Connecting The Petrochemical Enterprise

Mobile and wireless technology is rapidly reshaping the industrial world. Within the next ten years, almost every employee will have a mobile device which will be their all-in-one communication tool. It will provide voice communications, messaging, and access to corporate data anytime, anywhere. The handheld device will be able to “talk” directly to equipment and assets in the field. In effect, everything will have a wireless computer attached to it – either something as simple as an RFID tag or as complex as a wireless sensor. And many of these wireless sensors will relay information directly into your back-end systems. Last, but not least, employees will also have smart badges alerting them to hazardous environments and notifying emergency personnel when the employee is in danger. All of the technologies, and the infrastructure to support them, are available today.

Taking Operational Performance to the Next Level

Improve asset uptime:  With a mobile computer in hand, workers can monitor the real-time state of machinery, and proactively address issues before they impact production. And when the asset maintenance function is mobilized, the result is proper and timely scheduling of maintenance, including visibility into what services were performed as well as how they were performed.

Ensure employee safety:  When machinery is well maintained, workers are at less risk. And when workers have an RFID-enabled badge or an intrinsically-safe mobile device with locationing capability, employee whereabouts are always known. You can monitor the evacuation of all personnel from an area in the event of an emergency. And since these solutions allow you to monitor lack of movement as well, you can easily spot a man down even in very remote areas.

Increase workforce productivity: By placing all the functionality of the desk phone, a two-way radio and desktop computer in an easy to carry integrated mobile device, workers can access the information they need to tackle any task, wherever they happen to be. The need to spend time in the office focused on paperwork is practically eliminated. Workers can now access and transmit that information from the field, regardless of whether they are performing routine maintenance or monitoring production volume. And with a real-time connection to business systems, workers on a pipeline can access information that might be required to complete a repair, right at the point of work. The hours per day spent in the office can now be spent out in the field and time on tools is substantially increased.

Reduce cost of compliance:  A myriad of regulations requires the nearly constant collection of a large amount of data.  A mobile computer significantly automates the collection of that data through drop down menus and check boxes as well as the ability to read a bar code, direct part mark or RFID tag.  Data can be instantly transmitted to your business systems.  As a result, data accuracy is improved, up to date reports are available at any point in time, and data is collected in less time, bringing a new level of cost-efficiency to the compliance function.

Overcoming the Challenges of Deploying Wireless Infrastructure

Building the wireless infrastructure to support mobile and wireless applications is the necessary, but often overlooked, first step.  There are a number of reasons for the infrastructure decision being postponed but the most common reason is lack of authority to deploy wireless technology at the plant level.  The push is coming from the plant but the wireless authority and responsibility is generally held centrally by corporate IT.  Compounding the problem is that corporate IT's extensive wireless expertise is typically based on office (or indoor) deployments.  There is less resident experience related to industrial (outdoor) deployments that are much more complex in nature than office deployments.  Environmental considerations, distance requirements, and the breadth and scope of the applications make industrial deployments inherently much more complex than office deployments.

The decision to deploy wireless technology is also affected by concerns around reliability and security.  These concerns are often based on the assumption that the wireless infrastructure will be tied into the control system.  The control systems group is typically involved in the decision to deploy wireless in the plant and has a specific interest in the deployment of wireless sensors.  Senior management concerns about the deterministic ability of wireless systems may result in resistance to control system tie-in.  However, the myriad of other applications enabled by today's wireless technology justify the business case for wireless deployment - even without tie-in to the control system. 

Cost can also be a barrier to deploying wireless infrastructure in an industrial environment and much of the cost can, ironically, be attributed to wires.  Traditional wireless Access Points (APs) have to be wired and, in an industrial facility, wires must often be run in conduit.  Combined with safety requirements, including the possible need for APs with hazardous location ratings, the cost of deployment can often be ten times the cost of the wireless gear itself.  Advances in wireless mesh, point-to-point (PTP), and point-to-multipoint (PMP) technologies have significantly reduced the need for wires which translates directly into a significantly reduced cost of deployment.

Other challenges to deploying wireless technology include complex, multi-path environments; the need for ruggedization; potential fire and explosion hazards; and large, dispersed coverage areas.  These challenges have been addressed by recent developments in wireless technology and products.  Mesh APs have been designed for outdoor deployment and have multiple power options and hazardous location certifications.  New planning tools and the new 802.11n wireless standard mitigate the impact of multi-path environments.  The combination of mesh, PTP, and PMP technologies provides the coverage where you need it.

The technology barriers to deploying wireless technology in a difficult, industrial environment have been overcome and the cost of deployment has been significantly reduced.  But it is still not a simple undertaking.  The keys to successful deployment include understanding your technology options, taking a systems approach, and using the right planning tools.

"Process control and maintenance systems for improving operational efficiency and asset performance have been in place for many years.  What's been missing is the ability to connect these legacy systems with your mobile workforce.  It's not about replacing these systems - it's about allowing people and systems to communicate."

            - Jim Hanson, Motorola

            Energy Industry Director