Presentation Transcript

1. Remote Automation Solutions IEC62591 Wireless Interface

2. Business Challenges Reliability & Access Financial Results CRITICAL BUSINESS CHALLENGES Efficiency & Throughput Safety & Environment Personnel & Resources
3. 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
4. Business & Operational Challenges Facing Oil & Gas Producers Shortage of Trained Workforce Getting Online Faster High trenching, wiring, labor and Installation 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” New Oil / Gas Field Constructions (CAPEX)
5. 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
6. Solution Value Drivers 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 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 IEC62591 Wireless Interface For Flow Computers and RTUs Smart Wireless Field Link FloBoss ControlWave New Interface Modules ROC 6 Proprietary & Confidential
7. Solution Value Drivers 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 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 IEC62591 Wireless Interface For Flow Computers and RTUs Smart Wireless Field Link FloBoss ControlWave New Interface Modules ROC 7 Proprietary & Confidential
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
10. Smart Wireless Portfolio is Large …and Getting Larger Smart Wireless THUM Adapter 702 Wireless Leak Detection 702 Discrete 6081C Conductivity Smart Wireless Gateway DeltaV S-series Wireless I/O Smart Wireless Field Link Ovation Native Interface 6081 pH 648 Temperature 848T Multi Input Temperature 4300 Series Position Monitor Video Integration with DeltaV 2160 Vibrating Fork Liquid Level Switch 9420 Vibration DeltaV Native Interface 3051S Series Pressure, Level & Flow Current Portfolio New Products
11. Traditional Wireless Architecture Point-To-Multipoint Point-To-Point Solution Benefits Easy to install Low cost Generic Modbus Gateway Interface Supports legacy systems Diagnostics Tag ID Device Type Status Alarm RF Failure Low Battery Process Variable data Level Pressure temperature
12. Smart Wireless Gateway Architecture Solution Benefits Open, easy-to-deploy Secure & Reliable mesh network Automatic re-routing AMS & SCADA Flow Computer PLC/RTU RTU IEC62591 Standard Gateway integrates easily into legacy systems PC, RTU, PLC, FC Extends PlantWeb® Diagnostics Full access to Advanced HART diagnostics Transparent pass-through to AMS Process Variable data & full HART Diagnostics Temperature Level Pressure
13. Remote Automation Solutions Wireless Architecture AMS & SCADA Serial, Ethernet or long haul wireless Solution Benefits Easy to install Lower cost installation Secure & Reliable mesh network Automatic re-routing Low power consumption Radio Radio Flow Computer PLC/RTU RTU New Diagnostics Full access to Advanced HART diagnostics Only integrated Wireless Solution No Gateway No Modbus mapping IEC62591 Standard Process Variable data & full HART Diagnostics Level temperature Pressure
14. Remote Automation Solutions IEC62591
15. ROC, FloBoss & ControlWaveIEC 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
16. 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
17. IEC62591 Seamless Integration FC, RTU, PLC Platform FB107 ROC800 ControlWave Micro IEC62591 Wireless I/O Module IEC62591 Interface IEC62591 Interface IEC62591 Interface Smart Wireless Field Link
18. ROC800 & FB107 Integration Integrated into ROC800 & FB107 firmware Integrated into ROCLINK configuration software Integrated with OpenEnterprise™ Field Tools Device configurator
19. ControlWave Integration Integrated into ControlWave firmware Integrated into ControlWave Designer configuration software Integrated with OpenEnterprise Field Tools Device configurator
20. 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
21. Field Tools Wired & WirelessHART HART Server Comm Manager Device Configuration Wireless SNAP-ON network analysis and device alerts
22. Field Tools Wired & WirelessHART HART Server Comm Manager HART Modem Use in place of 475 Handheld
23. Field Tools HART Device Configurator Process Variable Monitor Wired & Wireless HART configuration Setup & Configuration Device Diagnostics HART is a mark owned by the HART Communication Foundation
24. AMS Wireless SNAP-ON Allows Users toEasily 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
25. 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
26. Set Maintenance Reminders Custom message & alert time Receive alerts when time expires
27. 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 INJECTION WELLHEAD MONITORING STEAM INJECTION HEAT EXCHANGER STEAM OR GAS INJECTION FLOW WATER INJECTION FLOW 27 Proprietary & Confidential
28. 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
29. IEC 62591 Transmission Applications 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 COMPRESSOR VIBRATION MONITORING STATION PRESSURE & RUN TEMPERATURE REMOTE PRESSURE MONITORING REMOTE TANK MONITORING
30. 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
31. WirelessHART Injection Well Monitoring 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 Producer Injector Water/Steam Injection Facility
32. 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
33. Test System Manifold Well Testing with WirelessHART 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 Test Manifold Producer
34. WirelessHart Natural Gas Wellhead Well Optimization Plunger Arrival Casing, Tubing, Bradenhead Pressures Valve Position and Control (Future)
35. Testimonials Where successful wireless networks have helped other customers achieve improved performance and financial results
36. 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 AllocationOffshore Topsides Wireless Application Production Manager  Decreasing Productivity HSE Managers  Rising Risks Field Technicians/Engineers  Rising Workload
37. 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
38. 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
39. 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
40. Leveraging HART to Turn Field Insight into Actionable Information 1 Statistical Process Monitoringvariable trending Standard deviation Coefficient of variation Mean Uncover opportunities by fingerprinting the process to know what "normal or good" looks like. 2 4 3 Proactively correct abnormal conditions and improve process performance Decide on accurate alerts for abnormal situation management