The use of Radio Frequency Identification (RFID) has grown substantially in the past few years. Driven mostly by the retail supply chain management industry and by inventory control (loss prevention), RFID technology is also finding more acceptance in the security and personal tracking sectors beyond simple pass cards. This growth has resulted in greater acceptance of RFID technology, more standardization of process and systems and decreased per unit costs. The oil and gas industry is now being exposed to the potential use of RFID technology, mostly through safety and equipment inspection in construction management. However, the application of RFID technology is expected to expand to the material tracking and asset management realms in the near future.

Integrating the information provided by RFID with Engineering, Procurement and Construction Management (EPCM) project and owner/operator Geographic Information Systems (GIS) is a logical next step towards maximizing the value of RFID technology. By linking assets tracked in the field during movement, lay-down and construction to a GIS, projects will have accurate, real-time data on the location of materials as well as be able to query those assets after commissioning. This same capability can be modified for post-commission use of RFID with a facility GIS. The goal here is to outline how an existing GIS used during the EPCM phases and those employed after commissioning can display, utilize and analyze information provided by RFID technology.

GIS and RFID

The two technologies of GIS and RFID have developed parallel to each other over the past couple of decades, and those two parallel courses are beginning to converge. Thanks to the rapid decrease in the cost of computer technology and improvements in battery life and operating systems for small units, RFID readers are now not only relatively inexpensive, they are powerful enough to complete a range of field data collection and processing activities. Similarly, part of the rapid growth of GIS as a tool for engineering, particularly in the EPCM world, is due to the decreasing costs of computer power and disk space. Gradually improving bandwidth and remote access are resulting in more distributed computing, increased acceptance of web portals as a communication tool, and remote data access.

As the paths of GIS and RFID technology come together, integration between these technologies will be much easier than what the engineering world has witnessed with other converging technologies. This results from a level of standardization inherent in today’s versions of the two technologies, and the well referenced lessons learned from past integrations of the two technologies into existing business and engineering processes. Rarely has the engineering world benefited from the lessons learned by two different technologies let alone as both technologies converge.

Both RFID and GIS have been tried and tested in other industries, and both have been adopted in various ways by the oil and gas industry, but our purpose here is to discuss how capital projects and owner operators in general can easily marry together these technologies to enhance the value of each of the technologies being employed. In essence, the marriage of RFID and GIS allows for the relational information in the former to be more efficiently managed, analyzed and communicated by the proven power of the latter.

Defining GIS

Many engineering and operations people in the oil and gas industry are familiar with the GIS concept. Still, it may be useful to elaborate upon their most basic functionality – making maps – for purposes of explaining the synergies between GIS and RFID. A GIS is a compilation of hardware and software designed for the storage, manipulation, analysis and communication of spatially referenced data (data containing a coordinate reference or an X, Y, and Z) and information derived from that data.

In the hydrocarbon industry, GIS has made significant ground in both the EPC of capital projects to the support engineering, and also after commissioning, to help manage the asset and provide analysis and data retrieval of complex related data sets such as integrity data, engineering and the retrieval of as-built documents and data. It is particularly helpful in high consequence area (HCA) analysis and emergency response planning.

There are various software vendors and data suppliers, and owners have hybrids and modifications of their own with respect to the systems and processes for using spatial data. But because of standardization and inexpensive conversion software, GIS and their data are considerably interoperable and easily shared among project or asset partners, stakeholders, contractors and the actual owners. On capital projects, subcontractors generating, manipulating and analyzing spatial data generally have no technical issues when sharing data sets. This is of great benefit to the engineering teams and the owners.

Centrally managed data

Centrally managed databases for projects and commissioned assets serve one primary purpose: change management. By establishing an information infrastructure for an asset, a central database insures standardized data collection and use and management practices; thus providing a system for the data collectors and users that are stable and reliable. A centrally managed database insures the four cornerstones of information management are in place:

• Data security

• Data integrity

• Metadata

• Change management.

The oil and gas industry has been investing in information management, and over the past several years, several owner/operators have begun to realize the value from their investments in centrally managed databases for assets. Often referred to as Master Databases (MDBs), major capital projects have been used as a springboard to launch the development of large, robust geospatial databases which are then later integrated with the parent MDB or Enterprise Database of the owner/operator. While various techniques have been presented in the past to valuate and prove the Return on Investment of MDBs and Enterprise solutions, for our purposes here, we wish only to acknowledge that centrally managed databases, and even more, their integration with Document Management Systems (DMSs) is being realized.

Field data collection

Though it has been experimented with and proposed for the past decade or so, the use of handheld units for detailed, accurate data collection has only really come into the fold of use by field operators in the past few years. Like many components of modern geospatial technology, municipal, county, and state/provincial officials as well as vendors have driven innovation. These stakeholders have helped drive the integration of handheld units and the capabilities of those units regarding overall data capture and manipulation (or updating) activities. Various vendors, big and small, as well as some larger user companies have advanced integration of field handheld devices and GIS. But due to the nature of the public versus private sectors and the related need for disclosure, the efforts of public agencies are often the best known and well documented.

The natural next evolutions in field data collection basically fall into two categories. First are the improved capabilities of hand helds, which derive from cheaper processing power and memory; more robust programming languages; and tools for application development on handhelds, including Bluetooth technology and wireless connectivity. Second is the enabling of handhelds with GPS (Global Positioning System) receiving and RFID reading capabilities. The two listed advancements are already taking place in full stride, and are growing in acceptance with many large endeavors in other industries. Application of these technologies is becoming well established in the realm of Supply Chain Management (SCM), and they are becoming rapidly integrated into large-scale data management programs. The proven value of this integration will be covered later.

Defining RFID

Radio Frequency Identification (RFID) technology entails the employment of two components: identification tags, and a reader/antenna unit. The tags range in size from that of a quarter to a tennis ball, with the smaller tags storing very little information (64 bits), and being induction-based; and the large tags containing their own battery and transmitter and being capable of storing several kilobytes.

The tags can be composed of various materials and structured in a multitude of forms. This allows them to act as security tags on clothing and in books, or form a metal identification plate that can be engraved to complement the tag data. Most RFID tags are intrinsically safe, and they can be imbedded in coating materials or slung onto objects with wires or bolts. They can operate in the harshest conditions and if unpowered, they have a near infinite life span. The tags can be shock, vibration and dust proof, and even chemically resistant. Like any small tag-sized item, they can be engineered to suit the environment, operating conditions, safety standards and functional necessities of an application.

One of the main benefits of RFID tags is their compliance with engineering standards. All certified high-frequency tags are ISO 15693 compliant. Under ISO 15693, they are classed as “Vicinity Cards” with an effective range of 1 to 1.5 meters; this is on contrast to “Proximity Cards,” which have greater ranges. For our purposes here, we refer generally to tags as RFID tags regardless of the range, since we are explaining the synergies between radio frequency identification as a data input or relation; and that integration with a GIS.

How RFID works

Working on a radio frequency of 13.56 MHz (HF), a reader/antenna flashes a radio signal at the tag and induces the tag to either write information to the tag or read the tag. Not all tags can be written to but all can be read. Security options are also available with most tags to protect the information on the tag or from improper writing to the tag.

The reader can be used to simply catalogue the tag; however, with a properly developed system and workflow, very robust and scalable data management capabilities are possible. The more powerful readers have interfaces which can be developed in a variety of programming languages, allowing for very complicated and robust data capture capabilities. These readers also offer the ability to write more detailed and updated information to the tags.

Technology exists that facilitates the reading of several tags per second, as well as the ability to write to the tags in a similarly short time period. The readers can also be enabled with GPS receiving capabilities, allowing for the capture of tag locations. The more expensive models are capable of wireless connectivity in addition to the GPS receiver. This enables the reader to pull and push data from a central database based on the tag identification that it recognizes. However, the most common method of synchronizing data is by connecting the reader to the data management system when the user returns to the office. The readers are programmed to instantly synchronize with the appropriate databases and systems with little or no user input.

This level of automation is easy to attain with the degree of interoperability of systems and programming standards available. Many systems have been built that automatically generate specific types of reports and documents designed around the user’s needs, such as inspection reports and certificates, compliance documents, or work tickets for assets identified in the field that require maintenance.

The key benefits

RFID typically only provides one main benefit: unique identification. Because RFID tags conform to ISO standards, they are globally unique and universally recognizable. Placing an RFID tag onto an object instantly gives that object a globally unique serial number. But, having a globally unique serial number alone does not mean much. It is the software behind the RFID tag that relates and ties in different sources of data to make use of it. Using handheld computers equipped with GPS receivers and RFID readers, a new combination of asset identification and asset location data is combined to deliver an unprecedented level of asset detail.

Integrating RFID and GIS

The value of combining RFID and GIS technology is in being able to provide more information in the field; and conversely return more accurate and timely information back to a central database. As stated, a GIS manages and manipulates data and communicates results. The details regarding an object identified by an RFID and its location are data points can be correlated in a GIS. No doubt RFID and GIS can be used and operated independently, but the two can be linked together through either the spatial location of a specific object (asset) or a particular attribute of the object, such as its item identifier (e.g., block valve serial number). Hence, it only makes sense that in some cases it would be valuable to bring the two sources of information together.

For facilities or assets which have a centrally managed database or a Document Management System (DMS) that has captured unique identifiers for asset components, the retrieval of information and the updating of information is quite easy. The integration of data in a GIS and DMS with the identity provided with RFID has already been developed and proven by the SCM industry, and other firms and organizations that use handhelds in the field to link to parent data systems.

Organizations specializing in and/or depending on SCM systems have spent the past decade developing and proving the value of both RFID, and integrating them into larger data systems. Many people have heard the success story of Wal-Mart and its efforts to manage all of its inventory movement through their vast and extensive supply chain. With almost all of their suppliers now incorporating the use of RFID on the shipments of palettes of inventory, Wal-Mart has attempted to realize exceptional gains through harnessing the value of tracking inventory with need for accurate inventory management.

While the Wal-Mart story, and others like it from retail, is one of SCM in a consumer industry, its story is important to an oil and gas audience for two reasons. First, it demonstrates that change can be made to how a large, multibillion dollar system is managed, without an IT project disaster occurring. Second, and more importantly, it serves to illustrate that in integrating RFID to standard operating procedures, and ultimately linking to parent database systems, oil and gas companies would not be inventing anything. RFID is a proven technology; and its integration into larger database management systems has been proven as well. Linking RFID and other data is the next step in the evolution of data.

Oil and gas can adapt and furnish RFID, and apply it to operations as appropriate, similar to how the industry was able to adapt advancements in enterprise-wide solutions and MDB systems in GIS for operations. Just as the authors are proposing here, GIS and centralized managed database solutions were adopted once proven by the public sector and a few industry leaders. It should be noted that some companies have already been applying RFID to operations for facility security, equipment inspection and fabrication, while others have begun to fully integrate RFID into operations.

Serving facilities and assets

There are two main ways in which RFID integration can support the construction and operation of an asset or facility: through personnel management and managing components of the asset. RFID is used extensively in personnel management, everything from swipe cards for access to buildings and rooms to tracking attendees during a conference. But, there is still room for growth in the application of this technology such as for helping first responders find personnel, or for checking workers in at a rally point. However, it is in managing a physical asset and its components from cradle to grave which possesses the most potential for expanded use of RFID and its integration into other systems.

Essentially, RFID does not replace the need for identifying asset components; rather it makes that identification better. It provides a more durable “label” that has a unique serial number that is ISO compliant, which can be read without being in physical contact with the asset or having a direct line of sight. The equipment used in the process inherently allows for more accurate data collection through a specially developed interface which can restrict inputs and retrievals to ensure accuracy.

These characteristics of RFID make it well suited for labeling and tracking components such as valves, fittings, whole modules and verifying that all the components that are supposed to be on the module are actually installed before it is shipped. Logically, it also makes RFID well suited for managing the movement of the components, identifying them once they arrive at site, and during their lifetime for inspection and salvage. During their life, the record of manufacture, installation, and maintenance of the component is accurately compiled and stored because of the unique identifier. Overall, there is the reduced human error through the use of the handheld readers and ease of communication with a properly managed central database or records system.

These same characteristics make inspecting and reporting on these components easier and more accurate. An example of this capability is the inspection of slings, ropes and harnesses for the heavy construction industry. Through their services, a vendor can provide inspectors with handhelds that have applications developed specifically for inspecting lifting apparatuses. Inspectors read RFID chips attached to slings and related components in the field, and use menus in the application on the handheld to accurately develop the report data. Upon return to the office, the handheld is synchronized with a central database and inspection reports are instantly generated. This can reduce inspection errors, expedite inspection time, and reduced the time to receive inspection reports.

Various levels of integration

Like any technology, the use of RFID has to be adapted to the problem, and not every situation will require a high level of integration. In fact, some will not require it at all. There are five levels of integration for RFID into an oil and gas operation:

1. Reading and recording only (Type I). This is the most basic type of use of RIFDs, and is highlighted by the example above. A reader is used to identify an asset component and notes are taken about the component through a user-friendly, but error-reducing application.

2. Reading/recording supported with existing data (Type II). This type data is only being read and recorded as with Type I, but the user is supplied with more detailed information such as a picture of the component, previous inspection documents or specifications, or work ticket information. The additional information is to support more detailed or complicated work beyond inventorying the component or verification. Perhaps a valve is being repaired and it would be helpful to have a picture to help identify it, view the damage, or support before and after pictures. Knowledge of its performance, maintenance, spatial location, and various pieces of other information from a database would clearly be helpful. This information is downloaded before leaving office.

3. Type III is the same as Type II, except that the information retrieved or uploaded is done wirelessly. For our purposes here, it is treated separately because of the clear technology differences between the handheld units required, and the availability of a wireless connection. The latter is unfortunately still problematic in many locations in the field.

4. Type IV is considered to be any combination of the first three types, but also includes the capability to write new information to the tag; or for the tag to be active and not passive, perhaps even a sensor in and of itself recording timely information. Similar to the difference between Types II and III, Type IV is separate because of the technological requirement of the reader and of the actual RFID tag. All RFID tags can be read, but not all can be written too, and they vary in capacity to hold information. Additionally, active RFID tags are available and because they emit their own signal, they can be read from further away, and can even be slightly buried or covered by certain materials. These naturally have a lifespan equal to their resident battery life and their operating environment. Most would also not be suitable for assets involved in cathodic protection.

5. Type V RFID integration involves the safety of workers. This type of integration would be specifically designed to help first responders find workers at a site, or track where people have moved within a facility. It involves the more complicated RFID tags; more elaborate software; an extreme level of reliability when activated; its own power source for stationary readers; consideration around privacy rights; and the complexities of wearing safety gear. However, it is by far the most valuable potential application of this technology. Advances have been made in this area, and it will continue to be an area of development.

Generational change

As consultants, we (the authors) engage in technology strategy discussions with clients everyday. One of the biggest problems that owner/operators know is coming is the pending retirement of the baby-boomers and the labor and knowledge gap that will result. While most firms are beginning to prepare for this eventuality, and there are good prospects that many of the knowledge holders will be available as required long into their retirement, the nature of facility and asset operation requires that operators examine methods to mitigate the risk of the knowledge gap. Additionally, technology is being sought to improve efficiencies and productivity to ease the strain on the field labor force that is expected as the baby-boomers retire. Because of the skills and quality of work required for field inspection, craftsmanship of construction, and operation in general, reliance on new workers to completely fill the expected labor shortage is a risky approach. The integration of RFID with centrally managed data and documents will improve productivity and reduce human errors, thus making field operations and construction more efficient and less risky overall.

One can also expect that the next generation of skilled workers and engineers coming into the workforce will be able to help ease the adoption of RFID technology for facilities and assets. The next generation, and even the current generation of new grads, can be considered early adopters of technology relative to their predecessors. The next generation will not only be much more comfortable using the latest technology, they will expect to use it. They might even be one of the drivers at facilities leading the integration of RFID to central databases. They will be drivers because they desire to harness the data that is available, combined with their predilection for using remotely assessable technology to retrieve and update information. As today’s work force questions the reliability of field technology, the next generation will question the accuracy of the pencil and paper logs of the past.

Conclusion

Any successful new system increases efficiency, reduces risk, and saves money. For a new system to be considered a paradigm shift, it must accomplish the above tasks, but also invoke a feeling that life before the system is (or was) incomprehensible. Similar to how email has changed the way companies communicate, RFID is changing the way companies deal with assets and relay information. This paradigm shift is already being noticed in safety compliance and inspection management. For the first time, the combination of RFID and GIS will allow for the next level of data analysis, and will include cradle to grave visibility with spatial data at every point. RFID and GIS technology naturally pair with each other, and seem to be a perfect fit for pipeline EPCM operations. n

Acknowledgments

The authors wish to thank WorleyParsons Geomatics for their enthusiasm in promoting the application of RFID technology to spatial data management and asset operational improvement. N4 Systems Inc. has provided considerable input to the technical understanding and support for application and its development. Phil Toohey of WorleyParsons was instrumental in the early part of the development of this concept and provided ongoing guidance. Based on a paper presented at the 8th International Pipeline Conference held in Calgary, Alberta.