Sensia Unlocks Full HART Device Integration for FPSO Project Using AMS Device Manager and Softing smartLink SW-HT
AMS Device Manager enables digital transformation by providing an application that embraces open standards and protocols that allow connectivity to a wide range of devices. It also enables predictive maintenance to reduce unplanned shutdowns, increase productivity, improve safety, and drive higher ROI.
This unique and flexible application provides real-time online access to intelligent instrument and valve diagnostics and alerts, delivering a view of device health and troubleshooting information when an issue is found.
Based on real-time condition data, maintenance and operations personnel can respond quickly and make informed decisions.
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Lonza Saves $98,000 and Achieves 200% ROI with AMS Device Manager
Learn how Lonza experienced rapid return on investment in commissioning 1,400 instruments at its research, development, and production center in Visp, Switzerland.
Business Results
- Seamless integration of Softing smartLink SW-HT, Rockwell PlantPAx, and Emerson AMS Device Manager to expose full HART diagnostics and device data.
- 20–30% reduction in control cabinet space compared to physical HART multiplexers.
- Significant reduction in wiring and engineering hours, enabling faster project delivery and commissioning.
- Scalable management of thousands of HART instruments across topside and hull systems with centralized visibility.
- Improved operational flexibility — easier to add, remove, or modify instruments without significant rewiring or cabinet changes.
- Demonstrated approach to unlock otherwise untapped HART diagnostic data (industry context: plants may have 100,000+ HART devices with much diagnostic data unused), enabling better predictive maintenance and reduced unplanned downtime.
Application
- A single AMS Device Manager server connected to seven smartLink SW-HT instances, providing full access to HART device data via software multiplexing rather than physical multiplexer hardware.
- Coverage included both Topside and Hull systems:
- Topside: PCS (~1,500 devices), PSD (~1,500), FGS (~2,000), PKG (third-party systems ~3,000)
- Hull: HCS (~500), HSD (~500), PKG (third-party systems ~3,000)
Customer
Sensia — a joint venture between Rockwell Automation (53%) and Schlumberger (47%), announced February 19, 2019 — delivers integrated automation and digital solutions for the oil & gas industry.
Rockwell Automation (NYSE: ROK) is a leading industrial automation company; Schlumberger (NYSE: SLB) is a global technology leader for reservoir characterization, drilling, production, and processing.onza | Visp, Switzerland
Challenge
An FPSO project required integration of 45,000 total I/O points, including 12,000 HART I/O distributed across 120+ system cabinets. Sensia’s Statement of Work (SOW) required full HART integration with Emerson AMS Device Manager. Key project constraints and objectives:
- Minimize control cabinet footprint where space was limited.
- Reduce wiring complexity and engineering hours versus physical HART multiplexers.
- Accelerate project delivery and commissioning timelines.Accelerate project delivery and commissioning timelines.
- Enable centralized monitoring and management of thousands of HART devices across topside and hull systems.
Solution
Sensia partnered with Softing, Rockwell Automation, and Emerson to deploy an Ethernet-based HART integration architecture that eliminated the need for hardware multiplexers.
Solution components and architecture:
- AMS Device Manager (central server) for centralized device configuration, diagnostics, monitoring, and troubleshooting.
- Softing smartLink SW-HT middleware — seven virtual smartLink SW-HT interfaces (each running on Microsoft Hyper-V) connected to HART I/O on seven Allen-Bradley PLCs.
- Rockwell PlantPAx DCS integration for process control alignment and visibility.
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