Truly Wireless Sensing Enabling a paradigm shift in process monitoring

Guru Sosale, Senior Scientist, ABB Forschungszentrum Deutschland, Hannover Messe, 25-04-2016 Truly Wireless Sensing Enabling a paradigm shift in process monitoring Slide 1

Background: Sensing in the Process Industry The most common sensors (instrumentation) in a process plant Slide 2

Background: The Cost of Sensing in the Process Industry The sensor is only part of the story Slide 3

Background: The Cost of Sensing in the Process Industry The sensor is only part of the story Cost drivers: Engineering + planning, Materials and Installation Shutdown costs and risks Non-intrusive and wireless sensors significantly reduce installation costs Slide 4

Application Classes for Sensors in the Process Industry Sensors for Safety, Control and Monitoring Safety Control Monitoring Class 0: Emergency actions Class 1: Fast control Class 2: Slow Control Class 3: Open Loop Control Class 4: Alerting Class 5: Logging Sensors are critical to operation Installation + shutdown costs easily justified Sensors have no immeadiate impact on operations Manual measurements more cost effective Non-intrusive + wireless sensors make automated monitoring more cost effective Slide 5 ISA 100.11a usage classes for sensors in the process industry

Typical Monitoring Applications Manually carried out on non-critical equipment Vibration + Temperature monitoring of non critical rotating equipment (pumps, motors, compressors etc) Condition and performance monitoring for non critical heat exchanging equipment Piping and process equipment corrosion monitoring Valve performance monitoring Chemical spill/leak detection Energy metering and management Shutdown valve position measurements Manual logging and recording from guages, charts etc. Slide 6

Wireless Mesh Technology for Monitoring Applications A Case Study Condition monitoring of rotating equipment Aggregate: Pump gearbox - motor Up to 50k aggregates per site Over 40% of Failure causes can be detected early by condition monitoring Slide 7 1 extracted from H.A.Abubakar, Journal of Engineering and Industrial Applications, V4, No1, pp79-85, 2008. Data corroborates with ABB use cases

Performance Resulting Cost Wireless Mesh Technology for Process Monitoring Condition Monitoring Basics of degradation Conditions start to change Increase in vibration and power consumption Increased noise and heat generation Smoke and shaking Time to failure Emergency Stop Time Slide 8

Performance Resulting Cost Wireless Mesh Technology for Process Monitoring Condition Monitoring Basics of degradation Conditions start to change Increase in vibration and power consumption Detection with Vibration analysis Time to failure Emergency Stop Time Slide 9

Performance Resulting Cost Wireless Mesh Technology for Process Monitoring Condition Monitoring Basics of degradation Conditions start to change Increase in vibration and power consumption Detection with Vibration analysis Assumed model Time Slide 10

Performance Resulting Cost Wireless Mesh Technology for Process Monitoring Condition Monitoring Basics of degradation Conditions start to change Increase in vibration and power consumption Detection with Vibration analysis Fast degradation Assumed model Slow degradation Time Slide 11

Condition Monitoring what are an operators options? Considering 100 s to 10,000 s of rotating equipment.. Option 1: Wired Condition Monitoring System Option 2: Manual Inspections Cost: >10k /asset Used only for critical equipment Cost: 2-3 Person Hours/year (every 2-3 months) Used for less critical equipment Tradeoff between acceptable repair and monitoring costs Slide 12

10 cm Wireless Mesh Technology for Process Monitoring ABB WiMon100 surface mounted condition monitoring sensors 1. The sensors or the new infrastructure should not influence or compromise the existing process in any way Weight -0.2Kg Accelerometer and signal processing designed for Vibration monitoring Ex Zone 0 certified Surface mounted on housing (screw, glued, magnetic) Battery lifetime > 5 years Wirelss Mesh networked Temperature Sensing through mount Slide 13

Wireless Vibration and Temperature Sensors Three basic requirements! 1. The sensing system should provide actionable information 2. The sensors or the new infrastructure should not influence or compromise the existing process and equipment in any way. 3. When I see the benefit, I want to be able to scale it quickly and cost effectively Slide 14

ABB WiMon100 surface mounted condition monitoring sensors 1. The sensing system should provide actionable information Standard variables: Temperature, RMS Velocity and Acceleration Envelope Slide 15

ABB WiMon100 surface mounted condition monitoring sensors 1. The sensing system should provide actionable information Standard variables: Temperature, RMS Velocity and Acceleration Envelope Regular upload of measured and processed wave forms Slide 17

ABB WiMon100 surface mounted condition monitoring sensors 2. The sensors or the new infrastructure should not influence or compromise the existing process in any way Rotating equipment Slide 19

ABB WiMon100 surface mounted condition monitoring sensors 2. The sensors or the new infrastructure should not influence or compromise the existing process in any way Rotating equipment Slide 20

ABB WiMon100 surface mounted condition monitoring sensors 2. The sensors or the new infrastructure should not influence or compromise the existing process in any way WiMon Datamanager DCS controllers Gateway WiMon100 Control net 24VDC User Interface Rotating equipment Connected to existing infrastructure may not be desirable Slide 22

ABB WiMon100 surface mounted condition monitoring sensors 1. The sensors or the new infrastructure should not influence or compromise the existing process in any way WiMon Datamanager Gateway WiMon100 Ethernet 24VDC User Interface Rotating equipment Additional installation costs and poor scalability Slide 23

ABB TropOS meshed IP networks and WiMon100 2. The sensors or the new infrastructure should not influence or compromise the existing process in any way ABB TropOS Gateway ABB TropOS Node Gateway WiMon100 WiMon Datamanager 24VDC User Interface Rotating equipment Slide 24

ABB TropOS - Meshed broadband IP communication Simple to deploy - Meshed 2.4/5 GHz Networks Secure and Manageable VPN and firewall in every device Monitoring, configuration, upgrades, fault management, security Multiple Applications High bandwidth: >10 Mbps, low latency: <1 ms per hop Virtual LANs with separate address spaces, security policies and QoS policies Slide 26

ABB TropOS meshed IP networks and WiMon100 - Scalability 3. When I see the benefit, I want to be able to scale it quickly and cost effectively ABB TropOS Gateway ABB TropOS Node Gateway 1 WiMon100 24VDC WiMon Datamanager 24VDC User Interface Rotating equipment Slide 27

ABB TropOS meshed IP networks and WiMon100 - Scalability 3. When I see the benefit, I want to be able to scale it quickly and cost effectively ABB TropOS Node Gateway 2 ABB TropOS Gateway ABB TropOS Node Gateway 1 WiMon100 24VDC WiMon Datamanager 24VDC User Interface Rotating equipment Slide 30

ABB TropOS meshed IP networks Scalability 3. When I see the benefit, I want to be able to scale it quickly and cost effectively ABB TropOS Gateway Incremental expansion based on requirements and capabilities Slide 32

Recap of Case Study Wireless Condition Monitoring 1) Sensors that are wireless and non-intrusive make automated condition monitoring more cost effective Significantly more effective and cheaper than manual approaches 2) Meshed wireless sensor and IP networks should be the technology of choice: Lower installation costs, low risk, incremental and cost effective scalability Slide 33

Typical Monitoring Applications What would you do for your next monitoring application? Vibration + Temperature monitoring of non critical rotating equipment (pumps, motors, compressors etc) Condition and performance monitoring for non critical heat exchanging equipment Piping and equipment corrosion monitoring. TropOS wireless IP Vibration monitoring Wireless Temperature Wireless Pressure Wireless IP Mesh routers Hannover messe, - Halle 11, Stand A35 Slide 34

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