Transcript
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Wireless solutions for the process industry
Today's agenda:
Introduction – the wireless landscape – WON & WSN
Why we selected ISA100
WON & WSN Use cases
What’s important when implementing wireless
WSN case study
Conclusion
Henk A. van der Bent
Marketing Manager Field Networks
Yokogawa Europe B.V.
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Yokogawa’s wireless solution portfolio
OPC
Field Wireless ConfiguratorNetwork Manager
WiFi
Modbus/TCP
Firewall
GW
SCADA/PAM PCS/PAM
Device Management
Field Backbone Network
YTA EJX 3rd partydevices
YTMX
(WSN)
(WON)
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Mobile operators – more productive– Access to real-time process information anywhere (in the plant) at any time
– Fully functional (or restricted) working environment• Graphics, historical data, asset management data
Mobile commissioning and maintenance staff – more efficient– Access to maintenance information anywhere (in the plant) at any time
• Loop testing, transmitter zero calibration “on location”
• Real-time on-line diagnostics
– Initiate, execute, close and report on work orders
Other wireless applications – Camera’s– Surveillance (fixed)
• Surveillance – Remote locations, access control, intrusion detection and people tracking
• Leak detection
– Remote maintenance support (mobile)• Remotely located problem solving expert has on-line view on equipment
• Safety – Less people to go into hazardous environments
Why use Wireless Operations Networks
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Enhanced Plant Asset Management (PAM)– Cost effective increase of process and asset monitoring
• Freeing up cable resource for higher priority measurements
– Replacement of pressure gauges and/or bi-metal temperature indicators
– Allows measurements that could not be justified before
Reduction of “blind spots” – higher visibility into operations– Allows measurements on rotating and/or moving equipment
• Wiring difficult - no power available
– Allows measurements in remote locations• “Unlock” remote processing units in general – well heads, tank farms, loading bridges e.g.
Once established, wireless sensor networks are scalable– Additional sensors can be added at low cost
– Temporary measurements for process diagnostics and optimisation
Why use Wireless Industrial Sensor Networks
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ISA100 sensor-to-boardroom wireless
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ISA100.11a
ISA100.15
ISA100.15
ISA100.21ISA100.14
ISA100.14
ISA100.14
ISA100.16
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Flexible network topologies – fit for purpose– Different device roles – I/O, Routing, I/O+Routing
– Backbone routing, Duo Cast and multiple subnets
High sensitivity radio’s– Large Line Of Sight (LOS) distances
Superior coexistence algorithms– Robustness – low packet error rates and low latencies
– High power efficiency
Dedicated and shared time slots– Slotted (fast) and slow hopping
Out-of-band (OOB) and Over-the-air (OTA) provisioning
ISA100 strengths
Universal Provisioning Tool
ir
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ISA100 strength – star, mesh and mixed topologies
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1 hop
Star
2 hops
Mixed
Multiple hops - latenciesBridges larger distances – routingLess power efficient - routingNot deterministic – monitoring onlyRedundant network
Single hop – low latencyHigh update speed – 1 secondDeterministic – suitable for controlHigh power efficiency – no routingRedundant BBR and “Duo Cast”
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WON and WSN Use CasesVisit: http://www.field-wireless.com/en/solutions/index.html
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Application; DCS and PAM (Plant Asset Management) Anywhere– Mobile workers - Commissioning in the field requires access at varying locations– Maintenance requires asset management in the field for trouble shouting
Challenge;– Plant wide WIFI coverage in a plant with lots of steel barriers– Eliminate local control rooms (used for start-up only)
Field Wireless Solution;– Wireless backbone– Notebooks suitable for rough environments and approved for use in hazardous areas– Roaming - While walking around switch automatically between Access Points
Field Wireless Benefits; – Faster commissioning time
• Loop testing and tuning in the field• Monitor smooth start up in the field
– Local control room eliminated• Temporarily tents are used for commissioning and start-up• Single database through wireless DCS and PAM Anywhere
Use Case 1 - Refinery complex (WON)
Practical Wireless
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Application; Process Monitoring, Mobile Operator, Camera’s– Temperature, level, pressure, valve position and vibration monitoring (several WSN’s)– Mobile workers (operator and maintenance staff), surveillance and mobile camera’s
Challenge;– Integrate WON and WSN into existing and running DCS system – large geographic area – Different wireless technologies from different vendors
Field Wireless Solution; – Wireless Industrial Gateways (WSN):
• GW’s (x9) with connected sensors (x21) and repeaters for redundancy– Wireless Access Points (WON)
• APx14– System separation by Firewalls where “wireless meets wired”
Field Wireless Benefits; – Add measurement points without infrastructure (no power/no cables)– Transparent WON + roaming – Remote maintenance support from HQ– Flexibility (Mobile Worker)
Use Case 2 - Chemical Plant (WSN + WON)
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Application; Maturing drum temperature monitoring– Replacement of mechanical temperature sensor/indicator– 150 seconds for one revolution; batch process duration is four hours
Challenge;– Temperature is monitored to maintain consistency of viscous fiber feed– Reliable temperature measurement in automation system– Wired temperature measurement is not possible - drum rotates
Field Wireless Solution; – Wireless temperature measurement on drum– Gateway and 2 repeaters– Repeater location carefully selected
– Radio signal path is changing continuously
Field Wireless Benefit; – Stable on-line temperature measurement– Robust wireless communication was confirmed
– Packet Error Rate is almost 0%
Use Case 3 - Textile Plant (WSN)
Repeater
Gateway
Repeater
About 3m
YTA
Drum
YTA
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Use Case 4 - Natural Gas Plant (WSN)
Application; Temperature and pressure monitoring – Temperature and pressure monitoring of natural gas well– Each well is surrounded by metal mesh/fence to prevent intrusion (security)– Area with heavy snow fall - snow builds on the mesh/fence
Challenge;– Replacement of aging existing optical cable network in the field– Low cost implementation– Concern that the metal mesh/fence and snow has effect on radio communication –
Wireless Solution; – Test conducted with temperature transmitter (3)– Transmitters located at the well inside the metal mesh/fence– Gateway to sensor distance is approximate 50 meter
Benefits; – Signal strength decreased due to shield by fence and snow– Robust wireless communication was confirmed
– Packet Error Rate is less than 1%
– Note Gateway to sensor distance of 50 meter
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Application; Utilities Management– Oil Consumption and inventory management– Flow (3), level (5) and pressure (2) measurement
Challenge;– 2-3 measurement points per measurement zone - zones about 400 meters apart– Cabling costly and tedious for just 2 or 3 measurements 400 meters distant– Measurement points almost at ground level– Trees in the plant in between the measurement zones
Field Wireless Solution; – EJX110 x 8 pcs (level & flow), EJX530 x 2 pcs– 1 GW (positioned on top of water tank )– Repeaters (3) at suitable locations
Field Wireless Benefits;– Elimination of 1600 m cable– Reduced modification work– Time saving– Flexible for future expansion
Use Case 5 - Utility Management (P&P) (WSN)
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Application; Level measurement – Storage tanks in two locations – 15 m high
Challenge;– Distance to central control room 800 meters– PVC plant - stray magnetic field present– Plant located in area with heavy rain fall
Field Wireless Solution;– EJX110 x 7 pcs, – YFGW Gateway (on top of water tank )– Repeater (1) at suitable location
Field Wireless Benefits;– Eliminate 800 m cable through the plant– Reduced modification work– Time saving– Future measuring point expansions
Use Case 6 - Chemical Plant (WSN)
Control Room
Distance from
control room to tank farm
800 Meter
Tank Farm
Gateway
EJX
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Application; Temperature Monitoring on Heat Exchanger– Monitor the efficiency of heat exchanger which maintains LNG temperature
Challenge;– High cabling construction costs due to many monitoring points over wide congested plant
• 20 points each for inlet and outlet – Update time required 5 Seconds– Integration with third party DCS System and Asset Management System– Transmitter locations 25 Meters high – Long Battery life required
Field Wireless Solution; – Temperature Transmitter (40) and Gateway (2) – Fast update time time (5 sec).– Gateway with 13 meter extended antenna
increased performance / reliability
Field Wireless Benefits; – Eliminate wiring, construction and installation costs– Long battery life (5-10 years) – No interference with existing Wi-Fi system.
Use Case 7 - Gas Plant (WSN)
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Is wireless “difficult”?
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No, not necessarily
It’s different
Is wireless “difficult”?
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GWGW
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Network lay-out, availability and prioritisation– Where to install access points, measurement devices and repeaters
• Site and/or desk survey is to be considered
– Network coverage in case of mobile workers
– Coexistence with other wireless signals, scalability
RF site survey, planning and simulation tool– Identifies existing wireless networks
– Modelling software - network design
Wireless sensor networks feature:– Reliability and redundancy
• Flexible network topologies; redundant BBR’s and GW’s
– Security and performance• Encryption, authentication, channel hopping, interoperability
When implementing wireless, what’s important?
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R
R
GW
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Chemical plant – brownfield– Implement a set of 3 measurement points at 7 locations
• Differential Pressure, static pressure and temperature
– The 7 locations are distributed over a 300 x 300 meter area
Action plan– Based on customer provided info and plant drawings
• Assess sensor and gateway locations
• Identify possible obstacles that prevent/limit LOS between sensors and gateay
– Design network layout• Identify if routers are needed and/or extended antennas
– Site survey• Site walk to assess the presence of other wireless signals
• Verify network layout design
– Proof of concept• Actually test worst case scenario to verify network layout in practice
Implementing wireless – a case study (1)
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Implementing wireless – a case study (3)
Distances to bridge:7 locations, 3 sensors eachOne gateway at CCR in location 5Distance location 5-2 is 200 meter
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Implementing wireless – a case study (4)
Network design:Location 4 and 5 direct to GWRepeaters for other locationsRedundant repeaters
Redundant pathOn-line battery exchange
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Implementing wireless – a case study (5)
Site walk:Asses other wireless signalsVisual network design verification
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Implementing wireless – a case study (6)
Proof of concept:Location 1 no LOS – signal ok
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Network management tool– Visualises network graphically
Network monitoring tool– Indication of network robustness
– RSSI, PER data
Signal quality router-gateway– Out of specification (it did work!)
– Moved GW from 2 -> 7 m high
– Performance as expected
Implementing wireless – a case study (7)
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Application; Temperature and pressure monitoring– Implement 21 wireless transmitters in 7 locations - wired infrastructure not available
Challenge;– The buildings are relatively high and close to each other
Field Wireless Solution; – Temperature and pressure transmitters, Gateway and 6 repeaters– Repeaters at different locations (redundancy)– Locations carefully chosen for optimal network reliability– Gateway located 7 m high
– Remote antenna could be considered
Field Wireless Benefit; – Stable measurements– Robust wireless communication was confirmed
– Packet Error Rate is almost 0%
– Repeaters provide redundant radio path– Repeaters allow “on-line” battery exchange– Significant saving on cabling, time etc.
Implementing wireless – a case study (8)
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GHz radio is sensitive to the existence of obstacles
Wireless is not much affected by “the climate”
ISA100 WSN is not much affected by other wireless networks– Coexistence by channel hopping and propper CCA, network and join keys
– Separate frequency bands - e.g. WiFi 5 GHz, sensor network 2.4 GHz
Mesh network (more than two paths) offers reliability– The higher the number of the devices the higher the “robustness” of the mesh
– Introduces latencies, is not deterministic, not suitable for control, battery in-efficient
– Response time is a useful indicator for the radio transmission condition• Response time fluctuations due to communication re-tries and mesh routing change
Star network (redundant BBR’s) has superior built-in robustness– High speed updates, deterministic, redundancy, suitable for control
Field experience – lessons learned
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Plant wide monitoring and process control– Integration of WON and WSN
Superior sensor network coexistence– Robustness – low packet error rates and low latencies
– High power efficiency
Flexible sensor network topologies – fit for purpose– Different device roles – I/O, Routing, I/O+Routing
– Backbone routing, Duo Cast, redundancy and multiple subnets
Properly design the network(s) – WON and WSN– Desk study, site survey and proof of concept
Ask your supplier to assume total wireless solution responsibility
Summary
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Wireless,
the next major technology transition in I/A
top related