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© ABB
| Slide 1May 2, 2016
Truly Wireless SensingGuru Sosale, Senior Scientist, ABB Forschungszentrum Deutschland, Hannover Messe, 25-04-2016
Enabling a paradigm shift in process monitoring
© ABB
| Slide 2May 2, 2016
Background: Sensing in the Process Industry
The most common sensors (instrumentation) in a process plant
© ABB
| Slide 3May 2, 2016
Background: The Cost of Sensing in the Process Industry
The sensor is only part of the story
© ABB
| Slide 4May 2, 2016
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
© ABB
| Slide 5May 2, 2016
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
ISA 100.11a usage classes for sensors in the process industry
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
© ABB
| Slide 6May 2, 2016
Typical Monitoring Applications
• 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
…….
Manually carried out on non-critical equipment
© ABB
| Slide 7May 2, 2016
Wireless Mesh Technology for Monitoring Applications
A Case Study – Condition monitoring of rotating equipment
1 extracted from H.A.Abubakar, Journal of Engineering and Industrial Applications, V4, No1, pp79-85, 2008. Data corroborates with ABB use cases
Over 40% of Failure causes can be detected early by condition monitoring
• Aggregate: Pump – gearbox - motor
• Up to 50k aggregates per site
© ABB
| Slide 8May 2, 2016
Wireless Mesh Technology for Process Monitoring
Condition Monitoring – Basics of degradationP
erf
orm
an
ce
Resu
ltin
g C
ost
Conditions start to
change
Increase in vibration
and power consumption
Increased noise
and heat
generationSmoke
and
shaking
Time to failure
Emergency
Stop
Time
© ABB
| Slide 9May 2, 2016
Wireless Mesh Technology for Process Monitoring
Condition Monitoring – Basics of degradationP
erf
orm
an
ce
Resu
ltin
g C
ost
Conditions start to
change
Increase in vibration
and power consumption
Detection with Vibration
analysis
Time to failure
Emergency
Stop
Time
© ABB
| Slide 10May 2, 2016
Wireless Mesh Technology for Process Monitoring
Condition Monitoring – Basics of degradationP
erf
orm
an
ce
Resu
ltin
g C
ost
Conditions start to
change
Increase in vibration
and power consumption
Detection with Vibration
analysis
Time
Assumed model
© ABB
| Slide 11May 2, 2016
Wireless Mesh Technology for Process Monitoring
Condition Monitoring – Basics of degradationP
erf
orm
an
ce
Resu
ltin
g C
ost
Conditions start to
change
Increase in vibration
and power consumption
Detection with Vibration
analysis
Time
Fast degradation Assumed model Slow degradation
© ABB
| Slide 12May 2, 2016
Wireless Mesh Technology for Process Monitoring
Condition Monitoring – what are an operators options?
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
Considering 100‘sto 10,000‘sof rotating equipment…..
© ABB
| Slide 13May 2, 2016
Wireless Mesh Technology for Process Monitoring
ABB WiMon100 – surface mounted condition monitoring sensors
Accelerometer and
signal processing
designed for Vibration
monitoring
10
cm
Weight -0.2Kg
Temperature Sensing
through mount
• Ex Zone 0 certified
• Surface mounted on housing
(screw, glued, magnetic)
• Battery lifetime > 5 years
• Wirelss Mesh networked
1. The sensors or the new infrastructure should not influence or
compromise the existing process in any way
© ABB
| Slide 14May 2, 2016
Wireless Mesh Technology for Process Monitoring
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
© ABB
| Slide 15May 2, 2016
Wireless Mesh Technology for Process Monitoring
ABB WiMon100 – surface mounted condition monitoring sensors
1. The sensing system should provide actionable information
• Standard variables: Temperature, RMS Velocity and
Acceleration Envelope
© ABB
| Slide 16May 2, 2016
Wireless Mesh Technology for Process Monitoring
ABB WiMon100 – surface mounted condition monitoring sensors
1. The sensing system should provide actionable information
• Standard variables: Temperature, RMS Velocity and
Acceleration Envelope
Alarm Thresholds
© ABB
| Slide 17May 2, 2016
Wireless Mesh Technology for Process Monitoring
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
© ABB
| Slide 18May 2, 2016
Wireless Mesh Technology for Process Monitoring
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
Equivalent to a manual measurement on the equipment, at least once a day
© ABB
| Slide 19May 2, 2016
Wireless Mesh Technology for Process Monitoring
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
© ABB
| Slide 20May 2, 2016
Wireless Mesh Technology for Process Monitoring
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
© ABB
| Slide 21May 2, 2016
Wireless Mesh Technology for Process Monitoring
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
WiMon100Gateway
24VDC
WiMon
Datamanager
© ABB
| Slide 22May 2, 2016
Wireless Mesh Technology for Process Monitoring
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
WiMon100Gateway
24VDC
WiMon
Datamanager
Connected to existing infrastructure may not be desirable
DCS
controllers
Control net
User Interface
© ABB
| Slide 23May 2, 2016
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
Rotating equipment
WiMon100Gateway
24VDC
WiMon
Datamanager
User Interface
Ethernet
Additional installation costs and poor scalability
© ABB
| Slide 24May 2, 2016
Wireless Mesh Technology for Process Monitoring
ABB TropOS meshed IP networks and WiMon100
Rotating equipment
WiMon100
User Interface
WiMon
Datamanager
ABB TropOS
Gateway
2. The sensors or the new infrastructure should not influence or
compromise the existing process in any way
ABB TropOS
Node
Gateway
24VDC
© ABB
| Slide 25May 2, 2016
Wireless Mesh Technology for Process Monitoring
ABB TropOS meshed IP networks and WiMon100
Rotating equipment
WiMon100
User Interface
WiMon
Datamanager
ABB TropOS
Gateway
> 50% lower installation costs, at least 2-3 times faster to deploy, low risk
2. The sensors or the new infrastructure should not influence or
compromise the existing process in any way
ABB TropOS
Node
Gateway
24VDC
© ABB
| Slide 26May 2, 2016
Wireless Mesh Technology for Process Monitoring
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
© ABB
| Slide 27May 2, 2016
Wireless Mesh Technology for Process MonitoringABB 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
Rotating equipment
WiMon100Gateway 1
WiMon
Datamanager
User Interface
ABB TropOS
Node
24VDC
24VDC
© ABB
| Slide 28May 2, 2016
Wireless Mesh Technology for Process MonitoringABB 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
Rotating equipment
WiMon100Gateway 1
WiMon
Datamanager
User Interface
ABB TropOS
Node
24VDC
24VDC
© ABB
| Slide 29May 2, 2016
Wireless Mesh Technology for Process MonitoringABB 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
Rotating equipment
WiMon100Gateway 1
WiMon
Datamanager
User Interface
ABB TropOS
Node
24VDC
24VDC
© ABB
| Slide 30May 2, 2016
Wireless Mesh Technology for Process MonitoringABB 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
Rotating equipment
WiMon100Gateway 1
WiMon
Datamanager
User Interface
ABB TropOS
Node
24VDC
24VDC
Gateway 2
ABB TropOS
Node
© ABB
| Slide 31May 2, 2016
Wireless Mesh Technology for Process MonitoringABB 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
Rotating equipment
WiMon100Gateway 1
WiMon
Datamanager
User Interface
Incremental and rapid scalability of sensor and IP networks
ABB TropOS
Node
24VDC
24VDC
Gateway 2
ABB TropOS
Node
© ABB
| Slide 32May 2, 2016
Wireless Mesh Technology for Process Monitoring
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
© ABB
| Slide 33May 2, 2016
Wireless Mesh Technology for Process Monitoring
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
© ABB
| Slide 34May 2, 2016
Typical Monitoring Applications
• 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…….
What would you do for your next monitoring application?
TropOS wireless IP
Hannover messe, - Halle 11, Stand A35
Vibration
monitoring
Wireless
Temperature
Wireless
Pressure Wireless IP Mesh routers
© ABB
| Slide 35May 2, 2016
