IoT in the Valve and Actuator Industry

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1 IoT in the Valve and Actuator Industry 3rd March 2017 Presented by: Mike Devrell Image source: Adapted from original by Wilgengebroed

2 Agenda What is the Internet of Things (IoT)? The Internet of Things is not about things! 6 Technology Buzzwords Smart Asset Management Improving Site Performance Existing Technology in the Valve Industry What might we see in the future? Security and Implementation Challenges 1

3 What is the Internet of Things (IoT)? The world will have 21 billion connected devices by 2020, predicted by Gartner. Isn t IoT just connecting things to the Internet? For the consumer this may be their air conditioning, fridge, toaster, mirror 2

4 What is the Internet of Things (IoT)? In 2010 Ericsson s former CEO Hans Vestburg predicted 50 billion connected devices by 2020 In 2011 Cisco also predicted 50 billion by 2020 In 2012 IBM predicted 1 trillion connected devices (The world s population is 7.5 billion people, so 133 devices each!?) Where are we now? In 2016 we had: Gartner: 6.4 billion International Data Corporation: 9 billion HIS: 18 billion, including smart phones and tablets These early predictions generated a lot of investment 3

5 The Internet of Things is not about Things! Where are my 1 trillion devices? The majority will be consumer devices, but IoT technology has a growing adoption in industry too IoT is not about things, or even the internet, it s about data Specifically real-time data, combining multiple data sources together to make smart, timely decisions that save money, save time, increase safety and improve performance 4

6 The Internet of Things is not about Things! 5

7 The Internet of Things is not about Things! 6

8 The Internet of Things is not about Things! Moved into the IoT world in 2012 when Belkin s WeMo was integrated. If This Then That 7

using software applications to make smart, timely and data-driven decisions Virtualisation Creation of a virtual resources such

9 Technology Buzzwords Smart Factory / Industry 4.0 / Industrial IoT All terms for the same thing: A merger of IT and manufacturing; interconnected and intelligent machines using software applications to make smart, timely and data-driven decisions Virtualisation Creation of a virtual resources such as an operating system, a server, a storage device or network Similar to partitioning a physical hard drive into two virtual drives for better organization, but scaled up Allows scalability and resource sharing 8

is inadequate Volume, Variety, Velocity, Variability of data Often related predictive analytics to extract value from data Example:

10 Technology Buzzwords Data Fusion Combining diverse data sets from multiple sources with different sample rates to give a new data set Example: Sea temperature, weather patterns, fish geo location Big Data Data sets so large or complex that traditional data processing is inadequate Volume, Variety, Velocity, Variability of data Often related predictive analytics to extract value from data Example: ebay uses 7.5PB and 40PB data warehouses for search, consumer recommendations and merchandising Already old, real-time data is the new thing! 9

bundle of hardware and software inside a single box Hyperconvergence means the integration is so tight, it cannot be broken down

11 Technology Buzzwords Hyperconvergence An architecture that tightly integrates storage, computing, networking and virtualization in a commodity hardware box all in one place The terms has come from converged infrastructure the idea of a pre-configured bundle of hardware and software inside a single box Hyperconvergence means the integration is so tight, it cannot be broken down in to individual components All system parts managed though a single toolset Augmented Reality Virtual reality meets actual reality 10

Smart Asset Management IoT in industry has most value in improving asset management Several sources define Asset Management as the "coordinated

12 Smart Asset Management IoT in industry has most value in improving asset management Several sources define Asset Management as the "coordinated activity of an organisation to realise value from assets The art and science of making the right decisions and optimising the delivery of value 11

13 Smart Asset Management ISO Set of 3 standards (from BSI PAS 55:2008) 12

14 Smart Asset Management Image source: ISO

15 Improving Site Performance Devices are getting smarter The data is not always used IIoT helps to gather data 14

16 Improving Site Performance Why doesn t existing device data get used? Difficult to collect Legacy fieldbus and control systems Hazardous areas: FM, IECEx, ATEX, CSA, etc. Confined spaces Environmental challenges Cost of tools and software Different methods for different equipment System required to record data Time consuming with little perceived business benefit 15

17 Improving Site Performance Operational Stability IIoT based Asset Management system installed 16

18 Existing Technology in the Valve Industry Netbiter is small module that allows remote access Connects to equipment using Ethernet Modbus (RS485 and 232) Digital & Analogue I/O Ethernet or 3G connection to the internet It has GPS location good for mobile fleet use ~ $440 for Ethernet only ~ $750 for Ethernet & 3G 17

19 Existing Technology in the Valve Industry Image source: Modified from HMS 18

20 Existing Technology in the Valve Industry Remote monitoring Remote control Logging Usage Alarms Produces graphs that can help customers better understand their process 19

21 Existing Technology in the Valve Industry Use Cases Can be added to a wide variety of existing equipment Useful for small sites, even down to 1 pump or tank Remote monitoring Leek, fault and theft protection Example - License requirement to obtain consent to store antifreeze rather than food products 20

22 Existing Technology in the Valve Industry Pipeline valve diagnostics Pump starts 21

5x safety factor Effect of starting pump was

23 Existing Technology in the Valve Industry Actuator rated torque was above calculated required value including 1.5x safety factor Effect of starting pump was underestimated, able to control pump using VFD to prevent tripping 22

24 Existing Technology in the Valve Industry Gearbox diagnostics 23

25 Existing Technology in the Valve Industry 24

26 Existing Technology in the Valve Industry 25

27 Existing Technology in the Valve Industry 26

28 Existing Technology in the Valve Industry 27

29 Existing Technology in the Valve Industry Actuator ejection 28

to process large data sets manually Requires specialist knowledge Automated

30 Existing Technology in the Valve Industry We have increasingly smart devices We can use IIoT to gather this data Data analysis is the next key step Difficult to process large data sets manually Requires specialist knowledge Automated analysis is required Simple rule based analysis Big data / machine learning models 29

31 Existing Technology in the Valve Industry 30

32 What might we see in the future? Increased device intelligence more sensors More connected devices, more data, easier connection Data collection and analysis across sites, countries and processes Nomura say this could make oil and gas companies more profitable at $70pb than they were previously at $100pb McKinsey say the effective use of IIoT could reduce capital expenditures by up to 20 percent Processes and oil fields that are not viable today could be brought back into play Wireless may have a large role however standardisation required! 31

coverage & use Frequencies: 900/1800/1900/2100MHz Fast data rates: 35-170kps (GPRS)

33 What might we see in the future? GPRS / 3G / 4G Good coverage Good range: 35km max for GSM 200km max for HSPA Worldwide coverage & use Frequencies: 900/1800/1900/2100MHz Fast data rates: kps (GPRS) 384Kbps-3Mbps (3G), 3-20Mbps (LTE) Power consumption relatively high Suitable for main link to the internet, not idea for individual sensors 32

What might we see in the future? WiFi Well known technology Based on 802.

4/5GHz Short range: Approximately 50m Data rates: Upto 1Gbps, 150-200Mbps is more

34 What might we see in the future? WiFi Well known technology Based on n/ac standard Frequencies: 2.4/5GHz Short range: Approximately 50m Data rates: Upto 1Gbps, Mbps is more typical Worldwide coverage & use High data throughput, but short range and high power requirements Suitable for manufacturing environments, less so for oilfields 33

What might we see in the future? Zigbee Large industrial installed base ZigBee 3.0 based on IEEE 802.15.4 Frequency: 2.

35 What might we see in the future? Zigbee Large industrial installed base ZigBee 3.0 based on IEEE Frequency: 2.4GHz Short range: 10m 100m Data rates: 250 kbps Low power operation, high security, robustness and high scalability Ideal for battery powered sensors requiring relatively infrequent data exchanges at low data rates 5 year battery life possible 34

36 What might we see in the future? Z-Wave Primarily home automation use Z-Wave Alliance ZAD12837 / ITU-T G.9959 Frequency: 900MHz Short range: 30m Data rates: 9.6 / 40 / 100 kbps Avoids busy 2.4GHz range Optimised for reliable low-latency communication of small data packets 35

37 What might we see in the future? LoRaWAN Designed for IoT applications Long range: 2 15km Data rates: kbps Avoids busy 2.4GHz range Designed to provide low cost, low power consumption, mobile, secure, bi-directional communication Ideal for sensor networks reporting small amounts of data Large networks with millions of devices supported 36

What might we see in the future? Sigfox Primarily home automation use Long range: 3 50km Frequency: 900MHz Data rates: 0.

38 What might we see in the future? Sigfox Primarily home automation use Long range: 3 50km Frequency: 900MHz Data rates: kbps Extremely low power, 10+ year battery life possible Robust and scalable Idea for large networks supporting millions of devices Currently being rolled out in cities across Europe, including ten cities in the UK 37

39 Security and Implementation Challenges Acceptance is a challenge Some customers are actively connecting their sites to internet based services Large companies saying wireless communication will become more secure than wired Wireless protocols are generally recent with high levels of security Wired networks such as Modbus, Profibus have no security Once you have broken into a wired network, you have full control Many customers are saying no way 38

40 Security and Implementation Challenges Security is extremely important Consequences of an attack could range from industrial espionage, DoS, ransomware and causing process, environmental or physical loss or damage Security cannot be added, must be built in from design stage Examples Electricity Smart Meters venerable to attack Not allowed to name manufacturer! Meters used same encryption key for all devices Weak encryption Default, weak passwords 39

41 Security and Implementation Challenges Examples 2015 Chrysler recall of 1.4 million vehicles Stuxnet, specific targeting of industrial control systems Code is now in the wild Global Ping In 2013 the entire Internet was pinged by a single operator Revealing about 114,000 manufacturing control systems vulnerable for attack About 13,000 could be accessed without inputting a single password 40

42 Security and Implementation Challenges Solutions Secure design, don t assume an attack won t be attempted Turn on security Use certificates Use strong passwords Solution appropriate for use case Data Diodes to securely export process data Laser transmitter and optical receiver 41

Security and Implementation Challenges There can be risks associated with connecting a site to the internet There are also risk associated with

43 Security and Implementation Challenges There can be risks associated with connecting a site to the internet There are also risk associated with not connecting and missing the valuable data that may predict a failure, leak, malfunction, etc The risks associated with each need to be balanced 42

44 Thank you! Brassmill Lane Bath BA1 3JQ UK T: E: E:

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