Enabling IoT in Existing Plants

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Alvin Norton
5 years ago
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1 Enabling IoT in Existing Plants Making Existing Facilities Smart Harry Sim, Cypress Envirosystems

2 IoT Connect EVERYTHING

3 Industrial Internet of Things (IoT) Nearly two-thirds (77%) of all businesses plan to increase their IoT investments over the next 12 months - BSquare Sources:

4 Reality of IoT Legacy mechanical, manual instrumentation for flow, temperature, pressure, pneumatic actuators cannot communicate with cloud

Process downtime Cybersecurity concerns There are thousands of these devices with critical process data, but it costs over

5 Difficulty of Digitizing Existing Plants Just to read a simple pressure process value: Run wires (power and/or signal) I/O panels, termination Break seals, leak checks, material compatibility, safety checks Engineering assessment, documentation Process downtime Cybersecurity concerns There are thousands of these devices with critical process data, but it costs over $20,000 to instrument each one using conventional technology, plus cost of process downtime. Typical traditional solution: INVASIVE AND COSTLY

6 Need for Non-Invasive Digitization Technology Sensors which do not affect existing system: No breaking seals, no leak checks, no wetted parts Lightweight, no structural impact No power wires, no signal wires Little/no engineering review/analysis Takes minutes to install, no plant downtime required No new software to install, works with existing plant infrastructure

7 Non-Invasive IoT Retrofit Applications - Examples Pneumatic Thermostats Need to save energy & improve uptime, but hindered by outdated facility? Dial Gauges Steam Traps Standalone Transducers, LED/LCD Displays Specialized Equipment: -80C Freezers Manual Instrumentation, Not Programmable, No Diagnostics Equals: Wasted Energy, Higher Downtime, More Labor Required

8 Non-Invasive IoT Retrofit Solutions WIRELESS PNEUMATIC THERMOSTAT Go from Pneumatic to DDC in minutes WIRELESS GAUGE READER Remotely Read Gauges in minutes WIRELESS STEAM TRAP MONITOR Avoid Expensive Steam Leaks NETWORK CONTROLLER WIRELESS TRANSDUCER READER Remotely Read Transducers No Wires WIRELESS FREEZER MONITOR Predicts and Avoids Costly Freezer Failure

Wireless Gauge Reader & Wireless Transducer Reader Electronic Eyeball reads gauges and transmits readings wirelessly Non-invasive, clamp-on to existing gauges in minutes No downtime, no leak check,

following outputs: 4-20mA, 0-5V, or 0-10V, RS-232, RS-485, thermocouple, thermistor Compatible with most existing flow meters, current meters, particle counters, thermocouples, weigh scales, etc.

9 Wireless Gauge Reader & Wireless Transducer Reader Electronic Eyeball reads gauges and transmits readings wirelessly Non-invasive, clamp-on to existing gauges in minutes No downtime, no leak check, no wiring, no drawings Battery life of 3+ years at typical sample rates IP66/NEMA 4 rated for outdoor use Enables wireless remote monitoring of virtually any analog transducer or instrument with the following outputs: 4-20mA, 0-5V, or 0-10V, RS-232, RS-485, thermocouple, thermistor Compatible with most existing flow meters, current meters, particle counters, thermocouples, weigh scales, etc. Enables data logging to enable trend analysis, notification, or statistical process control Non-Invasive Devices Enables Alarming, Trending, Historization for Process/Asset Monitoring and Troubleshooting of Legacy Equipment and Instrumentation

10 How Does This Compare with Alternatives? BENEFITS Non-invasive, clamp-on No downtime No leak check No audit/requalification (e.g. FDA, OSHA) No running wires No drawings and approvals Minimal retraining of staff No new enterprise software Comparison with Alternatives Wireless Gauge Reader Wired Transducer Transducer/Sensor $1,200 $300 Install/Wiring Labor $50 $1,500 Drawings, Reviews $0 $500 Code Compliance $0 $1,000 I/O Panel/Termination $0 $300 Process Downtime $0 $1,000 Total Cost (per point) $1,250 $4,600 About 65% Lower Cost Compared with Alternative Solutions

WGR Application - Compressed Air Customer Challenge: Compressed air systems are one of the largest energy users in a

Monitoring of the compressed air system is intrusive and expensive Installing additional compressed air capacity to

WGR Solution: Typically manual gauges are already installed throughout CDA systems or coolant loop systems.

11 WGR Application - Compressed Air Customer Challenge: Compressed air systems are one of the largest energy users in a manufacturing facility which often run at settings beyond what is needed. Monitoring of the compressed air system is intrusive and expensive Installing additional compressed air capacity to accommodate system needs due to excessive leakage and compressor duty cycling. WGR Solution: Typically manual gauges are already installed throughout CDA systems or coolant loop systems. WGR s can monitor and alarm pressure/flow to ensure process integrity and reduce energy use. App note available: Compressed Dry Air System Energy Savings Savings on 500hp Compressed Air System can be up to $100K per year, with a 8 month payback.

12 Compressed Air Design vs. Typical Case Design Case Compressor Working Pressure 105 psi 15 psi loss End User Pressure 90 psi Compressor Receiver Oil Filter Dust Filter Dryer Branch Pipe P P P P P P P P P P P P P P Valve Pipe Valve Receiver Valve Pipe Valve Filter Valve Filter Valve Dryer Valve Pipe Typical Case Compressor Working Pressure End User Pressure 125 psi Unknown Loss Must keep at least 90 psi Clogged Filters, Leaks, Peak Usage Typical Plant Operator Overpressures to Compensate for Potential Losses

notice, increasing potential fines and safety risks Manual inspection of analog systems is labor intensive

13 Legacy Baghouses Existing analog systems make maintaining baghouses challenging Typical Baghouse Regulatory audits can be cumbersome due to lack of historical data Failures can persist for weeks or months without notice, increasing potential fines and safety risks Manual inspection of analog systems is labor intensive Baghouses Require Frequent Maintenance and Inspection Production line efficiency can be impacted Energy is wasted

Retrofit Magnehelic Gauges and Flow Meters The Wireless Magnehelic Reader (WMR) is a version of our Wireless Gauge Reader (WGR) for Magnehelic gauges Analog Magnehelic Gauge Airflow

The WMR and WTR provide data for central monitoring and alarming of baghouses Trend data helps maintenance teams identify issues before failures occur Alarms can be set to avoid

14 Retrofit Magnehelic Gauges and Flow Meters The Wireless Magnehelic Reader (WMR) is a version of our Wireless Gauge Reader (WGR) for Magnehelic gauges Analog Magnehelic Gauge Airflow Meter Wireless Magnehelic Reader Wireless Transducer Reader The WMR combined with the Wireless Transducer Reader (WTR) access the data in existing Magnehelic gauges and flow meters The WMR and WTR provide data for central monitoring and alarming of baghouses Trend data helps maintenance teams identify issues before failures occur Alarms can be set to avoid catastrophic failure Historical data can be used to verify compliance making audits faster and easier Integration with existing systems can close control loops for more efficient operations

15 Gas Cylinder Monitoring Peoria, IL ~200 Cylinders Initial installation in 2011 Large site, basement areas Demanding, data driven end-customer Secure IT Environment Long Distances Basement Concrete and Metal walls

Wireless Transducer Reader (Battery Operated) Monitor Vibration

16 Wirelessly Capture Data from Vibration Sensors Wireless Transmission to Blue Box Accelerometers (DC-Response) DC Voltage Signal 0-10V Wireless Transducer Reader (Battery Operated) Monitor Vibration Changes Over a Period of Time (e.g. misalignment, not for high frequency analysis)

Monitoring of Legacy Air Handlers Typical Air Handler Units Most older Air Handler Units (AHU s) are not

BMS/BAS No downtime, no wiring, no leak checks Alarm notification for filter changeout, low air flow Condition-based

17 Monitoring of Legacy Air Handlers Typical Air Handler Units Most older Air Handler Units (AHU s) are not monitored/automated Labor intensive to detect problems, check filters Proper air flow is the critical parameter - but can only be seen via manual dial gauges (e.g. Magnehelics) Solution: Wireless Magnehelic Reader clamps on in minutes and transmits reading wirelessly to BMS/BAS No downtime, no wiring, no leak checks Alarm notification for filter changeout, low air flow Condition-based maintenance, not schedule-based Wireless Magnehelic Reader Monitors Filters and Airflow Wireless Readers Mounts Over Existing Gauges Enables Monitoring of Legacy Air Handlers for 70% Less Than Traditional Transducers

Ensure positive pressure in paint areas Replace air filters at optimal

18 Paint Shop Filter Monitoring Retrofit existing pressure gauges for remote monitoring, trending and alarming. Ensure positive pressure in paint areas Replace air filters at optimal intervals Reduce consumables cost, maintenance labor, and fan energy cost Analog Magnehelic Gauge Wireless Magnehelic Reader

19 Non-Invasive IoT Retrofit Solutions WIRELESS PNEUMATIC THERMOSTAT Go from Pneumatic to DDC in minutes WIRELESS GAUGE READER Remotely Read Gauges in minutes WIRELESS STEAM TRAP MONITOR Avoid Expensive Steam Leaks NETWORK CONTROLLER WIRELESS TRANSDUCER READER Remotely Read Transducers No Wires WIRELESS FREEZER MONITOR Predicts and Avoids Costly Freezer Failure

Wireless Steam Trap Monitor (WSTM) CYPRESS ENVIROSYSTEMS WIRELESS STEAM TRAP MONITOR Traps are a necessary part of the steam distribution system, usually hundreds of units per site 15-20% average

20 Wireless Steam Trap Monitor (WSTM) CYPRESS ENVIROSYSTEMS WIRELESS STEAM TRAP MONITOR Traps are a necessary part of the steam distribution system, usually hundreds of units per site 15-20% average failure rate; leaks steam Failed traps lose $5,000 per year (1/8 orifice) Manual inspection typically done annually labor intensive, do not catch problems in timely manner Solution: Wireless steam trap monitor detects faults and alarms on error, avoiding expensive leak loss Non-invasive installation: no breaking seals, wireless, integrates with BMS Battery life of 3+ years at typical sample rates IP65/NEMA 4 rated for outdoor use Leaking Traps Waste Energy Typical Steam Trap One year payback on investment Save Energy and Time Locating Faulty Steam Traps

21 WSTM Distribution System Applications Thermocouples Allow Remote Mounting of Transmitter Inaccessible Hot Vault traps Standard NEMA 4 Enclosure 25 foot deep cement bunkers Hard to Access Remote Monitoring = $$$ Savings & Eliminates Safety Incidents

22 Wireless Communication Architecture Options: 2.4GHz dedicated wireless network 900MHz LoRA using Plant Distributed Antenna System WSTM WGR WFM Green Box Controller WRE Repeater Built-in Web Page LAN OPC, RESTful API WRE Repeater HMI, Cloud Applications WSTM WGR WRE Repeater WSTM WRE Repeater WTR WGR Industry Standard OPC and RESTful API interfaces for Integration with Cloud and 3rd Party Applications

Non-Invasive IoT Retrofit Solutions WIRELESS PNEUMATIC

GAUGE READER Remotely Read Gauges in minutes WIRELESS STEAM

WIRELESS TRANSDUCER READER Remotely Read Transducers No

23 Non-Invasive IoT Retrofit Solutions WIRELESS PNEUMATIC THERMOSTAT Go from Pneumatic to DDC in minutes WIRELESS GAUGE READER Remotely Read Gauges in minutes WIRELESS STEAM TRAP MONITOR Avoid Expensive Steam Leaks NETWORK CONTROLLER WIRELESS TRANSDUCER READER Remotely Read Transducers No Wires WIRELESS FREEZER MONITOR Predicts and Avoids Costly Freezer Failure

24 Pneumatic Thermostats Waste Energy? Uncomfortable Occupants? No visibility, no BACnet connection to thermostats? Extra maintenance labor?

Non-Invasive Pneumatic to DDC Retrofit EXISTING LEGACY STAT WIRELESS

Manual control, non-communicating No fault detection, no energy savings

BACnet Integration with 3 rd party BAS Automatic Self-calibration

25 Non-Invasive Pneumatic to DDC Retrofit EXISTING LEGACY STAT WIRELESS PNEUMATIC THERMOSTAT DDC in 20 Minutes! Manual control, non-communicating No fault detection, no energy savings strategies Manual Calibration Required Remote Monitoring, Alarming, Control BACnet Integration with 3 rd party BAS Automatic Self-calibration Programmable energy savings, demand response Simply remove existing thermostat from wall, connect WPT, activate wireless interface

26 Sample Users

For Further Information www.cypressenvirosystems.com Harry Sim (California Headquarters) Phone: (408) 307-0922 Email: harry.

27 For Further Information Harry Sim (California Headquarters) Phone: (408) Mike Romanco (Chicago Area) Phone: (630)

28 Ameren Illinois Energy Efficiency Incentives Incentives have never been higher! No-cost/low-cost energy efficiency improvements Compressed air leak survey and repair Variable frequency drive (VFD) installs Lighting upgrades HVAC and water heater replacements Custom projects amerenillinoissavings.com/for-my-business/explore-incentives 28

BUSINESS PROGRAM ENERGY ADVISORS 29 1. Chad Whitehead Chad.Whitehead@gdsassociates.com 309.620.6333 2. Steven Smith Steven.L.Smith@leidos.com 309.212.5831 3. Rod Rhoads Rod.Rhoads@gdsassociates.

29 BUSINESS PROGRAM ENERGY ADVISORS Chad Whitehead Steven Smith Rod Rhoads Mark Steinmetz John Strode Mike Thompson Larry Erwin Ameren Illinois Business Program Energy Advisors Call to request a consultation with an Energy Advisor

Enabling IoT in Existing Plants. Harry Sim, Cypress Envirosystems

Enabling IoT in Existing Plants Harry Sim, Cypress Envirosystems IoT Connect EVERYTHING Industrial Internet of Things (IoT) Nearly two-thirds (77%) of all businesses plan to increase their IoT investments