Introduction
Process plants around the globe depend on smart HART-enabled field devices for precise process measurement and diagnostics. Although the HART protocol provides valuable secondary and additional device variables, diagnostics, and configuration capabilities, many of these advantages go untapped because the HART data remains isolated in the field. With the advancement of IIoT (Industrial Internet of Things), devices like the HES HART to Ethernet Gateway System simplify the collection of process variable data for mining and analysis, leading to operational efficiencies. A new feature of the Moore Industries’ HES HART to Ethernet Gateway System, called HART Tunneling, delivers a groundbreaking solution by allowing seamless access to remote HART devices and data without the necessity for complex infrastructure or host system upgrades.
This white paper examines the benefits of the HART tunneling feature of the HES, showing how it facilitates remote device configuration, predictive maintenance, and operational efficiency. It also presents a practical application example that demonstrates the feature’s value in a real-world process environment.
Understanding HART Tunneling with the HES
At its foundation, the HES Gateway System connects HART field devices installed on twisted-pair networks to plant monitoring and control or asset management systems over Ethernet using eithe Modbus/TCP or HART-IP protocols. This allows the continuous monitoring of not only the main process variable but also access to additional process variables and advanced diagnostics via HART from those critical field devices. Until now, communication with the HART field device was controlled only by the HES. In other words, the host system, which was connected to the HES on the Ethernet side, only communicated with the HES, and not the field device.
Now, with the HART tunneling feature built into the HES, a transparent and bi-directional connection to HART field devices is created. This allows common HART configuration, monitoring, and maintenance tools like PACTware, asset managers, and valve management tools, that reside remotely on the facility’s Ethernet infrastructure, to directly communicate with critical field device assets as if they were connected locally.
Figure 1. HES HART to Ethernet Gateway System with HART Tunneling
Key Features of HART Tunneling with the HES:
- Remote access to HART devices for full configuration, calibration and diagnostics.
- Elimination of manual field visits and handheld communicators.
- Compatibility with any HART-compliant device.
- Access with up to 16 HES Connected HART field devices.
- Embedded Read-Only Web Server to Monitor all HART Data with any Browser.
Benefits of the HES HART Tunneling Feature:
- Simplified Maintenance and Troubleshooting
With HART tunneling, technicians can remotely diagnose and configure devices without physically visiting the field, reducing labor time, minimizing exposure to hazardous areas, and shortening device downtime. - Enable Predictive Maintenance
Access to secondary or additional device variables and diagnostic alerts from HART field devices allows maintenance teams to spot developing issues such as sensor drift, plugged impulse lines, or calibration errors, before they lead to failure. - Centralized Device Management
All HART-enabled devices in a loop can be accessed from a centralized control room or even remotely via secure VPN, enabling better device fleet managementand audit readiness. - Maximized Investment in Smart Devices
Most facilities only use the 4–20mA signal from their HART devices, ignoring the rich data available via HART. HART Tunneling enables bi-directional communication and access to this data without costly host-side upgrades, improving the return on investment in HART instruments. - Reduces Commissioning Time
With remote tunneling, multiple devices can be configured simultaneously from the control room or maintenance office, reducing commissioning time for new or modified installations.
Application Example: Remote Monitoring and Configuration of Pressure Transmitters on an Offshore Platform
Scenario:
Numerous HART-enabled pressure transmitters are operated by an offshore oil platform and are situated in dangerous and challenging-to-reach locations. Through their 4–20mA signal, these transmitters give the DCS vital process pressure readings. They do not, however, have complete access to their HART settings and diagnostic data.
Challenge:
- Manual configuration requires a technician to travel offshore and access each device with a handheld HART communicator.
- High cost and risk associated with offshore travel and confined space entry.
- Diagnostic data from HART devices remains unused, increasing the risk of undetected sensor failures.
Using standard HART configuration tools, technicians onshore can:
- Remotely configure or update device settings.
- Monitor real-time and historical diagnostic information.
- Detect issues like sensor drift, plugged lines, or degraded device performance.
Results:
• Up to 80% reduction in field visits to offshore devices.
• Faster response to instrument issues.
• Improved safety by reducing technician exposure.
• Better asset utilization through full use of HART diagnostics.
Conclusion:
The HART tunneling feature of the Moore Industries HES Gateway System is a cost-effective and secure method to remotely access the full intelligence of HART devices. Whether used in oil & gas, chemical, power generation, or water treatment industries, the HES opens the door to a smarter, more connected plant.
The HES helps businesses realize the full potential of their HART-enabled equipment, enhancing operational excellence, safety, and efficiency by enabling remote configuration, lowering maintenance costs, and simplifying predictive diagnostics.