Wireless Technology Update

Craig Abbott

Emerson Process Management

Emerson in 2015

Emerson’s Five Business Platforms

Solving the process

industry’s toughest

challenges with

predictable

success any time,

any place

Process Management

Revolutionizing

manufacturing to

operate faster,

more efficiently

and cost effectively

Industrial Automation

Optimizing and

deploying critical

infrastructure for

today’s mobile,

always-on world

Network Power

Innovating to help

improve human

comfort, safeguard

food and protect

the environment

Climate Technologies

Making projects

easier, safer and

more efficient for

professionals,

contractors and

homeowners

Commercial & Residential Solutions

Agenda For Today

1. The Different Flavours of Wireless

2. IEC62591

3. System Integration

4. Available Instrumentation

5. WirelessHART Solutions

6. Wi-Fi

7. System Integration

8. Wi-Fi Application Examples

Industrial Wireless Comes in Many Forms

Radio Satellite3G/4G/LTEWi-FiWireless

Instruments

Wireless Field Networks

WirelessHART Based Solutions

A Summary from PharmOut (Grant South, Senior Consultant)

• https://www.pharmout.net/wireless-sensors-in-a-gmp-environment/

Pros Cons

•Relatively well priced compared to a traditional

wired sensor

•No cabling, wall penetrations or other installation

difficulties

•Attractive option for retrofitting existing facilities

•Particularly suitable for sterile facilities where

cabling can cause cleaning and contamination

issues.

•Additional maintenance activities (e.g. scheduled

battery replacement)

•Signal propagation issues can be caused by

interference, and physical obstacles (walls,

personnel, equipment), particularly when changes

are made in facilities, such as installation of new

equipment

•Communication speed/reliability may not be

sufficient for sensitive or time critical applications

•Wireless sensors by different manufacturers may

not be interchangeable due to differing RF bands,

proprietary protocols, etc.

Connecting Devices Wirelessly

Point to Point

NetworkStar Network

Self Managed Mesh Network

Gateway

Control Room

Obstruction

Obstruction

Obstruction

Obstruction

International Standard IEC62591

CSI

Good Manufacturing Practice – If you don’t measure you can’t manage

Reliability & Maintenance Energy Efficiency & Loss

• Pump

• Blower

• Air cooled exchanger (fin fan)

• Non-process compressor

• Cooling tower

• Pipe & vessel corrosion

• Valve

• Instrumentation

• Vibration, temperature, acoustic tester rounds

• Steam trap failure

• Heat exchanger fouling

• Cooling tower fan optimization

• Relief valve seat leakage

• Unit-wise energy consumption metering: water, air

(compressed), gas/fuel, electricity, and steam

Health, Safety, and Environmental (HS&E) Process Operations Productivity

• Emergency Safety shower and eyewash

• Manual and bypass valve position

• Relief valve and rupture disk release

• Toxic / flammable gas release

• Hydrocarbon leak detection

• Effluent discharge

• Operator rounds: gauge, sight glass, VA meter

• Tank farm storage tank

• Wellhead

• Separator and test separator

• Dosing

System Complexity

Wired Projects Wireless Projects

Security

Integration Options via an Emerson Gateway

WirelessHART

Network

Serial Modbus

IP Modbus

IP Modbus

Ethernet/IP

DeltaV

HART/IP

RS485

Serial Modbus

Ethernet

SCADA/HMI/Workstation

SCADA/HMI/Workstation

SCADA/HMI/Workstation

SCADA/HMI/Workstation

PLC/RTU

PLC/RTU/DCS

PLC/RTU (typically AB)

SCADA/HMI

Asset Management Tools

Each gateway has one Serial Port (2 wire RS485) and two Copper Ethernet Ports (RJ45, 10/100 Mbit)

The Ethernet can be converted to run over Copper, Fibre, 3G/4G/LTE, Satellite, Radio or ADSL

DeltaV DCS

OPCSCADA/HMI/Workstation

Instruments

Gateway

Isolation Options

Process Control

DCS ESD

Process Operators Energy Management Asset Management

RS485 Modbus

Installation

• Low installed cost– Clamp-on

– Strap-on

– Bolt-on

– Stick-on

– Stud

– Magnetic

– Slip-in

• Low risk– No cut

– No drill

– No weld

– Self organising

Clamp-on

Strap-on

Stick-on

Screw-on

Magnetic

Bolt-on

LaySlip-in

Swap

Instrumentation Options

• Pressure

• Single Spot Temperature

• Multi-spot Temperature

• Differential Pressure

• Combined Pressure & Differential Pressure

• Flow (annubar / conditioned orifice plate)

• Level (Guided Wave Radar)

• Level (Hydrostatic)

• Level or Dry/Wet (Vibrating Fork)

• Oil/Water/Sand interface detection

• Digital On/Off feedback

• Digital On/Off output

• Low Speed Counter (<50Hz)

• High Speed Counter (<10kHz)

• Steam Trap Health

• Acoustic flow (PRV release / leak)

• Vibration (motion and PeakVue®)

• Bearing Temperature

• Valve Position (On/Off)

• Valve Drive (Pneumatic Open/Close)

• Valve Position (% Open)

• Corrosion Monitoring

• Sand detection (erosion)

• Wireless Conversion Kit (THUM)

17Emerson Confidential

Water

Gas

Electricity

Air

Steam

Cooling

Cleaning

Inert Blanketing

Mixing

Instrument Air

Energy Management Requires Measurement

Raw Material

Heating

Process Control

Pumping

Combustion

Every process is an energy consumer

Condition Monitoring

Water Consumption Management

Consumption can now be allocated to plant areas

Allocation of costs

Efficiency management

No measurement of existing water storage

No cabling available

No power available

Would need to trench

GSK – Cork, Ireland

“Whenever we look to improve the plant with new equipment, we are always looking to minimise

capital expenditure and Smart Wireless can help achieve lower costs.”

Emmett Martin, Site Services & Automation Manager, GlaxoSmithKline

CHALLENGE

Wireless Pressure

Wireless Level

Wireless Flow

30 second updates

SOLUTION RESULTS

HSSE

RESULTS

Instrumentation Reliability

• Issues with instrumentation

are detected and corrected

before they can impact

product quality

CHALLENGE

Required additional data to monitor performance and reliability of control system

Existing PLC did not have instrument diagnostics capability

A Pharmaceutical Facility in Australia

Approximately 60 wireless transmitters and THUMs to collect diagnostics data from instrumentation

SOLUTION

RELIABILITY

Continually Changing Processes

Improved accuracy of

documentation to verify

that specific chemical

wastes have been

destroyed

Treatment, incineration, and distillation of waste products for the pharmaceutical industry

Cost of monitoring, tracking in a constantly changing environment

Technochem Environmental Complex Pte Ltd

PROCESS

CHALLENGE

WirlessHART Network with pressure transmitters that can be moved and repurposed within minutes.

SOLUTION RESULTS

“If I see a problem in some part of our process, it is fairly simple for me to take a pressure

transmitter and move it elsewhere. I can often determine what’s going on in just five minutes,

address the issue and quickly return the transmitter to its original application.”

Jan Huijben, Incineration Manager

Rotating Equipment

Greater reliability of

temperature measurement

leading to better process

control and improved

product quality

Carbon reactivation process uses a rotating kiln

Very difficult to accurately monitor temperature on the rotating equipment

Calgon Carbon

PROCESS

CHALLENGE

WirlessHARTtemperature transmitters connected to existing thermocouples to report data without the use of slip rings

SOLUTION RESULTS

“We used WirelessHART because of the ease of installing the network, the reduced cost of installation,

and the ability to communicate in spite of the constant rotation of the kiln. Non-wireless methods were too

expensive, and other wireless line-of-sight systems could not handle the kiln’s movement.”

Jeremy Dolan Site Manager, Calgon Carbon

Safety Shower Monitoring

Significantly increased

man-down awareness

Timestamped events

for inspection and

incident review.

Response times to safety events deemed too long

Need real time monitoring of safety showers and eye wash stations.

Monroe County Pure Waters

CHALLENGE

One WirelessHART digital transmitter per station.

SOLUTION RESULTS

WHSE

NaOH Leak Incident

“Although I was protected by the proper PPE, I still used a nearby emergency shower to dilute

the hypo. Despite my best efforts, the line continued to leak and I was unable to call for radio

help. I had to run to the solids control room for help.”

Jeff Helfer, Maintenance Manager, Montor County Pure Waters

Wireless Plant Networks

Wi-Fi Based Solutions

• Installed across all industries– Pharmaceuticals

– Food and Beverage

– Chemical

– Oil & Gas

– Power

• Supporting Multiple Applications– Mobile Worker

– Mobile Video

– Control System Bridging

– Field Device Backhaul

Hundreds of Wireless Plant Networks Globally

Wireless Plant Networks

• Star Network around Access Points

• May be meshed for backhaul

• High Speed Data Access

• IT Protocols and Applications

The Mobile Workstation

• Access to the control system at all times

– Laptop, Tablet, Mobile Desktop PC

– Thin or thick client

• Electronic Workbook

– Data sampling

– Digital rather than paper

– Timestamped records

• Online documentation

– Manuals, Procedures, Approvals processes

The Mobile Worker

• Integrated Hard Hat

– Video Camera

– Microphone

– Noise Cancelling headphones

• Two way communication with control room

– Expert sees what field tech sees

• Man Down

Mobility Tracking

• Location Triangulation from Wi Fi hotspots

• Proximity to Beacons

• Calculate direction

• Asset Tracking

• Personnel Tracking

• Proximity to Hazards

• Emergency Mustering

Security Enhancements

• Power And Comms Options

– Ethernet

– Wi-Fi

– POE

• Built in Video Analytics

• Built in Audio Analytics

Video Integration with the DeltaV DCS

• Live Video is streamed directly to the Operator Workstation

• Video can be embedded in the same display as the process data

• Full Pan, Tilt & Zoom control capability

Operator Mobility

Halved Workstations

Faster Calibration

New Production

Opportunities

Xolair® production

Localized control is essential

Three production levels

Geographically dispersed

Needed Mobile Workstations

Novartis

PROCESS

CHALLENGE

10 WiFi Hotspots

17 Mobile Operator Workstations

Cell cultivation, harvesting, purification and freezing

SOLUTION RESULTS

“Because of the wireless network, we do not need to systematically invest in new control stations, even if

the production of new products requires a change to the plant equipment or layout.”

Philippe Heitz, Head of Engineering, Novartis

Combined Wireless and Wi-Fi

• Emerson™ Smart Wireless Gateway 1552WU

• WiFi components

– 1550 Series Cisco Router

– 5GHz (an) WiFi for meshed backhaul

– 2.4GHz (bgn) WiFi for local data access

• WirelessHART components

– Embedded Rosemount 1420 Gateway

• Additional Wireless Applications

– Mobile Worker

– Safety Mustering

– Location Tracking

– Audio and Video support