H VanderBent Wireless Solutions

11/04/2012
1
Copyright Yokogawa Electric Corporation
WirelessSummitOslo_12041
! 1 ! ! 1 !
Wireless solutions "or the process in#ustry
$o#ay%s agen#a&
'ntro#uction ( the wireless lan#scape ( WO) * WS)
Why we selecte# 'S+100
WO) * WS) ,se cases
What-s important when implementing wireless
WS) case stu#y
Conclusion
.enk +/ 0an #er 1ent
2arketing 2anager 3iel# )etworks
Yokogawa Europe 1/4/
! 2 !
Yokogawas wireless solution portfolio
OPC
Field Wireless Configurator
Network Manager
WiFi
Modbus/TCP
Firewall
GW
SCADA/PAM PCS/PAM
Device Management
Field Backbone Network
YA !"#
$rd part%
de&i'es
YM#
(WSN)
(WON)
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2o6ile operators ( more pro#ucti0e
+ccess to real!time process in"ormation anywhere 7in the plant8 at any time
3ully "unctional 7or restricte#8 working en0ironment
9raphics: historical #ata: asset management #ata
2o6ile commissioning an# maintenance sta"" ( more e""icient
+ccess to maintenance in"ormation anywhere 7in the plant8 at any time
;oop testing: transmitter <ero cali6ration =on location>
?eal!time on!line #iagnostics
'nitiate: e@ecute: close an# report on work or#ers
Other wireless applications ( Camera-s
Sur0eillance 7"i@e#8
Sur0eillance ( ?emote locations: access control: intrusion #etection an# people tracking
;eak #etection
?emote maintenance support 7mo6ile8
?emotely locate# pro6lem sol0ing e@pert has on!line 0iew on eAuipment
Sa"ety ( ;ess people to go into ha<ar#ous en0ironments
W*% use Wireless Operations Networks
Bage 5
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Enhance# Blant +sset 2anagement 7B+28
Cost e""ecti0e increase o" process an# asset monitoring
3reeing up ca6le resource "or higher priority measurements
?eplacement o" pressure gauges an#Cor 6i!metal temperature in#icators
+llows measurements that coul# not 6e Dusti"ie# 6e"ore
?e#uction o" =6lin# spots> ( higher 0isi6ility into operations
+llows measurements on rotating an#Cor mo0ing eAuipment
Wiring #i""icult ! no power a0aila6le
+llows measurements in remote locations
=,nlock> remote processing units in general ( well hea#s: tank "arms: loa#ing 6ri#ges e/g/
Once esta6lishe#: wireless sensor networks are scala6le
+##itional sensors can 6e a##e# at low cost
$emporary measurements "or process #iagnostics an# optimisation
W*% use Wireless +ndustrial Sensor Networks
Bage 4
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+SA,-- sensor.to./oardroo0 wireless
Bage E
+
S
A
,
-
-

s
'
o
p
e
+SA,--1,,a
+SA,--1,2
+SA,--1,2
+SA,--13,
+SA,--1,4
+SA,--1,4
+SA,--1,4
+SA,--1,5
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3le@i6le network topologies ( "it "or purpose
Gi""erent #e0ice roles ( 'CO: ?outing: 'COH?outing
1ack6one routing: Guo Cast an# multiple su6nets
.igh sensiti0ity ra#io-s
;arge ;ine O" Sight 7;OS8 #istances
Superior coe@istence algorithms
?o6ustness ( low packet error rates an# low latencies
.igh power e""iciency
Ge#icate# an# share# time slots
Slotte# 7"ast8 an# slow hopping
Out!o"!6an# 7OO18 an# O0er!the!air 7O$+8 pro0isioning
+SA,-- strengt*s
6ni&ersal Pro&isioning ool
ir
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+SA,-- strengt* 7 star8 0es* and 0i9ed topologies
Bage
, *op
Star
3 *ops
Mi9ed
Multiple hops - latencies
Bridges larger distances routing
Less power efficient - routing
Not deterministic monitoring only
Redundant network
Single hop low latency
High update speed 1 second
Deterministic suitable for control
High power efficiency no routing
Redundant BBR and Duo Cast
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WON and WSN 6se Cases
4isit& http&CCwww/"iel#!wireless/comCenCsolutionsCin#e@/html
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Appli'ation: DCS and PAM (Plant Asset Manage0ent) An%w*ere
2o6ile workers ! Commissioning in the "iel# reAuires access at 0arying locations
2aintenance reAuires asset management in the "iel# "or trou6le shouting
C*allenge:
Blant wi#e W'3' co0erage in a plant with lots o" steel 6arriers
Eliminate local control rooms 7use# "or start!up only8
Field Wireless Solution:
Wireless 6ack6one
)ote6ooks suita6le "or rough en0ironments an# appro0e# "or use in ha<ar#ous areas
?oaming ! While walking aroun# switch automatically 6etween +ccess Boints
Field Wireless ;enefits:
3aster commissioning time
;oop testing an# tuning in the "iel#
2onitor smooth start up in the "iel#
;ocal control room eliminate#
$emporarily tents are use# "or commissioning an# start!up
Single #ata6ase through wireless GCS an# B+2 +nywhere
6se Case , . <efiner% 'o0ple9 (WON)
Bractical
Wireless
! 10 !
Appli'ation: Pro'ess Monitoring8 Mo/ile Operator8 Ca0eras
( $emperature: le0el: pressure: 0al0e position an# 0i6ration monitoring 7se0eral WS)s8
( 2o6ile workers 7operator an# maintenance sta""8: sur0eillance an# mo6ile cameras
C*allenge:
( 'ntegrate WO) an# WS) into e@isting an# running GCS system ( large geographic area
( Gi""erent wireless technologies "rom #i""erent 0en#ors
( Wireless 'n#ustrial 9ateways 7WS)8&
K 9W-s 7@J8 with connecte# sensors 7@218 an# repeaters "or re#un#ancy
( Wireless +ccess Boints 7WO)8
K +B@14
( System separation 6y 3irewalls where =wireless meets wire#>
( +## measurement points without in"rastructure 7no powerCno ca6les8
( $ransparent WO) H roaming
( ?emote maintenance support "rom .L
( 3le@i6ility 72o6ile Worker8
6se Case 3 . C*e0i'al Plant (WSN = WON)
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Appli'ation: Maturing dru0 te0perature 0onitoring
( ?eplacement o" mechanical temperature sensorCin#icator
( 1E0 secon#s "or one re0olutionM 6atch process #uration is "our hours
C*allenge:
( $emperature is monitore# to maintain consistency o" 0iscous "i6er "ee#
( ?elia6le temperature measurement in automation system
( Wire# temperature measurement is not possi6le ! #rum rotates
( Wireless temperature measurement on #rum
( 9ateway an# 2 repeaters
( ?epeater location care"ully selecte#
( ?a#io signal path is changing continuously
Field Wireless ;enefit:
( Sta6le on!line temperature measurement
( ?o6ust wireless communication was con"irme#
( Backet Error ?ate is almost 0N
6se Case $ . e9tile Plant (WSN)
Repeater
Gateway
Repeater
About 3m
YTA
Drum
YTA
! 12 !
6se Case 4 . Natural Gas Plant (WSN)
Appli'ation: e0perature and pressure 0onitoring
( $emperature an# pressure monitoring o" natural gas well
( Each well is surroun#e# 6y metal meshC"ence to pre0ent intrusion 7security8
( +rea with hea0y snow "all ! snow 6uil#s on the meshC"ence
C*allenge:
( ?eplacement o" aging e@isting optical ca6le network in the "iel#
( ;ow cost implementation
( Concern that the metal meshC"ence an# snow has e""ect on ra#io communication
Wireless Solution:
( $est con#ucte# with temperature transmitter 758
( $ransmitters locate# at the well insi#e the metal meshC"ence
( 9ateway to sensor #istance is appro@imate E0 meter
;enefits:
( Signal strength #ecrease# #ue to shiel# 6y "ence an# snow
( Backet Error ?ate is less than 1N
( )ote 9ateway to sensor #istance o" E0 meter
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! 15 !
Appli'ation: 6tilities Manage0ent
( Oil Consumption an# in0entory management
( 3low 758: le0el 7E8 an# pressure 728 measurement
C*allenge:
( 2!5 measurement points per measurement <one ! <ones a6out 400 meters apart
( Ca6ling costly an# te#ious "or Dust 2 or 5 measurements 400 meters #istant
( 2easurement points almost at groun# le0el
( $rees in the plant in 6etween the measurement <ones
( EOP110 @ I pcs 7le0el * "low8: EOPE50 @ 2 pcs
( 1 9W 7positione# on top o" water tank 8
( ?epeaters 758 at suita6le locations
( Elimination o" 1F00 m ca6le
( ?e#uce# mo#i"ication work
( $ime sa0ing
( 3le@i6le "or "uture e@pansion
6se Case 2 . 6tilit% Manage0ent (P>P) (WSN)
! 14 !
Appli'ation: ?e&el 0easure0ent
( Storage tanks in two locations ( 1E m high
C*allenge:
( Gistance to central control room I00 meters
( B4C plant ! stray magnetic "iel# present
( Blant locate# in area with hea0y rain "all
( EOP110 @ pcs:
( Y39W 9ateway 7on top o" water tank 8
( ?epeater 718 at suita6le location
( Eliminate I00 m ca6le through the plant
( ?e#uce# mo#i"ication work
( $ime sa0ing
( 3uture measuring point e@pansions
6se Case 5 . C*e0i'al Plant (WSN)
Control
Room
Distance from
control room to tank farm
800 Meter
Tank Farm
Gateway
EJ
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! 1E !
Appli'ationM e0perature Monitoring on @eat !9'*anger
2onitor the e""iciency o" heat e@changer which maintains ;)9 temperature
C*allengeM
.igh ca6ling construction costs #ue to many monitoring points o0er wi#e congeste# plant
20 points each "or inlet an# outlet
,p#ate time reAuire# E Secon#s
'ntegration with thir# party GCS System an# +sset 2anagement System
$ransmitter locations 2E 2eters high
;ong 1attery li"e reAuire#
$emperature $ransmitter 7408 an# 9ateway 728
3ast up#ate time time 7E sec8/
9ateway with 15 meter e@ten#e# antenna
increase# per"ormance C relia6ility
Eliminate wiring: construction an# installation costs
;ong 6attery li"e 7E!10 years8
)o inter"erence with e@isting Wi!3i system/
6se Case A . Gas Plant (WSN)
! 1F !
+s wireless Bdiffi'ultCD
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! 1 !
)o: not necessarily
't-s #i""erent
+s wireless Bdiffi'ultCD
Bage 1
GW
GW
! 1I !
)etwork lay!out: a0aila6ility an# prioritisation
Where to install access points: measurement #e0ices an# repeaters
Site an#Cor #esk sur0ey is to 6e consi#ere#
)etwork co0erage in case o" mo6ile workers
Coe@istence with other wireless signals: scala6ility
?3 site sur0ey: planning an# simulation tool
'#enti"ies e@isting wireless networks
2o#elling so"tware ! network #esign
Wireless sensor networks "eature&
?elia6ility an# re#un#ancy
3le@i6le network topologiesM re#un#ant 11?-s an# 9W-s
Security an# per"ormance
Encryption: authentication: channel hopping: interopera6ility
W*en i0ple0enting wireless8 w*ats i0portantD
Bage 1I
R
R
GW
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10
! 1J !
Chemical plant ( 6rown"iel#
'mplement a set o" 5 measurement points at locations
Gi""erential Bressure: static pressure an# temperature
$he locations are #istri6ute# o0er a 500 @ 500 meter area
+ction plan
1ase# on customer pro0i#e# in"o an# plant #rawings
+ssess sensor an# gateway locations
'#enti"y possi6le o6stacles that pre0entClimit ;OS 6etween sensors an# gateay
Gesign network layout
'#enti"y i" routers are nee#e# an#Cor e@ten#e# antennas
Site sur0ey
Site walk to assess the presence o" other wireless signals
4eri"y network layout #esign
Broo" o" concept
+ctually test worst case scenario to 0eri"y network layout in practice
+0ple0enting wireless 7 a 'ase stud% (,)
! 20 !
+0ple0enting wireless 7 a 'ase stud% ($)
Distances to bridge:
7 locations, 3 sensors each
One gateway at CCR in location 5
Distance location 5-2 is 200 meter
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+0ple0enting wireless 7 a 'ase stud% (4)
Network design:
Location 4 and 5 direct to GW
Repeaters for other locations
Redundant repeaters
Redundant path
On-line battery exchange
! 22 !
Site walk:
Asses other wireless signals
Visual network design verification
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Proof of concept:
Location 1 no LOS signal ok
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)etwork management tool
4isualises network graphically
)etwork monitoring tool
'n#ication o" network ro6ustness
?SS': BE? #ata
Signal Auality router!gateway
Out o" speci"ication 7it #i# workQ8
2o0e# 9W "rom 2 !R m high
Ber"ormance as e@pecte#
+0ple0enting wireless 7 a 'ase stud% (A)
11/04/2012
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! 2E !
Appli'ation: e0perature and pressure 0onitoring
( 'mplement 21 wireless transmitters in locations ! wire# in"rastructure not a0aila6le
C*allenge:
( $he 6uil#ings are relati0ely high an# close to each other
( $emperature an# pressure transmitters: 9ateway an# F repeaters
( ?epeaters at #i""erent locations 7re#un#ancy8
( ;ocations care"ully chosen "or optimal network relia6ility
( 9ateway locate# m high
( ?emote antenna coul# 6e consi#ere#
Field Wireless ;enefit:
( Sta6le measurements
( Backet Error ?ate is almost 0N
( ?epeaters pro0i#e re#un#ant ra#io path
( ?epeaters allow =on!line> 6attery e@change
( Signi"icant sa0ing on ca6ling: time etc/
+0ple0enting wireless 7 a 'ase stud% (E)
! 2F !
9.< ra#io is sensiti0e to the e@istence o" o6stacles
Wireless is not much a""ecte# 6y =the climate>
'S+100 WS) is not much a""ecte# 6y other wireless networks
Coe@istence 6y channel hopping an# propper CC+: network an# Doin keys
Separate "reAuency 6an#s ! e/g/ Wi3i E 9.<: sensor network 2/4 9.<
2esh network 7more than two paths8 o""ers relia6ility
$he higher the num6er o" the #e0ices the higher the =ro6ustness> o" the mesh
'ntro#uces latencies: is not #eterministic: not suita6le "or control: 6attery in!e""icient
?esponse time is a use"ul in#icator "or the ra#io transmission con#ition
?esponse time "luctuations #ue to communication re!tries an# mesh routing change
Star network 7re#un#ant 11?-s8 has superior 6uilt!in ro6ustness
.igh spee# up#ates: #eterministic: re#un#ancy: suita6le "or control
Field e9perien'e 7 lessons learned
Bage 2F
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! 2 !
Blant wi#e monitoring an# process control
'ntegration o" WO) an# WS)
Superior sensor network coe@istence
?o6ustness ( low packet error rates an# low latencies
.igh power e""iciency
3le@i6le sensor network topologies ( "it "or purpose
Gi""erent #e0ice roles ( 'CO: ?outing: 'COH?outing
1ack6one routing: Guo Cast: re#un#ancy an# multiple su6nets
Broperly #esign the network7s8 ( WO) an# WS)
Gesk stu#y: site sur0ey an# proo" o" concept
+sk your supplier to assume total wireless solution responsi6ility
Su00ar%
! 2I !
Wireless8
the ne@t maDor technology transition in 'C+

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11/04/2012

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