IoT in the Valve and

Actuator Industry
3rd March 2017

Presented by:
Mike Devrell

Image source: Adapted from original by Wilgengebroed

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
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
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
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
The Internet of Things is not about Things!

5
The Internet of Things is not about Things!

6
The Internet of Things is not about Things!

If This Then That

• Moved into the IoT

world in 2012 when
Belkin’s WeMo was
integrated.

7
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
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
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 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
Smart Asset Management

• ISO 55000 - Set of 3 standards (from BSI PAS 55:2008)

12
 Smart Asset Management

Image source: ISO 55000

13
Improving Site Performance

• Devices are getting smarter

• The data is not always used
• IIoT helps to gather data

14
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
 Improving Site Performance

Operational
Stability

IIoT based Asset Management system installed

16
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
Existing Technology in the Valve Industry

Image source: Modified from HMS

18
Existing Technology in the Valve Industry

• Remote monitoring
• Remote control
• Logging
• Usage
• Alarms
• Produces graphs that
can help customers
better understand their
process

19
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 anti-

freeze rather than food products

20
Existing Technology in the Valve Industry

Pipeline valve diagnostics

Pump starts

21
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
Existing Technology in the Valve Industry

Gearbox diagnostics

23
Existing Technology in the Valve Industry

24
Existing Technology in the Valve Industry

25
Existing Technology in the Valve Industry

26
Existing Technology in the Valve Industry

27
Existing Technology in the Valve Industry

Actuator ejection

28
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
Existing Technology in the Valve Industry

30
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
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: 35-170kps (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 802.11n/ac standard
• Frequencies: 2.4/5GHz
• Short range: Approximately 50m
• Data rates: Upto 1Gbps, 150-200Mbps 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: 2.4GHz
• 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
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
What might we see in the future?

LoRaWAN
• Designed for IoT applications
• Long range: 2 – 15km
• Data rates: 0.3-50 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: 0.01-1 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
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
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
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
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 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
 Thank you!
Brassmill Lane
Bath
BA1 3JQ
UK

T: +44 1225 733200

E: mail@rotork.com
E: mike.devrell@rotork.com
www.rotork.com