Honeywell is Making Industrial Wireless Real Unlocking the Value in Applications
Agenda • Environment is Right for Industrial Wireless • Exciting Opportunities/Benefits from Wireless • Choosing a Wireless Solution • Why Honeywell?
Environment • Growing Demand in the Following… – Economic need to further optimize the plant – Make government compliance easier – Make plants safer – Easier equipment health assessments • Wireless Technology is…. – Advancing – Becoming cost-effective – Standardizing Environment is Right for Industrial Wireless
Proven Products and Applications • Wireless Worker Solutions deploy applications and valuable plant information in places where they were not previously available utilizing mobile and wireless technologies. – IntelaTrac PKS – Automates field operator activities – Mobile PKS – Brings the control room to the field • Wireless Transmitters provide real-time, accurate and reliable process and asset data at lower cost than traditional wired sensors – XYR5000 – Senses field measurements wirelessly – XYR Gateway - Wireless IO for TDC/TPS • Wireless Services provides site assessments and implementation for wireless offerings at your site. State of the Art Offerings Delivering Value Today
Agenda • Environment is Right for Industrial Wireless • Exciting Opportunities/Benefits from Wireless • Choosing a Wireless Solution • Why Honeywell?
Unlocking the Value of Wireless-enabled Applications Reliability - Continuous Equip Health Monitoring Optimization - Automated Field Operator Rounds - Wireless I/O & Tools - Better Data for Advanced Apps Compliance Safety & Security - Emissions Monitoring - Safety Shower Monitoring - Leak Detection & Repair - People/Asset Tracking New Applications on the Horizon Enabling Multiple Applications in One Wireless Cloud
Reliability - Tank Farm Ethanol Plant Application - Tank Level in Explosion Proof Area Issue: • Wiring cost prohibitive $250K+ • Explosion-proof area • Volume at high customer demand • Spills are frequent and costly • Current Measurement: • Poly tube-style site glass • Readings are visual with error • Safety to Personnel • Inventory management impossible Solution: • Wireless pressure transmitter “We have not had a single spill or safety • Saved $230K first year violation since the installation!” ~ Production Mgr
Acoustic Measurement Leak Detection • In Acoustic applications the sensor will notice a noise detection deviation from threshold conditions on a leak. • Each valve has unique characteristics. A baseline must be established by viewing normal ambient noise and then the baseline identifies; – deviations as leaks (12-20 Ultrasound Value (UV) Typical) – major deviations indicate possible line rupture (100-140UV) – minor deviation may indicate leak in close proximity to valve • I.e. elbow, union, control valve, etc • Savings Comparison – 109 Points – 500Ft/Run @ $40/Ft – Wiring $2,200,000 • XYR - $120,000
Reliability - Compressor Application Refinery Application – Compressor Bearing Temperature Monitoring • 7 Large Rotary Compressors • Distant locations with no available wiring • Trenching or suspended wiring required • Wiring costs alone 200 – 1,000 ft runs/$120/ft =$800K/min • Existing instrumentation inadequate – Each Compressor equipped with local indicator – Operators monitor by clipboard hourly & some units are non-accessible • Installation needed to be completed immediately • Cost to plant significant upon failure - Est. loss $1,000,000/day Solution: • Wireless temperature transmitters • Installed cost = $76K -2 days Low Cost Temperature Monitoring – Potentially Saved Millions
Compliance - LDAR Applications • Most applications have no existing wiring • Costs typically required for plant operations and may have no ROI • Wiring runs from $30-120/ft – Hazardous Classified Areas • Energy Savings – Return Emissions for Fuel • Fugitive Emissions – Acoustic – Leak Detection, Full Release – Pressure – SRV release, filter blockage, replacement – Switched/Discrete – Rupture Disc, Valve Status – Temperature – Flare Stack Temperature, pilot status – Repeater – Gas & analytical sensors for sniffing. Simpler Way to Comply
Compliance - Butane Spheres • Customer Need: pressure measurements from top of sphere for level estimating • Specific cost is undetermined for area - Est. $80/ft = $500,000(+) • Longest shot 1,200 feet • Shortest is 600 feet • Installation time for field devices minimal • 7 Tanks • $12,000 total project cost Simpler Way to Comply – Instant Savings of ~$.5M
Spent Alcohol Tanks Current Result – Clipboard Measurement • Safety – 10,000gal spill of pharmaceutical used isopropyl alcohol. • Major safety • Major fines • Expensive clean-up Situation • 1,400 foot runs @ $50/ft • Trenching • 12 tanks • Est. – $300,000 Wireless Solution • Static Pressure • $15,000
Optimization - Rotary & Mobile Equipment Measurements on Rotary Equipment Application • Rotating Dryer Issue: • Requires ad-hoc designed electro-mechanical links to transmit the signal • Readings are not available (Temperature & Vacuum) • Adding measurement points is expensive • Current Method was inferred Solution: • Provided Wireless field device to give constant process data • Cost $5K/Dryer Better Alternative for Rotating Application
Safety - Safety Showers • OSHA is driving new requirements on shower monitoring for all new installations! Operator must alert in 5-10 seconds. • Flow switch indication on all Safety Showers • Cost to run wire @ $120/ft. Average run over 600’ this equates to about $75,000 per run. • 26 Showers • 26 Wireless = $32,000 with XYR • Simple Economics Safer Plant & Saved $1M+
Deployment: Pipeline & Process Fence line Applications
Safety & Security - People/Asset Tracking • Active RFID tracking – Using Active Ultra Wide Band (UWB) RFID tag technology – Real- Time tracking with ranges up to 1000’ – Track 1000’s of tags – 2D and 3D tracking with up to 1’ resolution. – Coverage of large areas • Integrated with Honeywell Experion PKS and/or EBI solutions – Integrated with Process Control and Physical Security Work Processes • Wireless integration option – Can augment “or” replace current Access control solution – Improved Safety by integration into process operations – Active Real-Time Mustering Solution. – More effective method of meeting OSHA Process Safety Management Standards (PSM) safety standards. – High Value return and integration to unique customer SOP People and Asset Location Becomes Data For Your Process Knowledge System
Agenda • Environment is Right for Industrial Wireless • Exciting Opportunities/Benefits from Wireless • Choosing a Wireless Solution • Why Honeywell?
Choosing a Wireless Solution The Right Consideration Set • Applications – Safety & Security – Reliability – Compliance – Optimization • Architecture • Services • Experience
Key System Requirements 8. Global Usage 9. Quality of Service 7. Scalable 7. Scalable 10. Multi-protocol Customer 6. Multi-functional 6. Multi-functional 11. Control Ready Architecture Requirements* 5. Multi-speed Monitoring 5. Multi-speed Monitoring 4. Open 4. Open 1. Security 1. Security 3. Good Power Management 3. Good Power Management 2. Reliable Communication 2. Reliable Communication Important Wireless Customer Requirements * - ARC Users Survey 2005 - Honeywell VOC 2003/2004/2005 “A Wireless Zone” Meeting all Requirements Concurrently
Usage classes of wireless data networks message timeliness increases Safety Class 0 : Emergency action (always critical) Class 1: Closed loop regulatory control (often critical) Control Class 2: Closed loop supervisory control (usually non-critical) Importance of Class 3: Open loop control (human in the loop) NOTE: Batch levels* 3 & 4 could be class 2, class 1 or even class 0, depending on function * Batch levels as defined by ISA S88; where L3 = "unit" and L4 = "process cell" Class 4: Alerting Short-term operational consequence (e.g., event-based maintenance) Monitoring Class 5: Logging & downloading/uploading No immediate operational consequence (e.g., history collection, SOE, preventive maintenance) • Alarms – Any class (human or automated action)
Where does it fit? Safety Class 0 : Emergency action (always critical) Class 1 : Closed loop regulatory control (often critical) Class 2: Closed loop supervisory control (usually non-critical) Class 3: Open loop control (human in the loop) Control NOTE: Batch levels* 3 & 4 could be class 2, class 1 or even class 0, depending on function * Batch levels as defined by ISA S88; where L3 = "unit" and L4 = "process cell" Class 4: Alerting Short-term operational consequence (e.g., event-based maintenance) Monitoring Class 5: Logging & downloading/uploading No immediate operational consequence (e.g., history collection, SOE, preventive maintenance) For industrial control this level of security requires authentication, ciphering, redundancy, high speed, encryption and a FHSS inherently secure hop sequence. (SP-100 & XYR-6000 Goals) For industrial control this level of security requires authentication, CRC encryption and a FHSS inherently secure hopping sequence. (XYR-5000 today)
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