Presentation Title

Speaker name and title

Keith J. Abate Sr. – Perpetuum Director of

Business Development

Vibration Energy Harvesting:

Perpetual Power for

Emerson Wireless Transmitters

Session: 12-2158

Presenters

Keith Abate

Dan Crainer

Tim Bonnin

Introduction Vibration Energy Harvesting for Wireless Automation Topics to be Covered:

– Construction, Operation, Performance, Usage – Why use an Energy Harvester– Market Segments and Applications– Maintenance Logistics and Costs of “Battery Only” Solutions– Vibration Energy Harvesters & Emerson Wireless Transmitters– Transmitter Performance With and Without Energy Harvesters– Site Walk Down & Installation– Current Field Trials

Topics presented will provide an understanding of the issues and costs associated with “battery only” powered wireless transmitters and how Vibration Energy Harvesters can eliminate or minimize these barriers.

The Evolution of Power for

Wireless Monitoring and Automation

Vibration Energy Harvesters convert vibration to electrical energy

providing perpetual power for Industrial Wireless Sensor Nodes (WSN)

Vibration Energy Harvesting

VEH Construction & Operation

Electromagnetic VEH Construction: Magnets, Coils & Springs Power management Temperature compensation

Vibration moves magnet across a fixed coil.

AC current is generated accordingto Faraday's Law.

AC current rectified to DC output.

MAGNET

COIL

SPRING

SPRING

VIBRATION

CASE

Robust and Reliable

Core Product Description

• Electromagnetic – Coils & Magnets

• Industrially robust & reliable

• Hazardous Area Certified

• Full Temp. Compensation -40C to +85C

• With or W/O internal energy storage

Vibration Energy Harvester

Detailed Product Description

• 20mW max Power output

• 4mA max current output

• ~ .3mA output with 0.025g vibration level

• Current drive independent of load voltage

• 316L stainless steel, hermetically sealed case

• ATEX, IECEx, FM, CFM certified. Class1 Div1.

• -40C to +85C Temperature Operation

•Standard IEC connector interface

Why Use a Vibration Harvester?

Battery (D Cell) Vibration Energy Harvester

Life Cycle ~4 years Indefinite

Start of Life Uncertainty 1-3 years None

Maintenance Difficult to Predict None Needed

Calculations based on:

* Single Lithium Thionyl Chloride Cell battery with 19,000 mA-hour capacity.

* 0.5mA @ 7.2V Average Transmitter Power Draw.

Market Segments & Applications

Industrial

• Oil & Gas

• Power Generation

• Chemicals

• Paper & Pulp

• Water / Waste water

• Process Monitoring

• Equipment Health

Transportation

• Rail

• Wheel bearing monitoring

• Cargo

• Security

• HazMat

Cost of Changing Batteries

Simple Case

Cost of Changing Power Moduales for Deployed WSN's: Battery

(Time): Identify & locate 30

(Time): Paperwork & Logistics 30

(Time): Pull repair stock items 15

(Time): Traveling to & locating, devices 30

(Time): Change time per Power Module 5

(Time): Number of Power Modules to change 1

(Time): Added travel time for multiple WSNs (5 mins/ea) 0

(Time): Power Module Change time - Total 5

(Time): Return & Verify operation 40

(Time): Disposal of old batteries 15

(Time): Total Time in minutes 165

(Cost): Burdened hourly labor rate $100

(Cost): Hourly Rate Cost $275.00

(Cost): Consumables / Other costs $15.00

(Cost): Replacements $150.00

(Cost): Inventory cost of spares $45.00

(Cost): Lost Labor Productivity $68.75

Total Costs $553.75

Cost of Scale

Wireless Sensors Networks can not scale using batteries alone

Battery Only

VEH Augmented Power

Staggered Battery Life Disruption

At

$500-

$1000+

Per

Battery

Change!

Battery Only Powered Transmitter

Wireless Transmitter

Measurement

Processing

Transmit Data

Control Panel

Battery Power

Costly, Disruptive

and Unnecessary

Maintenance Logistics

Ahead

VEH Assisted Transmitter

Fit & Forget

Control Panel

Harvester Enabled Power Module

Intelligent Power Management

Key features:

Same form factor and capability as current Emerson Smart

Power Module

Flexibility to add harvester benefits anytime

Harvester Power Module provides same capability as current

Emerson Smart Power Module but does not need to be changed

Interface to Wireless Transmitter

1

2

3

4

5

Battery Life – No Harvester

0

2

4

6

8

10

12

0 4 8 12 16 20 24 28 32

Batt

ery

Life

(Yea

rs)

Update Rate (Secs)

Battery Only

Battery Life Reduces Rapidly as Update Rate Increases

Impact of Using Harvesters

0

2

4

6

8

10

12

0 4 8 12 16 20 24 28 32

Batt

ery

Life

(Yea

rs)

Update Rate (Secs)

Battery Only With Harvester

No battery changes needed

for 4 sec Update Rates

Battery life increases from 1 to

3.5 years @ 2 sec Update Rates

Dramatic Improvements using Energy Harvesters

Business Case per Node (4 sec)

0

500

1000

1500

2000

2500

3000

0.00 2.00 4.00 6.00 8.00 10.00

Cost

($)

Time(Years)

4 sec Update Rate

Battery Only

With Harvester

Saving of $1870

over 10 years

(per node)

Business Case per Node (2 sec)

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

0.00 2.00 4.00 6.00 8.00 10.00

Cost

($)

Time (Years)

2 Sec Update Rate

Battery Only

With Harvester

Saving of $2870

over 10 years

(per node)

Perpetual Power for Wireless

End-User Field Trials - Oxea

End-User Field Trials – Dan Crainer & Oxea

Dan Crainer– Puffer-Sweiven account manager for Fisher Controls

products at Oxea, Bay City Location.

– Oxea operations:

Oxea Chemicals, Bay City Site is the largest production facility in North America. The site produces wide range of Oxo intermediates and derivative products.

– Emerson Wireless at Oxea:

Oxea has installed Emerson Wireless products in one production unit and has several additional projects in different stages of execution.

– Vibration Energy Harvester – Value Proposition:

The “Vibration Energy Harvester” allows for use of wireless field instruments with lower cost power supply than standard Emerson power module.

– Benefits– Alternate power options vs. batteries only– Faster update rates while minimizing/eliminating battery changes– Reduced overall maintenance logistics & costs

Pictures and Field Trial Overview

Oxea Quotes:

“Vibration Energy Harvesting offers Oxea a cost effective way to utilize the fastest

update rates available on any wireless instrument we choose without the costs

and maintenance logistics of frequent battery replacements. This is an obvious

aid in process optimization and we see it as the next step towards wireless control”.

“Low maintenance costs are critical to the operations of a small facility with limited resources.

Vibration Energy Harvesting is seen as a means to reduce maintenance costs due to fewer battery

replacements, reduction in stock and lower battery disposal costs. These benefits will also

increase as we consider new uses for wireless devices in more remote plant locations”.

Sherri Law

Senior Instrument & Electrical Engineer - Oxea

End-User Field Trials - Firestone

End-User Field Trials – Tim Bonnin & Firestone Polymer

Tim Bonnin– Senior Instrument Representative; Beaumont, TX

Firestone Polymer operations:

Firestone Polymers supplies synthetic rubber, thermoplastic elastomers and impact modifiers to rubber, plastics, adhesive and asphalt markets around the world

Emerson Wireless at Firestone Polymer

Firestone was an early adapter of Wireless HART. They have employed WiHart devices throughout the plant and continue to look to wireless instruments as reliable and inexpensive monitoring solutions

Vibration Energy Harvester – Value Proposition

The Vibration Energy Harvesters have performed exactly as advertised. The Harvesters has been a welcomed addition to the wireless network that is established at Firestone and gives greater confidence that signal loss due to power interruption will not be a problem. Faster update rates while minimizing/eliminating battery changes is a huge positive for Firestone. The use of the Vibration Energy Harvester should result in reduced overall maintenance logistics and costs

Pictures and Field Trial Overview

Firestone Polymer Quotes: “Firestone Polymers has benefited from being one of the facilities chosen to

host the beta testing of Perpetuum Vibration Energy Harvesters”. 

“We have learned that the concept is useful in more ways than one”.

 – “The cost savings that are realized by eliminating the continued

purchase and replacement of batteries for wireless instruments”. 

– “Harvesting technology can lead to an even greater reduction in cost for the prioritized wireless instruments in our facility. These instruments require the fastest update rates”.

 

– “Fast update rates drastically reduce battery life, it would be prudent to target these wireless instruments as a first justification toward putting this technology to work for our benefit”.

Christopher Julian

Senior Instrument & Electrical Engineer - Firestone Polymer

Key Points

Maintenance:

Overloaded and diminishing available skilled resources

Batteries present disruptive & unnecessary maintenance logistics

VEH can minimize or eliminate disruptive logistics

Impact on Battery Life:

Emerson 3051S: (Wireless Transmitter with Greatest Power Profile)

oBattery changes eliminated @ 4 sec Update Rate for life of equipment

oBattery life increased from 1 to 3.5 years @ 2 sec Update Rate

Business Case:

Close to pay back on 1

st avoided battery change (on easy assets)

Pay back on 1

st avoided change on more difficult assets

Installation

Simple Site Walk Down Logistics

Use Power Puck to determine optimal VEH Frequency Unit.

Measure the current with a multi-meter to verify the

exact current that will be supplied to transmitter when

connected to VEH.

VEH connected to multi-meter Power Puck

Installation Overview Find suitable asset to harvest from. (Power Puck)

Attach VEH to Transmitter Power Module.

Install wireless transmitter.

Power transmitter - connect to gateway & network.

Collect & Transmit PV’s / QV’s at up to maximum data rates.

Eliminate/Minimize battery change maintenance logistics >10 yrs.

Summary

Unplanned maintenance is disruptive and costly

Unnecessary maintenance is just bad business

Energy Harvester Payback ~ Cost of One Battery Change

How many Batteries are you planning to change?

Perpetual Power Solutions for

Wireless Monitoring & Automation

Who’s Harvesting Your Success?

Vibration Energy Harvesting