Smart structures: Emerson plant studies support use of wireless in capital projects

Emerson Process Management has unveiled quantified results and other findings of two independent real-world greenfield projects that recommend wireless infrastructure be a key component of all new projects.

02/04/2009



Emerson Process Management has unveiled quantified results and other findings of two independent real-world greenfield projects that recommend wireless infrastructure be a key component of all new projects.

In one use case, JDI Contracts applied Smart Wireless technology to applications in a new process plant for a major U.S. chemical manufacturer; in the other, Emerson modeled a hydrotreater capital project. Economics, efficiency, and other advantages made the case for wireless with both JDI and Emerson.

“Our recommendations regarding‘best practices’ are firmly centered around procedures and technology required to meet owner objectives and deliver expected project outcomes to our clients, including scope, schedule, budget, and less tangible outcomes such as maintainability and ease of use,” comments Roger Hoyum,principal engineer, JDI Contracts. “With wireless technology, we can deliver a better plant.”

JDI worked with a major EPC and end user to study the project impact of wireless. They compared engineering, construction, start-up, and overhead costs for approaches using wired HART, wired bus technologies, WirelessHART, and combinations of each. Wireless was used for non-safety, low speed control and monitoring—amounting to about 25 percent of the total points.

With each paradigm shift—wireless being the latest—plants realized savings and became smarter through simpler engineering and construction, flexible start-up, faster deployment, project completion, and changing automation needs. For the use of Smart Wireless on 25 percent of points, overall plant engineering, construction, and start-up savings were about 10 percent of considered costs as compared with wired HART; for the bus installation, wireless savings were on a par with wired busing. Although not quantified, other considerations of flexibility and schedule impact were deemed very important in each approach.

“Wireless is an important new tool for use with HART and FOUNDATION Fieldbus in capital projects,” concludes Hoyum. “It delivers savings, flexibility, and speed of implementation.”

In its own study, Emerson used real data from a near-6,000 point greenfield hydrotreater project. Wireless was applied to 44 percent of all points. Similar to the JDI study, Smart Wireless showed significant savings of 36 percent in automation and installation as compared with a completely wired HART solution; FOUNDATION fieldbus was slightly less expensive than WirelessHART due to use of high density temperature measurement, although as mentioned, wireless combines its relative low cost with the advantages of ease of use for difficult monitoring locations, flexibility and future growth.

In combination with its extensive experience in hundreds of wireless brownfield installations, Emerson's conclusions from the greenfield project studies are that Smart Wireless gives maximum cost advantage where installations are difficult, remote monitoring is required, and auxiliary systems are involved. Wireless eliminates the need for and cost of building in spare I/O capacity. Wireless devices are greatly flexible when it comes to making changes late in a project, and for temporary installations for start-up and troubleshooting. And, it’s very easy to add incremental wireless points compared to wired bus points. Training and engineering are simplified with the inherently easy wireless technology. And wireless delivers larger, long-term operational benefits due to its easy, low cost expandability.

“Our takeaway from these studies is that all three technologies—HART, FOUNDATION fieldbus and wireless—should be in the design toolbox for capital projects,” summarizes Peter Zornio, chief strategic officer of Emerson Process Management. “The studies confirm that FOUNDATION fieldbus continues to offer the lowest cost installation for process control points. For monitoring points, both FOUNDATION fieldbus and wireless offer good alternatives and similar installation savings. However, over the plant life cycle, wireless adds significant benefits with simplified training, flexibility and allows very easy and lowest cost incremental expansion.”









No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2013 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
The true cost of lubrication: Three keys to consider when evaluating oils; Plant Engineering Lubrication Guide; 11 ways to protect bearing assets; Is lubrication part of your KPIs?
Contract maintenance: 5 ways to keep things humming while keeping an eye on costs; Pneumatic systems; Energy monitoring; The sixth 'S' is safety
Transport your data: Supply chain information critical to operational excellence; High-voltage faults; Portable cooling; Safety automation isn't automatic
Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Plant Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.

Maintaining low data center PUE; Using eco mode in UPS systems; Commissioning electrical and power systems; Exploring dc power distribution alternatives
Synchronizing industrial Ethernet networks; Selecting protocol conversion gateways; Integrating HMIs with PLCs and PACs
Why manufacturers need to see energy in a different light: Current approaches to energy management yield quick savings, but leave plant managers searching for ways of improving on those early gains.

Annual Salary Survey

Participate in the 2013 Salary Survey

In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.

Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.

2012 Salary Survey Analysis

2012 Salary Survey Results

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.