Gareth Johnston MIET
Wireless
Instrumentation for
process Industries
www.abb.com/fieldbus
Wireless
Instrumentation for
process industries Contents
Wireless World
Drivers
Wireless For Instrumentation
Standards and Technologies
Typical applications
Process Monitoring
Maintenance Checking
Safety and Environmental
WirlessHART Summary
The wireless time line – “What happens next?”
© ABB - 2
Aug-07
Wireless
Instrumentation for
process industries
Wireless World
Drivers
Wireless for
Instrumentation
Standards &
Technologies
Applications
WirlessHART
Timeline
The World is
Becoming Wireless
© ABB - 3
Aug-07
Wireless
Instrumentation for
process industries Wireless Technology Use is Growing
Wireless World
Drivers
Wireless for
Instrumentation
Standards &
Technologies
Applications
WirlessHART
Timeline
Wireless World
Wireless Industry
© ABB - 4
Aug-07
Wireless
Instrumentation for
process industries Wireless Market Drivers
Wireless World Business Drivers
Drivers
Need to increase
Wireless for
Instrumentation productivity
Standards & Declining capital
Technologies investment
Applications
WirlessHART
Barriers removed
Timeline “The rapidly emerging
Available technology
market for wireless devices
Emerging standards
in manufacturing will grow
dramatically....” Benefits
– ARC ‘Wireless Reduced engineering,
commissioning and
maintenance costs
Improved productivity and
compliance
© ABB - 5
Aug-07
Wireless
Instrumentation for
process industries What is Wireless Technology for Instrumentation?
Long Range
Short & Long Range Information
Wireless World Plant & Mobile Transfer
Drivers Worker
Wireless for
Instrumentation
Standards &
Technologies
Applications
WirlessHART
Timeline
Communication
Backbone
Long Range
Process Information
Transfer
Short Range
Process Instrumentation
Mesh Reliability
© ABB - 6
Aug-07
Wireless
Instrumentation for
process industries ABB Wireless Product and Pilot 2005/6
Wireless World
Drivers
Wireless for
Instrumentation
Standards &
Technologies
Applications
WirlessHART
Timeline Long range - Utility Mesh – Pilot Process Plant Medium range – Rail
Switching
Diverse
Wireless
Short range - Factory Knowledge Short range - Remote
HMI Mobile Worker
Automation
© ABB - 7
Aug-07
Wireless
Instrumentation for
process industries ABB Wireless 2007
Wireless Instrumentation Wireless Condition Monitoring Wireless Asset Management
Wireless World
Drivers
Wireless for
Instrumentation
Standards &
Technologies
Applications
WirlessHART
Timeline
Wireless HART ABB Vibration Monitor ABB Wireless
MultiVendor Demo Self powered
Engineering
ISA 2006 Simple set-up
Condition Monitoring
ABB – Emerson – Link to CMMS
Siemens
© ABB - 8
Aug-07
AW2006 Technologies
Wireless
Instrumentation for
process industries Wireless Multivendor Demo HCF
Wireless World Wireless Instruments
Drivers
Wireless access to intelligent device
Wireless for
information (Pressure – Temperature – Positioner)
Instrumentation
Process
Standards &
Technologies Configuration
Applications Maintenance
WirlessHART
The only multivendor demonstration
Timeline
Battery and externally powered
instruments
Wireless network to Asset Management
tools, via AssetMaster
Via HART DD
Via HART DTM
Wireless network components
(Gateway – Antennae …)
Low cost infrastructure
Co-existence with other wireless
networks in the hall
Reliable
Secure
© ABB - 9
Aug-07
Wireless
Instrumentation for
process industries Demonstrations at AW2007
Wireless World
Topologies
Drivers Wireless Plant wide and instrument
Wireless for level
High Speed Ethernet backbone
Instrumentation
FF – HSE
Standards & Profinet
Technologies
Applications Mobile Worker
WirlessHART PC, Tablet and PDA Platforms
Timeline GSM/GPRS – 802.15.4 - WiFi
Data manager – Data
Gatherer
Long range information
access
Point to Point device support (fault FF – HSE WiFi Prototype
drill down Zigbee)
Wireless Device and Network
Monitoring
Device Integration Zigbee Point - Point HMI
Enhanced Visualization Methods
Improved Graphical Interface
(EDD and DTM), Consistent
look & feel and method of
operation
Enhanced DDs for Profibus,
FF, HART
© ABB - 10
Aug-07
Wireless
Instrumentation for
process industries End Users, Standards and Technologies
End Users: Standards:
Wireless World
Oil & Gas: Process
Drivers
Wireless for Future cost savings possible Two emerging standards
WirelessHARTTM and ISA SP100
Instrumentation Multi-vendor offering
General
Standards & ABB Pilot test BP and Statoil
WiFi, Zigbee, WISA and
Technologies Chemical Proprietary widely available
Applications Same concerns as Oil & Gas
WirlessHART Fewer obvious cost savings
Technologies:
Timeline Process
Authentication, Security etc
concerns Enabling component
manufacturers at an early stage
Utilities of development DUST, Xbow,
Long range wireless Accutech,
established General
Remote HMI and Maintenance WiFi, WISA, GSM etc, proven
monitoring technologies
© ABB - 11
Aug-07
Wireless
Instrumentation for
process industries End Users, Standards and Technologies
Wireless World Standards & Technologies End Users
Drivers No international standard for High level of input into
Wireless for automation today. the standard groups
Instrumentation Applications are proprietary
Standards &
Working groups include
Technologies Running pilots
WirelessHARTTM
Applications ISO SP100
WirlessHART Holding back on
Timeline Major automation providers
projects – waiting for
support these groups interoperability
How do they support the effort?
Will we have one standard?
Technologies need to adopt the
standard
DUST – Crossbow and others to
provide the silicon
Need competition in this area
Pilots are proving the radio and
throughput
Pilot projects
are currently
underway
© ABB - 12
Aug-07
Wireless
Instrumentation for
process industries Wireless HART – ISA SP100
Wireless World WirelessHARTTM ISA SP100.11a
Drivers
Wireless for
Instrumentation Standard Radio 802.15.4 Standard Radio 802.15.4
Standards &
Technologies MESH – Star – Linear Topologies MESH – Star – Linear Topologies
Applications All routing device Routing and non-routing devices
WirlessHART
Timeline
HART Command Response Provides structure to overlay
protocol HART – Profibus – Foundation
Existing tools can be used for Requires specific tools for
commissioning Instruments commissioning Instruments
Ballot voting passed Specification ready for ballot Q3
Pilot devices shown 2006 07 (Will miss this target)
Specification target August 07 Specification target Q1 08
Supported by the major automation vendors
© ABB - 13
Aug-07
Wireless
Instrumentation for
process industries Industrial Automation Use Cases
Wireless World ISA SP100 Use Case Definitions Logging
Drivers Data/messages with no
Wireless for immediate
operational
Instrumentation consequence
Standards &
Technologies
Most Widely Alerting
Short term operational
Applications
WirlessHART
Accepted Use consequence
Open Loop Control
Timeline Cases Human interaction
"We get a lot of head-
nodding…when we ask end
users if they want to use wireless
for closed-loop control. However, Closed Loop Supervisory
Control
when you peel the layers of the Usually non-critical
onion away, what we find out is
that they’re …. not looking for Closed Loop Regulatory
Control
closed-loop control. There’s no Often critical
one I’m aware of, an end user, Safety
who’s interested in wireless, at Emergency actions –
this point in their lives, for always critical
closed-loop control.”
© ABB - 14
Harris Kagan, WINA President
Aug-07
Wireless
Instrumentation for
process industries What’s Needed For Wireless Success
Wireless World
Secure
No Option – It Must be Secure Multi – Vendor Support
Drivers Encryption and Authentication Open Std Choose most appropriate
Make it flexible -> Enhance the level of instrument
Wireless for security
Instrumentation
Standards &
Technologies
Applications
WirlessHART
Changing Radio Environment
Co-Exist Maximize Co-existence
Timeline ReliableSelf healing networks - MESH Good Worker and Neighbour
Redundant Gateways
As Easy to Use as 4-20mA HART
Cost
CapEx Cost Justification
Simple Simple tools to commission and planning Equal or lower cost of
installation than 4-20mA
Retrofit
Fits Existing installed instruments
Simple to add
No impact on existing control loops
© ABB - 15
Aug-07
Wireless
Instrumentation for
process industries What are Target Applications
End User Input
Wireless World
Wireless - Same information as 4-
Drivers 20mA
Wireless for
Instrumentation But with greater flexibility
Standards & And reduced costs
Technologies Reliable
Applications Common Applications Likely to
WirlessHART be:
Timeline Process Monitoring
Asset Management
Health & Safety –
Environmental Monitoring
Applications
H&S Process Asset
Environmental Measurement Management
Area Gas Multivariable Instruments Device Support
Detectors Short term Maintenance
Water Effluent measurements Diagnostics
Gas Emissions Tank Level gauging
Relief Valves Plant Infrastructure
Steam Traps Supervisory control
© ABB - 16
Safety Shower
Aug-07
Wireless
Instrumentation for
process industries What are Target Examples
Asset Management Short Term
Wireless World Measurements
Maintenance Monitoring
Drivers Add a wireless adaptor Increase process visibility
Wireless for Detect maintenance Conditions Low cost wireless solution
Instrumentation Route messages (CMMS – Pager) Additional devices
Standards & improves mesh
Technologies robustness
Applications
WirlessHART
Timeline
Process Monitoring 4-20mA
Tank Gauging
Expensive & difficult
to run
new cable
Hazardous Instrument
locations
Gateway
Multivariable Instruments
Difficult to modify
marshalling cabinet
© ABB - 17
Wireless solution
could be low cost
Aug-07
Wireless
Instrumentation for
process industries WirelessHARTTM summary
Wireless World
Drivers HART is a simple Command Response protocol
Wireless for Wireless HART adds a new physical layer with additional commands
Instrumentation
Standards & Wireless HART has been designed to satisfy the major user requirements
Technologies
Reliability
Applications
WirlessHART Security
Timeline Ease of use
© ABB - 18
Aug-07
Wireless
Instrumentation for
process industries Host level. WirelessHART Applications
Control system equipment Network Manager Security Manager
•Forms the mesh network •Distribution of encryption keys
(Controller – I/O – Workstations)
•Allows new devices to connect to join
Control Networks (Ethernet – WiFi) •Sets the communication schedule
•Establishes the data paths
Asset Management Applications
•Monitors the network.
Gateway Function
•Relay the wireless data to the Host system
Location •The connection to the Host could be copper (Ethernet
•Filed Mounted RS485), Fiber , WiFi…… This does not need to be
defined by WirlessHART
•Control room
s
Field devices Wireless HART
er
et
•Pressure 2secs Function
m
10
•Robust mesh network
•Temperature
•Multiple paths
•Flow •Self building
8secs 2secs 8secs
•Reliable
•Analytical
•Coexists with other wireless
•Level rs networks (WiFi, Bluetooth …)
met e •Channel Hopping (find a free
•Positioner/Actuator 0 s
7
ete r frequency band)
•Router 0m •Time division – don’t transmit on
20 one frequency for a long time
•4-20mA Adaptor
•Self powered and externally
50mete powered devices
•Hand held Configurator rs
4 secs
2 secs
An open MultiVendor
© ABB - 19
Standard IEEE802.15.4 2.4GHz radio Wireless environment
Aug-07
Wireless
Instrumentation for
process industries Making Wireless Easy with wirelessHART + Enhanced DDL
Devices must support "Maintenance Port"
Wireless World Compatible with Existing HART Tools
Drivers Supports access to all Device properties
Wireless for Used to, for example, enter Network ID and Password.
Instrumentation
Standards & Troubleshooting a device that
Technologies fails to join the Network can be
Applications one of the most frustrating
WirlessHART wireless experiences.
Timeline Tracks Mode As Device
joins the Network
Device Joins
Tracks Progress
Lights Up
Bottom to Top
Example DD Showing Dialog
that Monitors Device as it
joins a Network
© ABB - 20
Image by HCF
Aug-07
Wireless
Instrumentation for
process industries Performance
Wireless World
Drivers
How quickly is data
Wireless for updated?
Instrumentation
Standards &
Technologies
Applications Instruments on the same
WirlessHART
Timeline network can update at
different rates from Seconds
to several minutes
Fast updates will exhaust
batteries quicker
The refresh rate required by
many process and
maintenance monitoring
applications does not need to
be fast.
© ABB - 21
Aug-07
Wireless
Instrumentation for
process industries The Wireless Clock is Ticking From Midday – Today
Wireless World Where Industry
Drivers is Today
Wireless for
Single Vendor Battery Operated
Instrumentation
Solution Wireless HART
Standards &
Technologies No Standard Instruments
Applications WirelessHARTTM ISA SP100
WirlessHART Ballot Passed Standard
Timeline
WirelessHARTTM Wireless Fieldbus
Standard (Pilot (FF, Profibus)
Instruments Instruments
available)
Silicon availability
Test specifications Where ABB
is Aiming
Wireless HART
retrofit adaptor ABB Wireless
Vibration Control loops
Condition Monitor
© ABB - 22
Aug-07
Certification
Wireless
Instrumentation for
process industries Conclusion
Wireless World
Drivers Wireless connectivity is not
Wireless for new
Instrumentation
Proprietary – Multi Vendor
Standards &
Technologies Process Automation has
Applications special requirements
WirlessHART
Timeline
First applications for
Monitoring
Control much later
User concerns for Reliability
and Security
MESH – Encryption
Open Standards
ISA SP100
WirelessHART
© ABB - 23
Aug-07
Wireless
Instrumentation for
process industries
© ABB - 24
Aug-07
