to capture production information INJECTION WELLHEAD MONITORING Pressure, temperature and DP flow Measurements provide better visibility of injection process WirelessHART Wellhead Monitoring Applications

35 First only truly integrated WirelessHART Interface for RTUs and Flow Computers Wireless Interface Significant Transmission Applications Significant Customer Value –Up to 60% faster installation and commissioning. –30% or more installed cost savings over wired alternatives –Easily add unmonitored points –Most robust diagnostics eliminate false readings and improves operational and maintenance decisions. –Platform harmonization with tightest Emerson integration –High reliability wireless data network –Low power consumption for remote installations STATION PRESSURE & RUN TEMPERATURE REMOTE TANK MONITORING REMOTE PRESSURE MONITORING COMPRESSOR VIBRATION MONITORING IEC 62591 Transmission Applications

36 FLOW & NET OIL/WATER MEASUREMENT IN TEST SEPARATOR THUM Adapter transmits diagnostics for maintenance and multiple variables for monitoring VIBRATION IN INJECTION PUMPS Monitors vibration of bases and bearings, providing data for predictive maintenance to improve availability PLUGGED FILTER DETECTION Differential Pressure across line filters Indicate maintenance is needed PIPELINE STATION PRESSURE Monitoring remotely located inlet and outlet pressures TEST MANIFOLD & WELL MONITORING Monitoring remote wells producing into a test manifold SEPARATOR LEVEL MEASUREMENT Monitors separator interface level OFFSHORE PLATFORM HEAT DETECTION Remotely monitor heat exchanger’s inlet and outlet temps in harsh, difficult -to-reach areas indicate performance SEPARATION PROCESS VALVE POSITION Monitors open / closed status and position of manual valves, relief valves, tank inlet and outlet valves, and shutdown valves REMOTE TANK MONITORING Monitoring low pressure points in a distribution system for efficient pressure management reducing leakage DISTRIBUTION SYSTEM POINT MONITOR Gauge pressure measured at headers is sent to historian to capture production information WirelessHART General Upstream & Transmission Monitoring Applications

37 WirelessHART Injection Well Monitoring Producer Injector Water/Steam Injection Facility RTU at the pump station, or in strategic field locations RTU logs history, provides long range communications, local display, flow control, logic At Injection wells Line pressure DP across meter Injection pressure Fluid temperature Valve/choke control

38 Use WirelessHART to Gather Required Data for Reporting –Injection Well monitoring Injection wells are spread out, minimal IO at each point Information is not time critical Injection pressures, rates and totals are of high value –Main drivers include governmental regulations and reservoir management needs RTUs to archive local histories and provide long range communication and data consolidation

39 Test System Manifold Well Testing with WirelessHART Producer Test Manifold RTU/Flow Computer at test manifold Automatic Well Testing Valve Control ( Fisher DVC) Measurement (Daniel Orifice, Turbine, MMI) Pressure, Temperatures (Rosemount) At producing wells Casing, Flow Line Pressures Line pressure Temperatures On/Off status Stuffing Box Leaks

40 WirelessHART Natural Gas Wellhead Well Optimization Plunger Arrival Casing, Tubing, Bradenhead Pressures Valve Position and Control (Future)

41 TestimonialsTestimonials Where successful wireless networks have helped other customers achieve improved performance and financial results

42 CHALLENGE Manual collection of key process parameters Conventional methods require high installation and maintenance costs SOLUTION Emerson Smart Wireless – Proven measurement technology – Pressure, Temp, Level, Flow, Discrete – WirelessHART technology RESULTS Decreased CAPEX & Operational Costs Lower Safety risks through online Casing pressure monitoring Smart Wireless Improves Wellhead Production Allocation Offshore Topsides Wireless Application Production Manager  Decreasing Productivity Field Technicians/Engineers  Rising Workload HSE Managers  Rising Risks

43 Emerson's Smart Wireless Improves Wellhead Monitoring at BP Wytch Farm CHALLENGE –Eliminate manual rounds to monitor wellhead pressure reading –Respond to problems and rectify more quickly SOLUTION –40 wireless Rosemount® pressure transmitters total Two transmitters installed per wellhead A single Smart Wireless gateway, mounted outside process area, connects transmitters to control system All devices on-line within 30 minutes RESULTS – Improved operations –Automated wellhead pressure monitor –Real time information regarding well performance –Improved maintenance responsiveness to process problems “The wireless instruments have performed without losing any data since they were installed in August …” - Chris Geen, BP Manager

44 Customers Are Solving Real Plant Problems: Chevron San Ardo, Calif. Application: –Pressure transmitters monitor steam injection on out-of-service wells Challenge: Over steaming caused lost production, increased wastewater discharge; field visits required Solution: Smart Wireless network improves personnel safety, increases production, reduces wastewater discharge Application: –Pressure transmitters check down-hole well pressure Challenge: RTU network obsolete, required hard wired power Solution: Battery-powered transmitters collect reliable production strategy data, less maintenance, installed for $60,000 savings “It only took three hours to install all the instruments, configure and establish the network IP address, and make the Ethernet connection to the control room,” Kinne said. “We have eliminated the excess steam usage and now have a reliable steam injection measurement at eight stations.” — Paul Kinne, Chevron head operator

45 Smart Wireless Improves Heat Exchanger performance at EnCana Oil Sands Facility CHALLENGE –Improve efficiency of heat exchangers in energy intensive steam injection process, prevent downtime Cost-effective way to measure heat transfer in HE’s for boiler feedwater Predict tube fouling to improve heat transfer and prevent tube rupture SOLUTION –Rosemount ® wireless transmitters measure boiler feedwater inlet and outlet temperatures –Wireless network installed and operating in 2 days RESULTS –Improved efficiency of several key heat exchangers –Saved $40,000 versus wired installation –Optimized cleaning schedules to prevent tube ruptures –Boiler fuel consumption reduced “We are now able to maximize heat exchanger operation and maintain the tubes more effectively to prevent heat losses and avoid devastating tube ruptures. We are pleased with the ease of installing the Smart Wireless network, which is working perfectly.” —Stephan Meerman, E&I Supervisor

46 Leveraging HART to Turn Field Insight into Actionable Information 1 1 2 2 3 3 4 4 Statistical Process Monitoring variable trending Standard deviation Coefficient of variation Mean Uncover opportunities by fingerprinting the process to know what "normal or good" looks like. Decide on accurate alerts for abnormal situation management Proactively correct abnormal conditions and improve process performance

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