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Wireless Instrumentation Wireless Instrumentation in the Pharmaceutical in the Pharmaceutical IndustryIndustry
Andy WallaceSmart Wireless® Solutions Product Manager
UK & Ireland
AgendaAgenda
Intro to wireless networks
– Star, Star Mesh and Mesh Network topologies
Simplified overview of Mesh Networks & TSMP
– Case study for reliability and redundancy
Application of wireless in a 4 storey pharma building
Unlocking the ‘Hidden Plant’
Wireless Sensor Networks
Operating Frequency 2.4GhzOperating Frequency 2.4Ghz License-free but regulated frequency band
Shares ‘space’ with many other wireless devices in that spectrum for example
• Bluetooth
• Radios
• Cordless Phones
• WiFi
IEEE 802.15.4 – 16 channels– (Home wifi is 802.11)
The key is
– Ensuring ‘your’ message gets through
Wireless Network - Must HavesWireless Network - Must Haves
Key Management
Anti-Jamming
Verification
Authentication
Encryption
Common Industry Practice Today
EmersonSmart Wireless
Key Management
Anti-Jamming
Verification
Authentication
Encryption
Common Industry Practice Today
EmersonSmart Wireless
Reliability
– Path Stability
– Better than 99.9999%
Security
– Avoid fake and random attacks
Low Power
– Only operate when needed – preserve battery life
Scalable
– Capable of expansion without architecture changes
Flexible
– Bandwidth Control - speed
– Power Control – limit number of jumps
– Channel Control – blacklisting if necessary
– Latency Control
Challenges for Wireless NetworksChallenges for Wireless Networks RF environments are dynamic – they change
– RF mirroring from infrastructure
• Doors opening/closing
• Portable plant
– Change over time; people, weather, temp structures
A link that is strong today may be weak tomorrow or even the same day!
Three major failure modes:
– Interference from other ‘wireless’ devices
– Changes in the physical environment that block communication links
– Loss of individual network nodes in some topologies
Star NetworksStar Networks
Central base-station communicates directly to sensor nodes - Generally mains powered.
All routes are ‘linear’ where each node only has one possible communication path – good distances
The failure of an individual link means that information is lost.
Generally requires site surveys and link-level configuration.
Each node must be positioned correctly and each point-to-point link tuned for maximum reliability.
Star Mesh (Cluster Tree)Star Mesh (Cluster Tree)
Star-mesh networks have redundant routing at the core (blue) and star routing at the edge – typically with mains powered routing nodes and optionally battery-powered end nodes.
Does not allow for true end-to-end redundancy nor do they eliminate the installation challenges of star networks.
Mesh NetworksMesh Networks
Full-mesh networks provide fully redundant routing to the edge of the network.
Increased reliability, easy network installation and long-term predictability
Every device has the same routing capabilities.
Lower power consumption
True self-organising and self-healing without constraints imposed by device type and architecture
Easy network expansion
Self Organising Mesh NetworksWirelessHART Networks
In-Plant Smart Wireless® Solutions are Easy to Install, Use and Are Reliable!In-Plant Smart Wireless® Solutions are Easy to Install, Use and Are Reliable!
ToHost
Modbus,
Ethernet,
WiFi,
OPC,
Self Organising!
Self Healing!
Gateway ‘grooms’ network for speed and loading
Together We Deliver Complete, Best-in-Class Wireless Solutions for the Process IndustriesTogether We Deliver Complete, Best-in-Class Wireless Solutions for the Process Industries
Cisco Unified Wireless Architecture
– Industrial-class Mesh IEEE 802.11 Access Points
– Wireless Control System for centralized network and security management
Plant applications include video, voice, mobility, tracking
– Leverage Cisco’s extensive partner network
– Customer chooses preferred partner
Your Smart Wireless Opportunities Are without Limits…Your Smart Wireless Opportunities Are without Limits…
The Device Join Process Has Almost Zero User Interaction ------ SimpleThe Device Join Process Has Almost Zero User Interaction ------ Simple
1. Put JOIN key into the WirelessHART Field Device (WFD) using standard tools (375, AMS, etc.)
2. Listen to neighbours3. Connect to a neighbour using JOIN key to authenticate4. Neighbour uses NETWORK key to pass message up to gateway5. Gateway determines optimised schedule6. Schedule is flooded to the devices
Developing NeighboursDeveloping Neighbours Typically 2 Parents
3 Children – Load Balanced
Many Neighbours (identified redundant paths)
C P
C
CP
N
N
N
N
Mesh Networks offers scalability…..Mesh Networks offers scalability…..
Animation courtesy of Dust Networks
Customer Site: Devices Scattered Throughout the Process Facility With No Direct Line of SightCustomer Site: Devices Scattered Throughout the Process Facility With No Direct Line of Sight
High Data Reliability
– 99.75 to 100.00%
– Readings every 10 seconds
Data Latency Varies
– 0.66 to 6.22 seconds
– 3.22 seconds Average
“Device Hop Depth”
– Demonstrated capability of up to 9 hops for at least 256 unique paths back to the gateway
Expansion is Simple: Added Online Devices to the Network also Increases Network ReliabilityExpansion is Simple: Added Online Devices to the Network also Increases Network Reliability
High Data Reliability
– 100.00%
– Readings every 10 seconds
Data Latency Varies
– 0.82 to 5.20 seconds
– 2.44 seconds average
“Device Hop Depth”
– Demonstrated capability of up to 12 hops for at least 4096 unique paths back to the gateway
Major Pharmaceuticals MfrFour-story pilot lab
Self-organizing WirelessSelf-organizing WirelessNetwork in a Process BuildingNetwork in a Process Building
Customers Are Solving Real Plant Problems:Major Life Sciences CompanyCustomers Are Solving Real Plant Problems:Major Life Sciences Company
Application: Moving platform/skid measurements
Eliminate need to continually re-configure process systems for instruments that move with portable process skids
– Pumps, filtration, milling, CIP/SIP packages
Startup and installation of all devices was completed in < 8 hrs
Initial trials achieved 100% reliability throughout 12” reinforced concrete building with five floors
– Moving platforms never had a measurement drop off the system
– Platform brought in from another storage building joined network withoutoperator assistance
Trial #1: How Many Floors from a Single 1420 Wireless Gateway?Trial #1: How Many Floors from a Single 1420 Wireless Gateway?
Rosemount Model 1420 Wireless Gateway mounted on wall
outside Third Floor Control Room.
12 Rosemount Model 648 Wireless Temperature transmitters
used to form network.
Devices T1 – 11 placed from First Floor to Roof.
Device T12 held in reserve.
Trial Building: Reinforced concrete constructionBuilt 1993. Main building dimensions: 246’ x 70’
Trial site from column #5-12: 153’ x 70’East Wing (column 7-11): 92’ x 70’
East Wing
Process bays/suites: Wide: 24’ w x 27’ d Narrow: 17’ w x 27’ d
Other areas: Aisle: 92’ l x 16’ w Mech/Util: 7’ w x 27’ d
First Floor
Suite C-1 Bay D-1 M/U
Suite K-1Bay J-1Bay H-1M/U
7
Device Placement: T7 in Mech/Util room on floor
Second Floor
Suite C-2 Bay D-2 M/UM/U
M/UM/U Suite K-2Bay H-2M/U Bay J-2
Device Placement: No devices on Second Floor
Third Floor
Suite C-3 M/U Bay D-3 M/U
M/U Bay H-3 M/U M/U Suite K-3Bay J-3
1
2
3
4
5
6
12
8
WG
Device placement (all dimensions are height from floor): 1420 Wireless Gateway (WG) to right of Control Room door on wall - 76” T1 in Mech/Util room on panel - 60” T5 on vessel in Bay D-3 - 30” T2 between vessel and wall in Bay H-3 - 18” T6 on shelf in stairwell - 54” T3 on vessel in Bay H-3 - 18” T8 in Mech/Util room on panel - 60” T4 on mezzanine (“Floor 3-1/2”) in Bay D-3 - 96” T12 on shelf in Aisle - 60” PT and TT (PT-1160 & TT-1160) in Control Room awaiting trial #2: Moving Cart
PTTT
Control Room
Fourth Floor
M/U
M/U M/U M/U
M/UBay C-M
Bay D-M
Bay H-M
Bay J-M
Suite K-M
11
10
9
Device Placement: T11 in Mech/Util room on panel - 60” T10 inside roof access door (“Fifth Floor”) on floor T9 on roof; steel roof access door closed
11May07 Test #1: TT-1160 & PT-1160 in Control Room; balance of devices per dwg
Trial #2 – “Moving Cart:” Moving an instrumented platform through a formed networkTrial #2 – “Moving Cart:” Moving an instrumented platform through a formed networkThe set-up, 11May07: “Cart” was a 4’ x 3’ x 9” high castered utility cart with 55-gal drum for
mass. PT-1160 (3051S) and TT-1160 (648) on cart at opposite corners.
Model 775 Wireless Upgrade Module (‘thumb”) added to spare 3144P (tag # TT80H280). Device kept in Control Room [process bay/suite area classification is Cl. 1/Div. 1].
Testing done in stages:
2A – No devices moved; Trial #1 set-up used; Cart starts @ position “A” on Third Floor moves to position “B.”
2B – All instruments re-positioned to Third Floor. Cart moves from “B” to “C.”
Third Floor
Suite C-3 M/U Bay D-3 M/U
M/U Bay H-3 M/U M/U Suite K-3Bay J-3
1
2
3
4
5
6
12
8
WG
Device placement (dimensions shown are height from floor): WG to right of Control Room door on wall - 76” T1 in Mech/Util room on panel - 60” T5 on vessel in Bay D-3 - 30” T2 between vessel and wall in Bay H-3 - 18” T6 on shelf in stairwell - 54” T3 on vessel in Bay H-3 - 18” T8 in Mech/Util room on panel - 60” T4 on mezzanine (“Floor 3-1/2”) - 96” T12 on shelf in Aisle - 60” PT and TT (PT-1160 & TT-1160) in Control Room awaiting trial #2: Moving Cart
PTTT
Control Room
A
B
2A
CartPT
TT
775
Third Floor
Suite C-3 M/U Bay D-3 M/U
M/U Bay H-3 M/U M/U Suite K-3Bay J-3
1
2
3
4
5
12
WG
Device placement (dimensions shown are height from floor) : WG to right of Control Room door on wall - 76” T1 in Mech/Util room on panel - 60” T7 on shelf in Aisle - 60” T2 on vessel in Bay H-3 - 18” T8 on panel in Bay J-3 - 48” T3 on vessel in Bay H-3 - 18” T9 in Mech/Util room on panel - 60” T4 on mezzanine (“Floor 3-1/2”) in Bay D-3 – 108” T10 on vessel in Bay J-3 - 30” T5 on vessel in Bay D-3 - 30” T11 on shelf in Aisle - 60” T6 on mezzanine (“Floor 3-1/2”) in Suite K-3 – 96” T12 on shelf in Aisle - 60” PT and TT (PT-1160 & TT-1160) on Moving Cart 775 is TT80H280 (spare 3144P, no RTDs)
Control Room
B
C
CartPT
TT
11
9
10
8
6
2B
775
775 Diagnostics! 1st application was to a 3144Pwith no RTD installed.
Unleash the hidden Plant
Why Predictive Intelligence? Catch Problems Before They OccurWhy Predictive Intelligence? Catch Problems Before They Occur
Equ
ipm
ent
Hea
lth
0%
100%
Time
Advanced Warning = time to respond before it causes a shutdown
A digital plant architecture that uses the power of wireless field intelligence to improve plant
performance
Detect Subtle Changes in Plant
Operation to Improve
Performance
SPM actively monitors process mean values and standard deviation
Detect Subtle Changes in Plant
Operation to Improve
Performance
SPM actively monitors process mean values and standard deviation
Equipment and Plant Availability Increased with Vibration MonitoringEquipment and Plant Availability Increased with Vibration Monitoring
Measurements delivered wirelessly through 1420 gateway
Available early 2008 - Trials in progress
Predictive and timely indication of failure trends
Delivers accurate and actionable data more effectively than monthly snapshots
Gives Peakvue and overall vibration readings
Send Maintenance ONCE to repair …
… Not 20 TIMES to CHECK
In-plant equipment or remote, hazardous, or unmanned area
Operating Costs Reduced with High Resolution Online Corrosion MonitoringOperating Costs Reduced with High Resolution Online Corrosion Monitoring Corrosion related leaks, spills, and
accidents are a serious concern in aging infrastructure
– Hard-wiring to install online systems is often difficult in mature assets
RCS Microcor Wireless Transmitter (MWT) enables cost effective, near real-time corrosion rate
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
7/14
/07
12:0
0 A
M
7/21
/07
12:0
0 A
M
7/28
/07
12:0
0 A
M
Met
al L
oss
(mils
)
0
1
2
3
4
5
6
7
8
Cor
rosi
on R
ate
(mpy
)
Metal Loss Corrosion Rate
Emerson partnering with Rohrback Cosasco Systems (RCS) to bring technology to the market
Measurements delivered wirelessly through 1420 gateway or ROC 800 gateway
Available early 2008
System detects an increase in the corrosion rate of pipelines, heat exchangers, distillation columns….
775 Diagnostics! 1st application was to a 3144Pwith no RTD installed.
Upgrade Installed HART Devices to Redundant Wireless CommunicationsUpgrade Installed HART Devices to Redundant Wireless Communications
Connect to already installed transmitters
2 versions
– One for valves
– One for other devices
Self contained power
– Uses energy from loop wiring
– Or encapsulated battery
HART comms pass through
– AMS connectivity
IS approval775 HART Upgrade
Module
Self Organizing Networks Will Unlock Stranded Diagnostics in Legacy PlantsSelf Organizing Networks Will Unlock Stranded Diagnostics in Legacy Plants
LegacyHost
20 million installed HART devices have underutilized diagnostics because the plant doesn’t
support a digital architecture
Wireless upgrade modules will unlock these diagnostics and extend ROI
Thank YouQuestions
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