Wireless asset monitoring gets IIoT ducks in a row

One famous “be careful what you wish for” scenario is wishing for more network connections and data. That’s because wishers can quickly drown in floods of information and tangled links that impede intelligence. To tame this firehose, Emerson has developed and launched its wireless, Industrial Internet of Things (IIoT), asset monitoring platform that helps digitalize inspection points, reduce manual tasks and improve operational decision-making.  

Of course, the flipside is the age-old problem of having too little information, and Emerson Synchros platform can help there, too. Emerson reports that tracking and maintaining assets still frequently depends on scheduled, manual rounds, especially in hazardous areas, which often creates gaps where developing issues go undetected. The platform applies continuous monitoring, lets operations and maintenance teams digitalize inspections, and extends user visibility with flexible, wireless architectures built on WirelessHART protocol.

“As always, users want agile measurement and high-accuracy monitoring for critical control of processes that need to respond in minutes or seconds,” says Ryan Lindsey, senior IIoT platform manager for Synchros at Emerson. “They traditionally used transmitters separately, but now Synchros can create a cohesive network, so groups of wireless process monitors and other devices can join a local IIoT network, which lets users know if their processes or equipment has changed.”

Because many operations, maintenance and reliability teams still lack or have only limited access to process data, the platform’s primary value is shortening or eliminating former distances and obstacles between users and actionable information. It’s also rated for hazardous areas without special clauses, and complies with Class I, II and III, Division 1, in North America, and with Zone 0 in Europe and globally.

“Synchros monitors and aids inspections, so users can see what’s happening, maintain processes over time, and schedule services more efficiently,” explains Lindsey. “This IIoT platform has two main parts, including connectivity via Synchros, and sensing by physical components, such as the temperature monitor and wireless repeater we’re launching with it. Because we’re building with WirelessHART and its gateways, network redesigns aren’t needed because the communications are the same no matter what sensor is deployed. Users value having a consistent experience, so we try to give them the same look and feel with these solutions.”

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More specifically, this initial release is accompanied by Rosemount Synchros temperature monitor and Synchros wireless repeater, which jointly provide scalable wireless monitoring. The temperature monitor enables new measurement points and reduces manual rounds through surface and ambient temperature readings, while the repeater extends network coverage to enable broader deployment without additional infrastructure. This can reveal abnormal conditions across assets, such as pumps, heat exchangers, rotating equipment, steam systems and heat-tracing systems, helping teams investigate issues sooner and make more informed operations, maintenance and reliability decisions.

“Synchros expands upon the use of temperature measurement to gain insights into your equipment and facility,” says Adam Edison, a global product manager for Rosemount temperature products at Emerson. “Prior to Synchros, Emerson’s Rosemount wireless temperature transmitter portfolio was geared towards process temperature measurements. The Rosemount Synchros Temperature Monitor uses an integral thermocouple designed for measuring ambient or surface temperatures. These measurements give users visibility into the health of their assets and operations easily and cost-effectively."

As the platform evolves, Emerson plans to introduce additional Synchros-enabled devices and connectivity options, enabling users to further expand monitoring programs and digital transformation efforts. These added devices will provide measurement for more process parameters, such as pressure and other parameters. Additional connectivity options, likely via long-range, wide-area network (LoRaWAN) and 5G cellular, will likewise accommodate wider ranges of applications, such as those with assets distributed across larger geographical areas, including water/wastewater systems and power grids.