Wireless Industrial Applications

Wireless Industrial Applications

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Purpose and learning objectives

• Overview of industrial wireless technologies (ISA100, HART Wireless, WiFi, WiMax), including economics and how to develop a new engineering mindset

• Engineering decision criteria, including essential requirements and desired requirements

• Need for a long-term wireless strategy• Specifications downfalls when evaluating radio aspects • Rapid prototyping of wireless sensors in an industrial environment• Define best practices to RF design in complex/harsh RF (radio

frequency) environments, such as manufacturing/ industrial/ power generation facilities

• Review real examples of wireless sensor deployments in industrial environments for workforce efficiency and condition-based monitoring.

Speakers

Moderator: Mark T. Hoske, Content Manager, Control Engineering, CFE Media, covering industrial wireless and, among other topics, since 1994.

Stephen Muenstermann, RoviSys Building Technologies, DC market manager- Lead wireless field solutions for a major automation company for North America and the global interface for all industrial wireless infrastructure. - More than 10 years of experience in industrial applications, radio frequency and communications military intelligence, industrial instrumentation and commercial wireless- Conducted more than 300 seminars on industrial wireless technology.Damon Brady, section manager, SAIC Energy, Environment & InfrastructureMore than 15 years of technical and managerial experience in network communications and critical infrastructure services, with 10 years leading network design, implementation, and integration processes for utility, energy, public safety, and Smart Grid clients.Douglas Bowers, senior project manager, SAIC Energy, Environment & InfrastructureMore than 15 years of experience in system integration for communication and network systems, identifying requirements, writing specifications, design, testing, and delivery, including rapid prototyping and development of sensor systems for industrial environments.

RF & Wireless Technology Simplifying the Beast!By: Stephen Muenstermann, RoviSys

Objectives

Learning objectives are to understand:• Overview of industrial wireless technology, including

economics and how to develop a new engineering mindset• ISA-100, HART Wireless, WiFi, WiMax, proprietary

• Engineering decision criteria, including essential requirements and desired requirements

• Need for a long-term wireless strategy• Specifications and downfalls when evaluating radio

aspects of the technology

What do we know?

• Wireless will happen (or has happened) at your facility!

• Wireless creates some level of fear• We can access a wealth of information today

through wireless• There is power in using wireless• It is not an engineering norm to use wireless in

an industrial environment• Not in typical FEL practice

FEL = front end loading

Today

• The cloud has created forced adoption; it cannot be ignored.– Scalability– Design and set-up immediately– Proof of concept with minimal infrastructure cost– Plant floor security is rock solid– Great economic advantage– Huge savings a reality

• Brownfield apps carry biggest gains• Regulatory wins huge• Inventory management• LDAR• SCADA (supervisory control and data acquisition)

Whose standard is best?

• 802.11 a, b, g, and n• 802.15.4 (ZigBee®)• ISA® 100.11a• HART Wireless• 802.16 (WiMax®)• Proprietary• Coexistence?

ZigBee is a registered trademark of Zigbee Alliance in the U.S. and/or other countries. ISA is a registered trademark of the International Society of Automation in the U.S. and/or other countries. WiMax is a registered trademark of WiMax Forum in the U.S. and/or other countries.

Evaluation criteria

• Do wireless! But, have a strategy.• DIY? (Do it yourself?)

– Things to consider– Shortcuts can cost– Vendor claims will hurt

• Outsource? – Evaluation process– Background– RF or IT – Big difference

• Success in connectivity can only derive if RF worksRF = radio frequency IT = information technology

Evaluation criteria

• Do wireless! But, have a strategy.• Building a managed radio frequency (RF)

network – How would you do wired?• Control your cloud• Wireless FEED (front-end engineering design)• Build for scalability• Integration is easy – Learn RF’s simple

tribulations

Need for strategy

Sensor networkISA®, HART and

proprietary

HandheldHMI/remote worker

SCADA/HMI/BMS/EPMS

Security/regulatory

Safety

HMI = BMS = EPMS =

ISA is a registered trademark of the International Society of Automation in the U.S. and/or other countries.

Other reasoning strategy planning

• Don’t leave design to ad-hoc measures• Current security issues likely exist

– Business-level over plant floor• Managing RF/noise environment• RF and antenna management • Appoint a wireless manager

lead/leader

RF = radio frequency

Specifications and shortfallssimple observations to learn

• Communication – antenna and RF• Near field and robbing BW• Hops – rings and understanding mesh• Organized process – Is it self-healing?• Spectrum analysis tools• Coexistence with everything and noise floor• Simple security/HR problems• LOS – line of site – true meaning• ISA® symbols to live by: RF = radio frequency HR = Human Resources BW =ISA is a registered trademark of the International Society of Automation in the U.S. and/or other countries.

Communication – antenna and RF

D

Near field

RF = radio frequency

Directional = greater distanceYagi and parabolic typical

Communication – antenna and RF

D

RF = radio frequency

Problems:• Antenna signal warping due to metal proximity• All antennas at same frequency mounted at same level• Crowding near field, which means receiver sensitivity breaks down,

data loss/overlap

Near field and coexistence potential mounting issues

Near field and coexistence potential mounting issues

Problems:• Busy tower• Antennas are properly staggered• Directional antennas aimed to not

cross paths

Rings of mesh! CR

1

2

3

4

5

Every hop results in a 50% drop in packet delivery. Mesh design strength is only as solid as its design.

Beware of the vendor that says, “Just throw in another repeater.” You may get the data, but with what issues?

Within your four rings, it is possible to have hundreds of sensors, depending on architecture.

Mesh has different meanings

• Not all mesh networks are self-healing– Does it require a master controller?– Can the nodes/routers act as gateways?– How many routes will it list internally?– Does it require integration to organize mesh?

• Is the mesh only radio sets or sensors?• Can end-points mesh?• Where does redundancy end?

– Any single point of failure?

Spectrum analysis tools

900 MHz

2.4GHz/5GHz

ISM bands Wall

Attenuating sourceISM = industrial, scientific, and medical

Coexistence-noise floor

• Every transmitter adds to the noise floor• Most industrial wireless networks will coexist• Microwave ovens, CCTV, other; proximity is key

CCTV = closed-circuit television

Security – HR issues

Real security• Authentication• Encryption• Deterministic• FHSS• Anti-collision• Notification

Attacks • Extremely expensive• Highly sophisticated• No real impact if successful

Real insecurity - easy

Chain-link fence tossed into substation

FHSS = frequency hopping spread spectrum

LOS/Fresnel zone

LOS = line of sight

Spectrum analysis/Line of RF site

900 MHz

2.4 GHz/5 GHz

ISM bands Wall

Attenuating sourceISM = industrial, scientific, and medical

Summary of objectives

• Overview of industrial wireless technology, including economics and how to develop a new engineering mindset• ISA-100, HART Wireless, WiFi, WiMax, proprietary

• Engineering decision criteria, including essential requirements and desired requirements

• Need for a long-term wireless strategy• Specifications and downfalls when evaluating

radio aspects of the technology

Wireless Monitoring, Sensing

By: Damon Brady, SAICDouglas Bowers, SAIC

Objectives

• Educate viewer on rapid prototyping of wireless sensors in an industrial environment.

• Define best practices to radio frequency (RF) design in complex/harsh RF environments such as manufacturing/industrial/power generation facilities.

• Review real examples of wireless sensor deployments in industrial environments for workforce efficiency and condition-based monitoring.

• Enterprise cyber security assessments, design, and remediation

• Critical infrastructure IT network design and build (IP voice and data, fiber/copper cable plant)

• Wireless networking• Control systems hands-on experience• Infrastructure design, implementation

and operations

Wireless and mobility – field and plant (IT) services• Real-time data and predictive

analytics• Comprehensive technology support• Location-based services for people

and assets• Asset management and optimization• Application support (work

management, asset management, scheduling)

32

IP = Internet Protocol

Wireless and mobility –Wireless design practiceBusiness challenge: To design wireless connectivity for multiple domestic nuclear power plants. Including power block and turbine facilities (radioactive areas).

Approach• Senior-level engineering teams with proper

credentialing for passive and active surveys to each location

• Develop advanced computer-based modeling of each facility in order to develop highly accurate radio frequency (RF) model and drive final design and bill of materials

• Retain RF engineers for installation process oversight• Perform commissioning, testing and validation

Results• This approach will deliver highly accurate designs,

reducing materials costs and need for design modification after installation,

• Allows for delivery of new, advanced applications into all areas of facility, increasing safely and efficiency

• Lower dose for install crews (less time in radioactive environments). It gets done faster …

33

Wireless infrastructure deploymentDesign development process

• Discovery activity• Requirements verification• Engineering analysis (RF allowability, etc.)• Analysis of drawings• Site walkdown (challenge briefings, etc.)

• Onsite wireless surveys• Passive survey: RF data collection, spectrum analysis, building composition

analysis, outdoor features/topology noted. Deliverable: preliminary design• Active survey: Validation exercise for our preliminary AP placements.

Measure actual signal performance. Deliverable: final design

• Wireless modeling and network design• Final bill of materials (equipment specifications and unit counts)

• Design team:• Range of skills (systems/RF/network engineering)

34

RF = radio frequency AP = Access Point

35

The critical infrastructure problem• Critical infrastructures have unique monitoring needs that are not being

met.– Old: expensive to instrument, monitor and maintain – accidents happen– New: generate an unmanageable “firehose” of uncorrelated data

• Compliance requirements are reactionary and constantly evolving• The market is flooded with fragmented point solution offerings• Industry lacks a “systems approach” solution to the market• Results from failure to monitor and act

– Accidents– Shutdowns– Cyberattack

These are not perceived problems – they are happening today and are a matter of national and international importance.

• Problem – legacy, aging equipment may be “un-instrumented,” and data acquisition on performance and maintenance may be natively impossible. Being able to retrofit adhoc instrumentation and communicate to gather data and metrics would allow better operational monitoring and maintenance planning and reduce downtime

• Solution – technology and approach – development of ad-hoc (off- the-shelf) modules for sensor types (humid, temperature, vibration, pressure, magnetic) to allow rapid deployment of communicating sensors to gather data

• Advantages, benefits and efficiencies – allows ad-hoc, short-term, or emergency surveillance of problem devices. Allows a modular approach to wireless sensor measurement in an aging plant environment without large-scale digital equipment upgrades

Ad-hoc instrumentation and meteringThe availability of a pervasive wireless network within the plant allows the deployment of extremely low-cost sensors and meters for tactical or short-term operational needs. A ‘”bug-like” approach for the deployment of multi-sensor devices, specific for operation’s needs is used. For example, suspect faulty motor or pump gets a camera, vibration sensor, Hall-effect monitor attached to the housing. In the new world, the sensor takes three minutes to assemble the modules in the “plant shop,” and one minute to provision on the network.

• Wireless acts as a common enabling technology• How

- Provides ubiquitous communications capabilities

- Cross-operational value and utility- Common IP access using standards with robust

cybersecurity- Reduces lead-time and costs associated with

wired cabling

Wireless plant communications

Provides the communications foundation to address many of the challenges of facility process transformation

Innovation areas of focus• Goal: Develop innovative technology solutions to achieve strategic

goals.

• Guiding principles– Enabling– Modular– Scalable and replicable– Standards-based … generally– Financially viable

• Focus areas – Operations/workflow efficiency– Radiation protection and safety– Regulatory compliance

Critical infrastructure integrity monitoringreference architecture

P2P/PMP = Point to Point/Point to Multipoint ULP = Ultra Link Processing XML = Extensible Markup Language S/A = Situational Awareness MOM = Manager of Managers PCN = Process Control Network ERP is enterprise resource planning software

®

ERP

Connecting

software

Emergency planning zone radiation monitoring• Key business drivers

– Support real-time emergency decision making– Extend emergency planning zone (EPZ) monitoring area to 50 miles

– Provide low-cost situational awareness• Innovative approach

– Developed long-life battery-powered sensors– Benefit from unique RF communications technology– Deliver data via SQL plus XML stream– XML standard equals reduced software integration to PDS

• Return on investment targets– Reduce regulatory compliance costs– Increase planning accuracy – resource targeting– Low-cost insurance and customer service benefit

• Status– Pilot phase successful, very strong business case identified– Have been asked to field a complete system at second facilityPDS = Plant Display Software SQL = Search and Query

Language XML = Extensible Markup Language

Wireless micro vibrational sensor• Key business drivers

– Preventive/predictive maintenance of critical components through• Vibration analysis• Condition monitoring• Machine health• Independent monitoring and diagnostics• Safety shutoff sensing

• Innovative approach– Enable independent data capture outside of traditional SCADA systems– Significantly reduce cost to allow monitoring of a larger sample of components– Leverage ORW to reduce overall infrastructure costs

• Battery life, form factor, etc.• Reduce number of access points (APs), network infrastructure• Significantly increase number of sensor sets able to communicate across unlicensed bandwidth

• Return on investment targets– Enable dose optimization, achieve/exceed ALARA targets– Reduced worker time in plant through automation of equipment monitoring function– Shift from predictive to condition-based maintenance

ORW = On ramp wireless ALARA = As low as reasonably achievable (radiation exposure levels)

Today’s Webcast Sponsors

Question and answer sessionAsk a panelist a question by entering your question in the “Question & Answer” box and clicking submit. 

Mark T. Hoske, webcast moderator, content manager, Control Engineering

Stephen Muenstermann, RoviSys Building Technologies, DC market managerwww.rovisysbt.com

Damon Brady, section manager, SAIC Douglas Bowers, senior project manager, SAIC

www.saic.com/EEandI

Wireless Industrial Applications

Sponsored by: