Wireless System Applications for Process Control

1
Wireless System Applications for Process Control

• Matthew R. Piecuch
• Adalet Wireless

2
Why Wireless?

• Eliminate the expense, time, and associated costs
  of conduit, wire, and cable installations
• Lower installations costs
• (no wires, no conduit, less labor required)
• Lower maintenance costs
• Faster startups with increased flexibility
• Provides sensor monitoring in locations where
  running conduit and cable is impossible due to
  cost, location, or safety considerations

3
Save Project Eliminate the following items
from a budget?

• Trenching material
• Lift machine rental
• Concrete/blacktop
• Scaffolding
• Backfill
• Cable
• Conduit
• Permits
• Delays
• All associated labor

4
Division 1 Areas Keep it simple and SAVE ()

• Labor costs 35 / ft of conduit average
• Material costs
• Conduit
• Wire
• Fittings
• Project Time

5
Wireless Applications
TV DVD / CD Remote Cell Phone
Security HVAC Lighting Control Access Control
Consumer Electronics
Building Automation
Irrigation Golf Course Farm / Ranch
Patient Monitoring Fitness Monitoring
Precision Agriculture
Wireless At Work
Health Care
Residential Lighting
Industrial Control
Asset Management Process Control Environmental Ene
rgy Management
Security Lighting Emergency Lighting Lighting
Control
6
Industrial Wireless Applications
Gas Pipeline Monitoring
Petrochemical
Oil Gas Applications
Tank Farm Applications
Water / Waste Water
Pharmaceutical
7
Typical Applications

• Heavy Industry
• Extraction, Refining
• Conveying, Processing
• Manufacturing, Storage
• Water/Wastewater
• Municipal, Rural
• Environmental
• Pump Control
• Tank Levels
• Flow Measurement
• Preventative Maintenance

8
Markets

• Industrial Wireless products have been designed
  to meet the needs of all industries
• Industrial
• Petrochemical, oil gas, mining, chemical,
  pharmaceutical, power plants, mills,
  manufacturing facilities, tank level
• Utilities Municipalities
• Waste waste water, gas and electricity
  distribution
• Industrial Plant Control
• Process monitoring, machine control
• Transportation
• Traffic light control, traffic flow and
  monitoring, rail yard switching
• Also
• Temperature, Pressure, Level, Flow, On/Off,
  Run/Stop, Alarm, and more

9
Wireless System Architecture
Outputs
Receiver
Communication Protocols Data Scaling Power
Management
Inputs
Transmitter
Firmware
Wireless System
Thermocouples RTDs Pressure Transducers Vibration
Sensors Flow Sensors Level Sensors Contact
Closures
Power Supply Antennas Solar Panels Batteries
Sensors
Accessories
Housings
Division 1 Rugged OEM
NEMA 4X DIN Mount Other
10
Point to Point System Architecture
Up to 3000 wireless transmission through
obstructions
Base Radio inside control room
Wireless Transmitter at gas pipeline
A point to point wireless system connects one
field sensor to a control room via wireless
transmitter and base station receiver
11
Multipoint System Architecture
Sensor
Tank
Sensor
Tank
Sensor
Computer PLC / DCS
Tank
A multipoint wireless system connects multiple
field sensors to a control room via multiple
wireless transmitters and one base station
receiver
12
Wireless System with Repeater Architecture
Sensor
Tank
Computer PLC / DCS
A wireless system with a repeater provides
extended transmission distances for applications
with no line of sight or obstructions.
13
Industrial Wireless Advantages

• Lower Costs Atleast 50 less cost than wiring
  with additional savings associated with
  maintenance, troubleshooting, and upgrading
  networks
• For factories or applications with 100,000s
  square feet, the potential savings are enormous
• Ease of Installation Especially in hazardous
  areas labor costs associated with installation
  and maintenance are cut in half
• Maintenance Reduced labor and costs involved in
  inspecting, testing, troubleshooting, and
  repairing wires, conduit, and cable
• Reliability Tested and trusted technology
• Service Local company offering immediate
  support and service throughout the country

14
Wireless Instrumentation and Control Application
Considerations

• Steven Walker, P.E.
• Adalet Wireless

15
Users Functional Requirements

• User Type
• Automation professional
• Facility manager / process engineer
• Non-technical

16
Users Functional Requirements

• Application Type
• Class 0 Emergency action
• Class 1 Closed Loop regulatory control
• Class 2 Closed Loop supervisory control
• Class 3 Open loop control
• Class 4 Alerting
• Class 5 Logging, down/uploading

17
Users Functional Requirements

• Budgetary
• Wireless vs. wire cost/benefit depends on what
  wire
• Available resources on site technicians may be
  unfamiliar with wireless

18
Users Functional Requirements

• Warm fuzzy factor how comfortable is user
  with technology?
• Even engineers can be risk-averse
• Wireless manufacturers must demonstrate
  reliability.

19
Users Functional Requirements

• Security
• Intrusion
• Eavesdropping
• Corruption

20
Users Functional Requirements

• Operational
• Reliability
• Robustness
• Latency
• Throughput
• Range
• Margin
• What does failure mean? - FMEA

21
Installation design requirements

• Node locations
• Spread out
• Distance issues
• Link gain margin
• Directional / high-gain antennae
• Concentrated
• Interference

22
Installation design requirements

• Obstructions
• Fixed
• Mesh networking
• Relay points / bridges
• Mobility
• Either end or both ends of wireless systems may
  be mobile.
• Obstructions can be mobile, too.

23
Installation design requirements

• Environment
• RF
• Noise
• Shielding
• Physical
• Explosive
• Corrosive
• Weather
• Regulatory
• 900 MHz ISM unlicensed in N. America, Australia,
  Israel
• 2.4 GHz ISM unlicensed everywhere

24
Installation design requirements

• Future expansion
• Radio type
• Narrow band
• DSSS
• FHSS
• UWB
• Power supply
• Availability
• Type
• Longevity

25
Installation design requirements

• Coexistence/Interoperability
• Co-Existence is the ability of one system to
  perform a task in a given environment where there
  are other systems that may or may not be using a
  similar set of rules.
• RFID, pagers, telephony
• Interoperability is the ability of two systems to
  perform a given task using a single set of rules.
• WiFi
• Interworking is the ability of two systems to
  perform a task where each system implements a
  different set of rules.

26
Infrastructure requirements

• Process interface
• Analog
• Discrete
• Digital
• Modbus, Ethernet, HART, Fieldbus, ProfiBus, etc.
  
• Data presentation
• Hard I/O
• Digital data to control system
• Wireless worker

27
Maintenance Requirements

• Remote calibration of field device
• HART
• Wireless HART
• Proprietary cal procedure
• A/D and D/A calibration
• Each conversion adds error.
• Batteries
• Status
• Longevity
• Replaceability

28
Wireless System Evaluation

• Choose metrics important to you
• Establish fixed, normalized scale
• Rank application metrics
• Rank candidate system metrics
• Radar plot application and candidate systems

29
Wireless System Evaluation
30
Wireless System Evaluation
31
Wireless System Evaluation