IEC62591 Wireless Customer Presentation

Report
Remote Automation
Solutions
IEC62591 Wireless Interface
Business Challenges
Reliability &
Access
Efficiency &
Throughput
Financial
Results
CRITICAL
BUSINESS
CHALLENGES
Personnel &
Resources
Safety &
Environment
Key Customer Stakeholders
Asset Manager Reduced Profitability
High operating cost, low yield
Oil & Gas
Industry
Business
Challenges by
Functions
Operations/SCADA Manager  Rising
Operating, Maintenance & Compliance Costs
Production Manager  Decreasing Productivity
Difficulty optimizing production
HSE Managers  Rising Risks
Detecting Safety & Environment problems
Field Technicians/Engineers  Rising Workload
Costly frequent trips to remote sites
Business & Operational Challenges Facing
Oil & Gas Producers
High trenching, wiring,
labor and Installation
Getting Online
Faster
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 Trained
Workforce
“Shortage of O&G
workforce will lead to
critical impact on
business”
New Oil / Gas Field Constructions (CAPEX)
Smart Wireless Vision Adopted at
Over 3000 Customer Sites Globally
Emerson’s Wireless Experience update:
• ~8000 wireless Networks in operation
• Over 3000 SmartWireless installations
• ~100,000 wireless process devices
installed
• ~950 million operating hours
Offshore Installations
Land Installations
IEC62591 Wireless Interface For Flow
Computers and RTUs
Wellhead Customer Solution
Value Drivers
Challenge
Smart
Wireless
Field Link
Time to first oil drives
investment decisions
60% faster installation and
commissioning.
Declining Production rates
for unconventional
wells
30% or more installed cost
savings over wired
alternatives
Operating and field
maintenance cost inflation
impacts margins
Need common standards
that provide future
architectural flexibility thru
production development
spectrum
Most robust diagnostics
eliminate false reading
leading to bad operational
and maintenance
decisions.
Platform harmonization
with tightest product
integration from Emerson
6
Proprietary & Confidential
FloBoss
ControlWave
New
Interface
Modules
ROC
IEC62591 Wireless Interface For Flow
Computers and RTUs
Midstream CustomerSolution
Value Drivers
Challenge
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
Smart
Wireless
Field Link
FloBoss
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
7
Proprietary & Confidential
ControlWave
New
Interface
Modules
ROC
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
Simple – Reliable - Secure
Self-Organizing Network
Auto-Recognition of New
Devices
99% Field Proven
Reliability
Self-Healing Network
Repairs Itself
Finds Alternative Paths
Industry Standard 128-bit
AES Encryption
Unique Encryption Key for
Each Message
No Site Surveys
No Trenching
Robust, Multi-tiered,
Always-on Security
Coexists with other
Wireless Networks
Robust and Tolerant to all
Types of Interference
without any Site Survey
Data Integrity and Device
Authentication
Reports Message and
Authentication Failures
Smart Wireless Portfolio is Large …
and Getting Larger
Current Portfolio
New Products
702 Wireless
Leak Detection
702
Discrete
6081C Conductivity
Smart Wireless
THUM Adapter
Smart Wireless
Gateway
Ovation Native
Interface
6081 pH
648 Temperature
848T Multi Input
Temperature
9420
Vibration
3051S Series
Pressure, Level & Flow
DeltaV Native
Interface
4300 Series
Position Monitor
DeltaV S-series
Wireless I/O
Video
Integration with
DeltaV
Smart Wireless
Field Link
2160 Vibrating
Fork Liquid
Level Switch
Traditional Wireless Architecture
oPoint-To-Multipoint
oPoint-To-Point
Process Variable
data
Level
Pressure
temperature
Easy to install
Low cost
Generic Modbus
Gateway Interface
Supports legacy
systems
Tag
ID
Device Type
Status
Alarm
RF Failure
Low Battery
Smart Wireless Gateway Architecture
AMS &
SCADA
Flow
Computer
Open, easy-to-deploy
Secure & Reliable mesh
network
Automatic re-routing
PLC/RTU
RTU
Process
Variable data
& full HART
Diagnostics
Temperature
Level
Pressure
Gateway integrates easily
into legacy systems
Full access to Advanced
HART diagnostics
PC, RTU, PLC, FC
Extends PlantWeb®
Transparent pass-through
to AMS
Remote Automation Solutions Wireless
Architecture
Serial,
Ethernet or
long haul
wireless
Radio
Easy to install
Radio
Flow
Computer
AMS &
SCADA
PLC/RTU
RTU
New
Lower cost installation
Secure & Reliable mesh
network
Automatic re-routing
Low power consumption
Process
Variable data &
full HART
Diagnostics
No Gateway
No Modbus mapping
Level
IEC62591 Standard
temperature
Pressure
Full access to Advanced
HART diagnostics
Remote Automation Solutions
IEC62591
Feature
IEC62591 / Smart Wireless
for RTU
RTU Functionality needed?
Yes
Existing EMR RTU available
Yes
Greenfield O&G
Yes
Low Power
<1.2 Watts
Number of Devices
20/60/100
Redundancy
No
Mounting Requirements
In the RTU
Support 1 sec Update Rate
Yes, after November 2013
Discrete I/O Support
702, 4310, 4320, after Nov 2013
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
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
IEC62591 Seamless Integration
FC, RTU, PLC Platform
FB107
ROC800
ControlWave Micro
IEC62591 Wireless I/O
Module
IEC62591
Interface
Smart Wireless Field Link
IEC62591
Interface
IEC62591
Interface
ROC800 & FB107 Integration



Integrated into ROC800
&
FB107 firmware
Integrated into
ROCLINK configuration
software
Will be integrated with
OpenEnterprise™ Field
Tools Device
configurator
ControlWave Integration
oIntegrated into
ControlWave firmware
oIntegrated into
ControlWave Designer
configuration software
oWill be integrated with
OpenEnterprise Field Tools
Device configurator
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
Smart Wireless Field Link
750 ft (225 m)
2600 ft (800 m) Extended
range antenna
Wireless Field Devices
Field Tools* (coming soon)
HART
Server
Wired &
WirelessHART
Comm
Manager
Device Configuration
Wireless SNAP-ON
network analysis
and device alerts
* Excepted Availability November 2013
Field Tools* (coming soon)
Wired &
WirelessHART
HART
Server
Comm
Manager
HART Modem
Use in place of 475 Handheld
* Excepted Availability November 2013
Field Tools HART Device Configurator*
* Excepted Availability November 2013
HART is a mark owned by the HART Communication Foundation
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
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
Set Maintenance Reminders
Custom message & alert time
Receive alerts when time
expires
IEC 62591 Production Applications


First only truly integrated WirelessHART Interface for RTUs and Flow
Computers Wireless Interface
Significant Production Applications
WATER
INJECTION FLOW

STEAM OR GAS
INJECTION FLOW
INJECTION WELLHEAD
MONITORING
STEAM INJECTION
HEAT EXCHANGER
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
27
Proprietary & Confidential
WirelessHART Wellhead Monitoring
Applications
WELLHEAD PRESSURE
AND TEMPERATURE
Indicates health of well
and composition of fluids
FLOW & NET OIL/WATER
MEASUREMENT AT WELL
THUM Adapter transmits
diagnostics for maintenance
use and multiple process
variables for monitoring
WATER INJECTION FLOW
Measures and transmits
water flow data and
predictive diagnostics
WELL ANNULUS PRESSURE
Indicates casing pressure – an increase
indicates fluid leakage and need
to relieve pressure or kill well
OIL PRODUCTION VALVE POSITION
Monitors open / close status
and position of choke valves,
manifold valves, and manual valves
STEAM OR GAS INJECTION FLOW
Measures and transmits steam
or gas injection flow data
and predictive diagnostics
WELLHEAD FLOW
Measures temperature for use
as an indirect indication of flow
OIL PRODUCTION
TOTALIZED FLOW
Multivariable transmitters efficiently
calculate and provide totalized
flow output
GROSS OIL PRODUCTION
Gauge pressure measured
at headers is sent to historian
to capture production information
WELLHEAD FLOW LINE
VALVE DIAGNOSTICS
Wireless THUM Adapter transmits
Predictive diagnostics
to aid maintenance
STEAM INJECTION HEAT
EXCHANGER MANAGEMENT
Measures pressure and
differential pressure
across heat exchangers
to monitor performance
INJECTION WELLHEAD
MONITORING
Pressure, temperature and DP flow
Measurements provide better visibility
of injection process
IEC 62591 Transmission Applications


First only truly integrated WirelessHART Interface for RTUs and Flow
Computers Wireless Interface
Significant Transmission Applications
REMOTE TANK
MONITORING

REMOTE PRESSURE
MONITORING
COMPRESSOR VIBRATION
MONITORING
STATION PRESSURE &
RUN TEMPERATURE
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
WirelessHART General Upstream &
Transmission Monitoring Applications
FLOW & NET OIL/WATER
MEASUREMENT IN TEST
SEPARATOR
THUM Adapter transmits
diagnostics for maintenance
and multiple variables for monitoring
TEST MANIFOLD
& WELL MONITORING
Monitoring remote wells
producing into a test manifold
SEPARATION PROCESS
VALVE POSITION
Monitors open / closed status
and position of manual valves, relief
valves, tank inlet and outlet valves,
and shutdown valves
VIBRATION IN INJECTION PUMPS
Monitors vibration of bases
and bearings, providing data
for predictive maintenance
to improve availability
SEPARATOR LEVEL MEASUREMENT
Monitors separator interface level
REMOTE TANK MONITORING
Monitoring low pressure points
in a distribution system
for efficient pressure
management reducing leakage
PLUGGED FILTER DETECTION
Differential Pressure across line filters
Indicate maintenance is needed
OFFSHORE PLATFORM
HEAT DETECTION
Remotely monitor heat exchanger’s
inlet and outlet temps in harsh,
difficult -to-reach areas
indicate performance
DISTRIBUTION SYSTEM
POINT MONITOR
Gauge pressure measured
at headers is sent to historian
to capture production information
PIPELINE STATION PRESSURE
Monitoring remotely located inlet
and outlet pressures
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
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
Test System Manifold Well Testing with
WirelessHART

RTU/Flow Computer at test
manifold





At producing wells

Test Manifold



Producer
Automatic Well Testing
Valve Control ( Fisher DVC)
Measurement (Daniel Orifice,
Turbine, MMI)
Pressure, Temperatures (Rosemount)
Casing, Flow Line Pressures
Line pressure
Temperatures
On/Off status
Stuffing Box Leaks
WirelessHart Natural Gas Wellhead

Well Optimization



Plunger Arrival
Casing, Tubing, Bradenhead
Pressures
Valve Position and Control (Future)
Testimonials
Where successful wireless
networks have helped other
customers achieve improved
performance and financial results
Smart Wireless Improves
Wellhead Production Allocation
Offshore Topsides Wireless Application
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
Production Manager  Decreasing Productivity
HSE Managers  Rising Risks
Field Technicians/Engineers  Rising Workload
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
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
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
Leveraging HART to Turn Field Insight into
Actionable Information
1
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.
2
4
Proactively correct
abnormal conditions and
improve process
performance
3
Decide on accurate alerts for
abnormal situation
management

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