Stephan Neuburger Future Trends in Field Instrumentation for the Process Industry MCAA Industry Forum Keynote

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Stephan Neuburger 2017-04-24 Future Trends in Field

1 Stephan Neuburger Future Trends in Field Instrumentation for the Process Industry MCAA Industry Forum Keynote

2 1.Introduction KROHNE 2. Field instrumentation today 3. New requirements 4. Future trends and technologies 5. Summary Future Trends in Field Instrumentation for the Process Industry Agenda

KROHNE Group Stephan Neuburger since 1999 CEO KROHNE Group 1995 1999 Member of Executive Board 1993 1995

International Service Associate 1985 1986 Trainee Since 2003: Board Member of the German Electrical and Electronics

3 KROHNE Group Stephan Neuburger since 1999 CEO KROHNE Group Member of Executive Board International Sales Director Export Director Regional Sales/Export Manager International Service Associate Trainee Since 2003: Board Member of the German Electrical and Electronics Manufacturers' Association (ZVEI) in the field of Measuring Technology and Process Automation Future Trends in Field Instrumentation

KROHNE Group Facts and figures Supplier of innovative products, solutions and services for the process industry Founded 1921 in Duisburg, Germany 100 % family-owned 2015 turnover: USD 543 mio. (incl.

4 KROHNE Group Facts and figures Supplier of innovative products, solutions and services for the process industry Founded 1921 in Duisburg, Germany 100 % family-owned 2015 turnover: USD 543 mio. (incl. Joint Ventures) 3,691 employees > 350 Employees in R&D 16 production facilities in 12 countries 45 KROHNE companies and joint ventures 55 representatives Future Trends in Field Instrumentation

5 KROHNE Group Turnover in mio USD Including Joint Ventures Future Trends in Field Instrumentation

6 KROHNE Group Clients, mission and vision Our Mission: We offer the right solutions for our clients process measurement applications around the world. Global Contracts & Private Label Partners: We achieve this through innovative and high-quality products and services qualified and competent employees long-term and reliable partnerships with our clients and partners Future Trends in Field Instrumentation

7 KROHNE Group Industries Chemical and Petrochemical Food and Beverage Water and Wastewater Oil and Gas Marine Power Paper Iron, Steel, Metal Pharmaceuticals Future Trends in Field Instrumentation

8 KROHNE Group Worldwide presence: Local business, local people KROHNE production and sales companies KROHNE sales companies Future Trends in Field Instrumentation

KROHNE Group Global accounts We have aligned our organisation according to the needs of our global clients: Global client = ONE client: consistent scope, consistent service, consistent pricing,

9 KROHNE Group Global accounts We have aligned our organisation according to the needs of our global clients: Global client = ONE client: consistent scope, consistent service, consistent pricing, worldwide Industry/application-specific products and solutions Consistent, standardized global project management Key-Account managers have direct access to our corporate management Fast implementation of customer requirements through R&D Future Trends in Field Instrumentation

10 KROHNE Group Production sites KROHNE Messtechnik GmbH Duisburg, Germany KROHNE Pressure Solutions GmbH Minden, Germany KROHNE Ltd. Wellingborough, UK KROHNE INOR Process AB Malmö, Sweden KROHNE Altometer Dordrecht, The Netherlands KROHNE S.A.S. Romans-sur-Isère, France KROHNE Oil & Gas Breda, The Netherlands KROHNE Marine Brevik, Norway Future Trends in Field Instrumentation

11 KROHNE Group Production sites CRK Chengde, China KMTS Shanghai, China SGAIC Shanghai, China KROHNE Conaut Embu, Brasil KROHNE Oil & Gas Malaysia Kuala Lumpur, Malaysia KROHNE Marshall Ltd. Pune, India KROHNE Engineering Ltd. Samara, Russia KROHNE Inc. Beverly, MA, USA Future Trends in Field Instrumentation

Peabody, MA NAFTA-wide sales and support network Oil&Gas

12 KROHNE Group US operations: KROHNE, Inc. Established in 1979 Head office and service located in Peabody, MA NAFTA-wide sales and support network Oil&Gas Division office in Houston, TX Future Trends in Field Instrumentation

13 KROHNE Group US operations: KROHNE, Inc. KROHNE is becoming a large local producer New facilities in Beverly, MA (nearby Peabody and Boston-Logan Airport) 90,000 sq ft office and production facility under construction Total investment USD 25 mio Opening end of 2017 Clear commitment to NAFTA clients, partners and staff Staff expanded to >100 employees We are ready to grow: we rely on the trust of our clients in our products, solutions and services! Future Trends in Field Instrumentation

14 1. Introduction KROHNE 2.Field instrumentation today 3. New requirements 4. Future trends and technologies 5. Summary Future Trends in Field Instrumentation for the Process Industry Agenda

15 Field instrumentation today Expectations towards an instrumentation partner for the process industry Large portfolios AND master all technologies in depth Process parameters AND substance composition, inline AND online Reliable performance under difficult process and environmental conditions System solutions Services beyond the plain measured value Future Trends in Field Instrumentation

16 The concept in field instrumentation Flow, Level, Pressure, Temperature + Analysis Complete product portfolio spanning over all measurement principles and applications For liquids, gases, steam; from single- to multi-phase flows Process safety and process optimisation, e.g. through build-in diagnostic functions Industry-specific solutions and services for the entire product life cycle Future Trends in Field Instrumentation

17 The concept in field instrumentation Flow, Level, Pressure, Temperature + Analysis Complete portfolio of level transmitters and switches for liquids, pastes and solids Large choice of wetted materials Standard devices also for demanding applications, e.g. - changing media in reactors at high/low process temperatures - low-reflective, abrasive solids in dusty environments Future Trends in Field Instrumentation

18 The concept in field instrumentation Flow, Level, Pressure, Temperature + Analysis Complete portfolio for measurement of differential, process and hydrostatic pressure Application-specific transmitters, primary elements, diaphragm seals and accessories Reliable, robust and cost-effective measuring points Future Trends in Field Instrumentation

19 The concept in field instrumentation Flow, Level, Pressure, Temperature + Analysis Wide range of temperature assemblies and transmitters, configurations, materials and connections Standard and special designs for solids, liquids and gases For applications with high or cryogenic temperatures, high pressures, and special thermowells for high flow rates Future Trends in Field Instrumentation

20 The concept in field instrumentation Flow, Level, Pressure, Temperature + Analysis Reliable analysis of liquids under harsh conditions Extensive portfolio of analytic sensors, also with integrated transmitter technology Complete measuring systems, assemblies and accessories From hygienic to Ex applications Future Trends in Field Instrumentation

System solutions Metering systems / LACT units Custody transfer loading system for rapeseed oil Full scope of delivery: gas separator, control valve, mass flow meter,

21 System solutions Metering systems / LACT units Custody transfer loading system for rapeseed oil Full scope of delivery: gas separator, control valve, mass flow meter, piping, dosing control system Custody-transfer-relevant project management Commissioning, training and documentation Future Trends in Field Instrumentation

custody-transfer flowmeters, actuators, etc.

22 Sytem solutions Metering systems / LACT units Turnkey, skid-based-measuring system Including mixer, analyser house, custody-transfer flowmeters, actuators, etc. Integration of measured data in customer's ERP system Future Trends in Field Instrumentation

23 System solutions Pipeline leak detection and localization system Adapts to existing pipeline flow, pressure and temperature instrumentation KROHNE engineers create mathematical model of this specific pipeline, covering all operational statuses based on application knowledge Measured data of inline sensors is continuously compared with the mathematical model Software interprets the deviation based on pattern recognition as true leak or as safe Can integrate into DCS/PLC or operate as standalone system Zero false alarms Future Trends in Field Instrumentation

24 KROHNE Group Services From engineering and planning to commissioning, training and documentation Complete project management - e.g. for metrological accreditation of custody transfer applications All services can be offered local, up to on-site premises Global product and aftersales service network Future Trends in Field Instrumentation

KROHNE Group Core competence calibration Every instrument is

performance KROHNE operates over 140 calibration rigs for -

Pressure Accuracies traceable to (inter)national metrology

most accurate flow calibration rigs up to 120" Kalibrierstand

25 KROHNE Group Core competence calibration Every instrument is wet calibrated to guarantee maximum accuracy, quality and performance KROHNE operates over 140 calibration rigs for - Volume Flow - Mass flow - Level - Temperature - Density - Pressure Accuracies traceable to (inter)national metrology standards Kalibrierstand KROHNE Altometer World`s largest and most accurate flow calibration rigs up to 120" Kalibrierstand Kalibrierturm KROHNE Altometer Future Trends in Field Instrumentation

26 1. Introduction KROHNE 2. Field instrumentation today 3.New requirements 4. Future trends and technologies 5. Summary Future Trends in Field Instrumentation for the Process Industry Agenda

27 New requirements for field instrumentation Basic principles of plant operation Safety Availability Flexibility Efficiency Future Trends in Field Instrumentation

28 New requirements for field instrumentation Basic principles of plant operation: related requirements Safety Availability Flexibility Efficiency Simplify safety concepts SIL/non-SIL in one device Diagnostics and predictive maintenance Standard devices Wide application range Integrate communication technologies IoT ready Match plant lifecycle concepts: Seamless integration of measurement devices Future Trends in Field Instrumentation

29 New requirements for field instrumentation Basic principles of plant operation: related requirements Safety Availability Flexibility Efficiency Simplify safety concepts SIL/non-SIL in one device Diagnostics and predictive maintenance Access to additional data and trends in processes Access to additional product properties Information on various phases and transition states Standard devices Wide application range Integrate communication technologies IoT ready Additional requirements from our clients Match plant lifecycle concepts: Seamless integration of measurement devices Conclusion: more and additional information out of the field is required to be able to optimize processes Future Trends in Field Instrumentation

30 1. Introduction KROHNE 2. Field instrumentation today 3. New requirements 4.Future trends and technologies 1. Network Architectures 2. Enlarged functionalities of instrumentation 3. Innovative enabling technologies and their potentials 5. Summary Future Trends in Field Instrumentation for the Process Industry Agenda

31 1. Introduction KROHNE 2. Field instrumentation today 3. New requirements 4. Future trends and technologies 1. Network Architectures 2. Enlarged functionalities of instrumentation 3. Innovative enabling technologies and their potentials 5. Summary Future Trends in Field Instrumentation for the Process Industry Agenda

Network Architectures Establish uniform and open standards: NAMUR Open Architecture (NOA)

an open architecture framework for process plant automation Includes all levels of the

implementation of new requirements, e.g.

32 Network Architectures Establish uniform and open standards: NAMUR Open Architecture (NOA) NAMUR is a large User Association of Automation Technology in Process Industries NOA is an open architecture framework for process plant automation Includes all levels of the automation pyramid Main objective: Expand existing automation structures for a flexible implementation of new requirements, e.g. IoT without compromising basic principles of plant operation, e.g. safety, availability, Future Trends in Field Instrumentation

33 Network Architectures Establish uniform and open standards: NAMUR Open Architecture (NOA) Central Monitoring + Optimization Applications and services related to both process and enterprise Production Network Simulation Historic Trends Top level Scheduling Reliability/Optimisation Center Further IoT/4.0 Use Cases e.g. energy efficiency, environmental protection Conclusion: M+O must not affect plant availability and must not interfere with regular automation tasks Core Process Control DCS/PLC 4 20mA, Fieldbus, etc. Remote I/O Level Sensor Flow Sensor Plant Specific Monitoring + Optimization Applications and services close to process; e.g. Advanced Process Control IoT/4.0 Out (additional low-cost) Analysis Sensor But: How to get data from the field into the control infrastructure without effecting the core process? Production Plant Future Trends in Field Instrumentation

Network Architectures Establish additional communication channel to handle

standard - safe - but slow and expensive Second channel (e.g.

networks - Access for value added services - First demonstrator available Data

34 Network Architectures Establish additional communication channel to handle large amounts of data from field Point-to-point wiring (first channel) is standard - safe - but slow and expensive Second channel (e.g. wireless) offers new possibilities - Fast communication - Decentralised sensor networks - Access for value added services - First demonstrator available Data can be clustered for context-sensitive perspectives Future Trends in Field Instrumentation

35 1. Introduction KROHNE 2. Field instrumentation today 3. New requirements 4. Future trends and technologies 1. Network Architectures 2. Enlarged functionalities of instrumentation 3. Innovative enabling technologies and their potentials 5. Summary Future Trends in Field Instrumentation for the Process Industry Agenda

36 Enlarged functionalities of instrumentation Step 1: Smart sensors Process instrumentation will be the primary supplier and information hub for measured values and process diagnostic data. To fulfill this role, they need to be smart. They must be able: To intelligently connect with population (instrumentation) To collect and assess information on product properties and on the various phases and transition states of a process To compare measured data with a mathematical model of this application To provide selected information packages to different stakeholders The sensors of tomorrow will provide diagnoses; they will recognise information and network with each other intelligently, and draw the right conclusions Future Trends in Field Instrumentation

Enlarged functionalities of instrumentation Step 2: Instrumentation & control module The instrumentation & control module is an intelligent combination of sensors, actuators, and process analytics

37 Enlarged functionalities of instrumentation Step 2: Instrumentation & control module The instrumentation & control module is an intelligent combination of sensors, actuators, and process analytics integrates smart sensors represents a modular, decentralized intelligence To be more specific, it is a combination of: an interconnected system of physical and soft sensors Application-specific instrumentation, including mathematical model of the application miniaturized system solution Future Trends in Field Instrumentation

of beer intensity of the hops alcohol content fizziness color size and shape of the bottle and

38 Enlarged functionalities of instrumentation Instrumentation & control module: IoT case study personalized beverage IoT situation: When ordering individual beer online, you can choose: type of beer intensity of the hops alcohol content fizziness color size and shape of the bottle and have this information printed on personalized label Future Trends in Field Instrumentation

39 Enlarged functionalities of instrumentation Instrumentation & control module: IoT case study personalized beverage Today situation: Filling process is a control loop: measuring device (flow meter) and valve are individually connected to PCS Our challenge: How to ensure profitable, efficient production and consistent product quality with customized beverage products in small quantities? A possible solution: Instrumentation & control module for automatic filling and quality control of each bottle: the smart filling head Future Trends in Field Instrumentation

Integrate control loop into measuring device - PCS sends information how much beer should be filled - Flow meter

turbidity or alcohol content to ensure production according to specs 3.

40 Enlarged functionalities of instrumentation Instrumentation & control module: IoT case study personalized beverage Smart filling head in 4 steps: 1. Integrate control loop into measuring device - PCS sends information how much beer should be filled - Flow meter opens and closes valve independently 2. Add inline analyzer - measure e.g. turbidity or alcohol content to ensure production according to specs 3. Add ERP connection - Automated stock management - Automatically send (WhatsApp-)message to customer with delivery date and analysis report 4. Integrate all functionalities into a single device - Traceable "fingerprint" of each bottle Future Trends in Field Instrumentation

41 1. Introduction KROHNE 2. Field instrumentation today 3. New requirements 4. Future trends and technologies 1. Network Architectures 2. Enlarged functionalities of instrumentation 3. Innovative enabling technologies and their potentials 5. Summary Future Trends in Field Instrumentation for the Process Industry Agenda

Enabling technologies and their potentials Entrained Gas Management for Coriolis mass flow meters Process diagnostic: reliable detection and indication of air or gas entrainments / 2-phase flows

42 Enabling technologies and their potentials Entrained Gas Management for Coriolis mass flow meters Process diagnostic: reliable detection and indication of air or gas entrainments / 2-phase flows Continuous measurement even through complete transition from pure liquid phase to a gas phase and back (full-empty-full) Considerable improvements with: - Plant start-up and shut-down - Air-containing products - Troubleshooting in the process Future Trends in Field Instrumentation

Enabling technologies and their potentials Magnetic resonance multiphase flow meter Substance-specific flow meter Developed in cooperation with US institutes: - Shell International Exploration and

43 Enabling technologies and their potentials Magnetic resonance multiphase flow meter Substance-specific flow meter Developed in cooperation with US institutes: - Shell International Exploration and Production group, Houston - Southwest Research Institute (SwRI), San Antonio Already available for oil&gas industry: - simultaneous inline measurement of oil, gas and water in upstream applications - fully automated inline fluid characterization Future Trends in Field Instrumentation

$Enabling technologies and their potentials Magnetic resonance multiphase flow meter: measuring principle in a nutshell How to measure oil and water fractions (gas and solid fractions excluded): Oil$

44 Enabling technologies and their potentials Magnetic resonance multiphase flow meter: measuring principle in a nutshell How to measure oil and water fractions (gas and solid fractions excluded): Oil and water contain bound hydrogen Flow mixture is magnetised with permanent magnetic field Oil-bound hydrogen magnetises faster than waterbound hydrogen Therefore, oil is more strongly magnetised than water when leaving the magnetic field Substance-specific magnetisation can be read out using high frequency signals Future Trends in Field Instrumentation

Enabling technologies and their potentials Pipeline leak detection and localization system This intelligent combination of Physical sensors Soft sensors

45 Enabling technologies and their potentials Pipeline leak detection and localization system This intelligent combination of Physical sensors Soft sensors Mathematical models of process control Application knowledge can be integrated into sensors in whole or in part Future Trends in Field Instrumentation

R&D projects: - Micro flame ionisation detector (µfid) - Micro mass spectrometer (µms) Tomographic methods monitor dynamic

46 Enabling technologies and their potentials How to get more information on substance composition, transition states, etc.? Move the laboratory into the field Microsystem technology manufacture analysers cheaper and smaller in size current KROHNE R&D projects: - Micro flame ionisation detector (µfid) - Micro mass spectrometer (µms) Tomographic methods monitor dynamic processes almost real-time current KROHNE R&D projects: - Impedance tomography Future Trends in Field Instrumentation

47 Enabling technologies and their potentials R&D project: Micro flame ionisation detector (µfid) Create microsystem to be integrated in field device Detect organic substances in ppm range Applications: - Quality monitoring - Leak monitoring, e.g. detect hairline cracks in heat exchangers Future Trends in Field Instrumentation

Enabling technologies and their potentials R&D project: µfid measuring principle in a nutshell Use hydrogen (blue) and oxygen (green) for combustion process Ignite pure hydrogen flame between two

48 Enabling technologies and their potentials R&D project: µfid measuring principle in a nutshell Use hydrogen (blue) and oxygen (green) for combustion process Ignite pure hydrogen flame between two electrodes: - flame has no conductivity (no ions are emitted) - no current flows when electrical voltage is applied Now introduce sample (red) into the hydrogen: very small current flowing between electrodes The current is a direct measurement of the organic carbon concentration in the sample Future Trends in Field Instrumentation

49 1. Introduction KROHNE 2. Field instrumentation today 3. New requirements 4. Future trends and technologies 5.Summary Future Trends in Field Instrumentation for the Process Industry Agenda

Future Trends in Field Instrumentation for the Process Industry Summary KROHNE is a global company with complete instrumentation portfolio, application-specific system solutions, complementary

50 Future Trends in Field Instrumentation for the Process Industry Summary KROHNE is a global company with complete instrumentation portfolio, application-specific system solutions, complementary services We actively push innovative technologies without compromising basic principles As IoT arrives in process industry, it requires uniform open standards, new architectures and smart field instrumentation Smart measuring modules will determine the process automation of the future and generate additional benefit Driven by deep customer partnerships we are evolving from being a pure hardware manufacturer to a measuring services provider KROHNE is your partner for the future! Future Trends in Field Instrumentation

51 Thank you very much for your attention!

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