HART Device Integration for FPSO Asset Management System
Software-based HART integration for Emerson AMS Device Manager in a large-scale offshore automation project
The Mero-3 FPSO, a Floating Production, Storage and Offloading vessel operating off the coast of Brazil, required automation across 45,000 I/O points, including 12,000 HART-enabled instruments spread across more than 120 system cabinets. For Sensia, the joint venture between Rockwell Automation and Schlumberger responsible for the project, the biggest challenge was doing it without adding hardware complexity.
To solve this, Sensia needed centralized diagnostics, monitoring, and configuration of all HART field devices through Emerson AMS Device Manager. The team built an Ethernet-based HART integration architecture using Softing's smartLink SW-HT. This software-based approach eliminated the need for traditional hardware-based HART multiplexers and provided scalable access to HART device data without altering the existing Rockwell Automation control system infrastructure.
At a glance
- Industry: Oil & Gas / Offshore
- Application: FPSO automation and asset management
- Project: Mero-3, Brazil
- Softing product: smartLink SW-HT
- Asset management system: Emerson AMS Device Manager
- Control system environment: Rockwell Automation PlantPAx / ControlLogix
- Communication: HART-IP, EtherNet/IP, ControlNet pass-through
- Scale: Approx. 45,000 I/O points, including approx. 12,000 HART-enabled I/O points, initial project phase: connect 400 HART-enabled field devices
The challenge: Connecting HART devices without adding hardware complexity
The FPSO automation system included a large number of HART-enabled field instruments across both topside and hull systems. These instruments needed to be accessible from Emerson AMS Device Manager to support centralized diagnostics, monitoring, configuration, and troubleshooting.
The project also faced typical offshore constraints. These included limited cabinet space, high engineering complexity, tight commissioning schedules, and the need to keep the existing Rockwell Automation infrastructure in place.
Using traditional hardware HART multiplexers would have required additional cabinet space, more wiring, and increased installation effort. Sensia therefore needed a scalable and reliable solution that could provide access to HART device parameters and diagnostics while minimizing hardware footprint and engineering work.
Reduced hardware footprint
The software-based architecture eliminated the need for traditional hardware HART multiplexers and reduced control cabinet space requirements.
Lower engineering and installation effort
Less wiring and fewer hardware components simplified integration and helped accelerate project delivery and commissioning.
Centralized device diagnostics
HART device parameters, diagnostics, and configuration data became accessible through Emerson AMS Device Manager.
Improved maintenance workflows
Real-time visibility into instrument health and valve diagnostics supported faster troubleshooting and more efficient maintenance.
Scalable architecture
The virtualized smartLink SW-HT setup enabled reliable access to thousands of HART-enabled instruments across topside and hull systems.
Future flexibility
The software-based approach makes it easier to add, remove, or modify instruments without significant rewiring.
Why smartLink SW-HT?
Softing smartLink SW-HT enables Ethernet-based access to HART field device data from asset management systems such as Emerson AMS Device Manager. It acts as HART-IP server middleware. This lets users connect HART devices to Rockwell Automation systems without traditional HART multiplexing hardware. In practice, HART data traveled over the plant's EtherNet/IP backbone—effectively HART over EtherNet/IP—to AMS via smartLink SW-HT, strengthening HART integration with the existing environment.
For large-scale process automation projects, this provides a scalable and efficient way to make valuable HART diagnostic data available for commissioning, maintenance, and predictive maintenance applications.
Discover how smartLink SW-HT enables software-based HART integration for asset management systems.
Software-based HART multiplexing with smartLink SW-HT
Sensia partnered with Softing Industrial, Rockwell Automation, and Emerson to implement a software-based HART integration architecture using Softing's smartLink SW-HT.
smartLink SW-HT was deployed as HART-IP server middleware between Emerson AMS Device Manager and the Rockwell Automation control system. The solution enabled transparent access to HART field devices connected to ControlLogix controllers, primarily via EtherNet/IP. In selected safety-critical applications, ControlNet pass-through was used to access HART modules.
In the initial project phase, 400 HART field devices were connected using smartLink SW-HT. Seven virtual smartLink SW-HT instances were deployed on Microsoft Hyper-V. This software-based setup removed the need for physical HART multiplexers and reduced both wiring and hardware footprint.
Implementation overview
The implemented architecture included:
- Seven virtual smartLink SW-HT instances running on Microsoft Hyper-V
- Emerson AMS Device Manager as the central platform for diagnostics, monitoring, configuration, and troubleshooting
- Integration with the Rockwell Automation PlantPAx DCS environment
- HART-IP communication between AMS Device Manager and smartLink SW-HT
- EtherNet/IP communication with field devices via ControlLogix controllers
- ControlNet pass-through in selected safety-critical applications
This architecture provided reliable access to HART device data while maintaining the existing automation infrastructure.
The result: Scalable device diagnostics with reduced infrastructure effort
By replacing traditional hardware HART multiplexers with software-based HART multiplexing in the initial project phase, the project achieved significant infrastructure and operational benefits.
The smartLink SW-HT solution helped reduce control cabinet space by approximately 20–30% compared to a hardware multiplexer-based setup. It also reduced wiring complexity, engineering effort, and installation work — all important factors in an offshore environment where space and commissioning time are limited.
Centralized access to HART diagnostics gave operators and maintenance teams a clear view of instrument health and valve performance. This improved troubleshooting and supported more effective predictive maintenance.
The following questions address the most common technical and project-related aspects of this HART integration case study.
Why did Sensia choose a software-based HART integration instead of traditional hardware multiplexers?
The Mero-3 FPSO project faced tight space, wiring, and commissioning constraints typical of offshore environments. Using hardware HART multiplexers would have added cabinet count, wiring complexity, and engineering effort. By adopting Softing's smartLink SW-HT, Sensia enabled centralized access to HART device data without extra hardware. This reduced the hardware footprint and simplified installation while keeping the existing Rockwell Automation infrastructure intact.
How does smartLink SW-HT connect HART devices to Emerson AMS Device Manager in a Rockwell PlantPAx / ControlLogix environment?
smartLink SW-HT acts as HART-IP server middleware between AMS Device Manager and the ControlLogix-based control system. HART data travels over the plant's EtherNet/IP network — effectively HART over EtherNet/IP — to AMS Device Manager via smartLink SW-HT. In selected safety-critical applications, ControlNet pass-through was used to access HART modules. This approach provided transparent HART connectivity without changing the existing control system architecture.
What did the large-scale implementation on the FPSO look like?
The project covered approximately 45,000 I/O points, including around 12,000 HART-enabled points distributed across more than 120 system cabinets. In the initial project phase, 400 HART field devices were connected using smartLink SW-HT. Seven virtual smartLink SW-HT instances were deployed on Microsoft Hyper-V. This gave centralized, reliable access to HART instruments across both topside and hull systems via Emerson AMS Device Manager.
Which communication protocols were involved, and what does "HART over EtherNet/IP" mean in this project?
AMS Device Manager communicated with smartLink SW-HT via HART-IP. Field connectivity used EtherNet/IP through ControlLogix controllers. In selected safety-critical cases, ControlNet pass-through was used. "HART over EtherNet/IP" refers to transporting HART device data across the site's EtherNet/IP network to AMS Device Manager through smartLink SW-HT — without dedicated hardware HART multiplexers.
What results did the software-based approach achieve?
The solution reduced control cabinet space by approximately 20–30% compared to a hardware multiplexer-based setup. It also cut wiring, engineering, and installation effort — critical factors in an offshore environment where space and commissioning time are limited. Centralized access to HART diagnostics in AMS Device Manager improved troubleshooting, supported more effective predictive maintenance, and gave the project team future flexibility to add or modify instruments without significant rewiring.
