Industrial Wireless Solutions

2

Agenda

• Introduction

• Products & Specs

• Applications

3

Introduction to wireless

• Imagine

4

Introduction to wireless

• Imagine

5

Introduction to Wireless• Conventional Monitoring Conditions

– Long conduit runs between sensors and control room– Cost of materials- estimated $100/ft to run conduit or

cable– Lack of resources to do maintenance

6

• The reality with wired solutions– Long distances from critical monitoring– Large obstructions can make wiring impractical or

impossible– Processes or equipment need monitoring in use– No power available in remote applications– Expense

Introduction to Wireless

7

• Wireless adaptation

Radios simply eliminate the need to run wires for any sensor application

Radios simply eliminate the need to run wires for any sensor application

Introduction to Wireless

8

“What, no fittings?”

9

• What is industrial wireless?– Transmitting information via radio

• Transmitters• Receivers• Gateways

– Monitoring solution• Tank levels monitors• Motor operated valves• Pumps• Heat trace

– No need for wires or cable – Radios are programmable

• Multiple radios on a reliable path• To send data upon

– Request– Periodically– Pre-determined signal values

Introduction to Wireless

10

• Applications considerations

– Monitoring (90+%)

• Requirements

– Pipelines

» Pressure monitoring, heat tracing

monitoring

– Motor operated valves

» Feedback needed to confirm valve

position

Introduction to Wireless

11

• Applications considerations

– Control

• Requirements– Process control

» Automated and manual process

control for various industries

– Alarms

» Monitor conditions and

automate alarms when needed

Introduction to Wireless

12

• Why go wireless?– Cost effective solution

• Avoiding long wire or conduit runs• Eliminating trenching and cable trays• Facilitating solutions for applications hindered by physical

obstruction

– Added value• Increased operational safety by continuous monitoring• Mobile and flexible monitoring• Easy to upgrade as you grow• Low cost per access point• Easy to install

Introduction to Wireless

13

Wireless technology advantage

Mass I/O

I/O Monitoring

I/O I/O

Introduction to Wireless

…

14

Introduction to Wireless

• Application: Oil & Gas– Well-head and pump monitoring system – Pipeline pressure, flow and valve monitoring – Protection system monitoring – Leak detection monitoring – Underground gas storage monitoring – Pump/compressor station control systems

15

• Application: Process IndustriesEg Chemical plants, Pulp & paper, steel mills,

power gen, glass manufacturing – Flow monitoring – Tank level monitoring – Condition monitoring of equipment – Utility plant alarms – Effluent treatment plants – Security and access-control – Remote water pumps – Monitoring of fire-fighting and safety systems – Gas detection systems

Introduction to Wireless

16

• Application: Factory AutomationEg. Assembly plants, component manufacturers,

Pharmaceutical, food & beverage, packaging • Detection of moving machinery • Power network monitoring • PLC interconnection • Alarm monitoring of portable machinery • Utility plant alarms • Effluent treatment plants • Security and access-control • Rotating and moving machinery • Alert and Evacuation alarm systems

Introduction to Wireless

17

• Application: Utilities & Municipal – Water management

• Pump station control • Tank monitoring, level and security • Flow metering systems • Irrigation monitoring and control • Water quality monitoring • Large network SCADA systems • Treatment plant monitoring • Early flood-warning systems

– Electricity distribution• Monitoring of power poles • HV Feeder alarm fault monitoring

– Gas reticulation• Valve stations • Pressure monitoring

Introduction to Wireless

18

Wireless driven by business need

• Process monitoring• Rotating equipment – e.g. Kilns• Safety systems – showers, etc.• Operator safety status

• Mobile asset tracking• On/Off valve

position/control• Remote process set-up• Temporary

installations• Wired alternative

Application Examples

19

Wireless best fit when…• Manually collected data: Wireless can eliminate the need to send

technicians into the field to read gauges• "Must have" measurements: Environmental or safety regulations may

require additional measurements. Wireless allows the easy placement of instruments where needed.

• Need for diagnostics: Many plants have hundreds of field devices. Wireless allows access to diagnostic information in certain of these areas

• Temporary Monitoring: process may only need a short ( 1-3 months ) monitoring. Wireless allows easy, fast, and inexpensive install for these requirements

• “Want to have" measurements: Wireless permits adding instruments in locations that could not previously be justified.

• Long distances involved: Wireless can eliminate the need for long cable runs and trenching to connect tank farms and similar assets spread over a wide area.

20

Wireless best fit when… • Many pumps and motors: Plants often have hundreds of pumps and

motors. And while continuous condition monitoring is noble in concept, wiring vibration sensors to all of them would be prohibitive. Wireless allows an easy connection.

• Extreme environments: Hot, dangerous and/or hazardous environments make it difficult to install instruments and run wire. Wireless minimizes the problem.

• Crowded environments: Wireless eliminates the need to snake new wires through crowded enclosures and conduit.

• New wiring is too expensive: Installed costs of $50 to $100 per foot can make adding new wired measurement points cost-prohibitive.

• Need for feedback: Manual valves that have no position feedback can cause safety problems. Wirelessly monitoring can cost as little as 10%of a wired solution.

• No other way: Wireless works for mobile assets, remote sites and rotating equipment where using wired instruments is impossible or impractical.

21

Standard terms and definitions• WIBnet™ - wireless-information-backbone. Network technology

allowing flexible, secure and scalable peer-to-peer connectivity of wireless data.

• Industrial-grade –This means temperature , vibration, humidly specs, certification to at least Class I Div 2 , and superior power options and packaging.

• Event data management –exception reporting technique to transfer wireless data that ensures the most reliable, secure and fastest transfer physically possible. This technique also provides easy scalability and increased bandwidth.

• Frequency Hopping Spread Spectrum (FHSS) –random use of a defined band of frequencies. Invented during the WWII as a way to send wireless data more securely with less interference.

• AES (Advance Encryption Standard ), WEP (Wired Equivalency Privacy ) –these are encryption techniques used in today’s wireless world.

22

Time/mSec

PowerWatt

Frequen

cy

928M

Hz

902M

Hz

Frequency Hopping SS - Security

869.

4 M

Hz

869.

65 M

Hz

The Products

24

The Products• One–way communication

– Transmitters• 2 digital outputs &

1 analog signal

– Transmitters & Receivers• 2 digital outputs, 1 thermocouple

& 1 analog signal

Digital Analog Pulse

Digital Analog Pulse

Digital Analog Thermocouple

Digital Analog

25

26

The Products• Two-way communication devices

– Transceivers

– Gateways

Digital Analog Pulse

Digital Analog Pulse

Radar Station

Fuel Tanks

Standby Generator

Airport Management SCADA

27

28

The Products

• I/O Expansion Products– Serial units

Up to 32 units

29

30

31

32

33

34

The Products

• Enclosures

– Explosionproof Enclosures

• NEMA 4, 7, 9

– Non-metallic Enclosures

• NEMA 3, 4, 4X, and 12 applications

35

• Class I Div 1 Installations– Wireless components require:

• Explosion proof enclosure kit– EJB

– GUB

• Division 1 Antenna

The Products

36

Industrial and Class I Div 2

– Wireless components require:

• “Enclosure suitable for the

environment”

• Non-metallic Enclosure

NEMA 4X

Fiberglass Reinforced Polyester

The Products

37

The Products

• Antennas

Dipole, collinear, Yagi, and whip antennas in various lengths and ratings are available to meet all power, range, and

direction variables.

38

The Applications

39

The Applications

40

The Applications

41

The Applications• Tank Farm

– Remote tank monitoring

• Power plant– Stack gas monitoring

42

The Applications

Remote Tank Monitoring

43

44

Power Plant - Stack Gas Monitoring

Control Room

Stack

Blower

Stack Monitoring System

The Applications

45

Key Features• Key features of Wireless Solutions:

– Flexible• Vast selection of digital, analog, and pulse inputs per transceiver• Repeaters are not necessary

– Expandable • Up to 31 serial expansion units • Each radio is capable of sending / transmitting 20 miles when

using an antenna– Reliable

• Redundant paths can be formed • Routine connection verification• Frequency hopping spread spectrum

– Secure• Radios use a highly secure data encryption technique

46

Benefits• Benefits

– Cost savings stem from:• Reduced repair costs, and machinery downtime/damage (leaks,

corrosion, etc)

• Improved operational efficiency and process control

• Safety costs (avoided injuries)

• Reduced manual/personal monitoring

• Eliminated conduit/cable systems/cable trays installations

47

Manufacturer BreakdownIndustrial Wireless Process Manufacturers (902-

928MHz Range)* % Market ShareGE MDS 15%

Cooper Crouse-Hinds 12%Ferguson Beaurogard 6%

Fedd Systems 6%Phoenix 6%

Accutech 5%Adalet Wireless 4%Bentek Systems 4%American Innovations 3%Cameron Measurement Systems 2%Emerson Process Management 2%

Honeywell 2%Others 32%

Total (Market Size $66.4 MM) 100%

* Source: Arc Advisory Group, 2008

48

Things to take away• Cost-effectiveness - When directly compared to wired installations, wireless is a very cost

effective alternative. Wireless modules allow seamless integration into all applications enabling installation costs to be kept to a minimum.

• Reliability - Radio protocols include multiple addressing levels, error checking, handshaking and automatic re-try mechanisms that guard against transmission failure. Should a communications failure occur, wireless solutions can provide multiple levels of alarm.

• Security - Most technology employed is state-of-art. As a result, each product has four levels of protection.

– Data is embedded in wireless transmissions using a unique modulation technique. – The data format has a unique structure with added security features, including network

and address validation. – Data is encrypted using a high-security encryption algorithm. – Wireless protocol operates on an exception-reporting basis, transmitting when there is a

change. This greatly increases the difficulty in collecting wireless samples for decoding.

• Ease of installation - Our modules have built-in diagnostics and remote configuration abilities that are designed to save time and hassles. Our free 24 hour technical support provides further assistance should you require it.

Questions?

OMS POWER TRAINING AND RESEARCH INSTITUTE

N-2/170, IRC VIllage, Nayapalli, BHUBANESWAR-751015. Tel. : 0674-2552984, 2552985.

website - www.omstraining.net. Email - info@omstraining.net