WirelessHART Integration

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Dwain Price
6 years ago
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1 WirelessHART Integration

2 1,000 Wireless Devices At Every Site Beyond the P&ID How we operate unmanned sites How we operate in the field How we look at energy consumption 2 How we maintain assets

3 Topics Covered The ABC of application classes WirelessHART meeting plant needs For every fieldbus there is an Ethernet Wireless gateway integration today and tomorrow HSE today! HSE for package unit integration + 3

4 The ABC of Application Classes Areas where wireless technology is applied

5 5 NAMUR NE124 Application Classes - Do you know your ABC? Application Description Remarks Class A Functional safety Time-critical applications in the area of functional safety, process interventions and interaction with other applications and systems are governed by the requirements of critical safety applications. B Process management/control Time-critical, deterministic applications which must meet high requirements with regard to availability and reliability. Interactions with other applications and process interventions are included. C Display monitoring Applications which are not time-critical and exclusively provide additional information. Interactions with other applications and systems are excluded. Most wireless applications are class C : Reliability: Essential Asset Monitoring Energy Efficiency: Energy Conservation Measures Personnel Safety: Reducing operator rounds Integrated Operations: Unmanned sites

6 A Second Layer of Automation - for Missing Measurements ; Beyond P&ID Essential Asset Monitoring (EAM) Heat exchanger Pump Blower Air cooled exchanger (fin fan) Unmonitored compressor Cooling tower

6 6 A Second Layer of Automation - for Missing Measurements ; Beyond P&ID Essential Asset Monitoring (EAM) Heat exchanger Pump Blower Air cooled exchanger (fin fan) Unmonitored compressor Cooling tower Pipes & vessels Filters & strainers Health, Safety, and Environmental (HS&E) Safety shower and eye wash station Manual valve Relief valve Gauge, sight glass, variable areas flowmeter, dip stick Grab sampling Vibration, temperature, acoustic tester Stranded diagnostics Control valves Passing valves Energy Conservation Measures (ECM) Steam trap failure Heat exchanger fouling Steam consumption Chiller water consumption Filter & strainer blocking Cooling tower fan Integrated Operations (iops) Production well Injection well Separator Storage tank Modernization User Guide Available

7 7 Wireless Essential Asset Monitoring - Process Equipment Diagnostics: Smart Assets Heat exchangers Pumps Blowers Air cooled exchangers (fin fan) Unmonitored compressors Cooling towers Filters Pipes & vessels etc. Pre-engineered packages using WirelessHART and multiparametric software algorithms for process equipment diagnostics

8 Types of Diagnostics 2. Device Diagnostics Electronics (memory etc.) Internal mechanical parts Supply 1. Signal Diagnostics Communication Errors 4-20 ma integrity Wireless signal strength 3. Process Connection Diagnostics Valve Actuator Impulse line 4. Process Equipment Diagnostics Heat exchanger Pump Blower Air cooled exchanger 8 ISA108 Process equipment diagnostics is a new type of diagnostics for which WirelessHART is ideally suited

9 Intelligent Device Management ISA108 Plant Asset Management System Machinery Health Management Rotating Machinery Turbine Compressor Pump Process Equipment Management Heat Exchanger Pump Blower Air cooled exchanger Cooling tower Compressor Intelligent Device Management Instrumentation Transmitter Analyzer Control valve On/off valve Motor drive Gas Chromatograph Intelligent Device Management (IDM) is one of many parts in an Asset Management System (AMS) 9

10 Reduce Field Operator Rounds - Getting rid of the blind spots Dial gauges Sight glasses Variable area flow meters Dip sticks Portable testers Vibration Temperature Ultrasonic (leak) Grab samples 10

11 Increased Operator Awareness - Other Monitoring not on the P&ID Safety shower & eyewash stations Steam trap failure Pressure relief valve release Manual valve position feedback 11

12 Integrated Operations (iops*): - Unmanned Sites Pressures Temperature Differential pressure Valve position Central operation Optimization Reservoir modeling Production wellhead Casing/annulus pressure Gas lift Water wash Chemical injection Injection wellhead Gas Water Chemical Steam Separator Storage tank 12 * Also known as: Smart Fields, e-field, i-field, Digital Oilfield, Intelligent Oilfield, Field of the future and Intelligent Energy

13 WirelessHART meeting plant needs

14 WirelessHART Technology - Based on User Requirements NAMUR NE124

stats Adapters Planning tools B/Profibus/OPC Conf. & diag.

stats 8 bit response code 200 bits of MSA Specific commands

Certification Long Battery Life IEEE 802.15.

/Reliability Wireless for Process Applications Version Management

Integration Coexistence Interoperability EDDL Planning tool Config.

14 14 WirelessHART Technology - Based on User Requirements NAMUR NE124 Same tools as 4-20 ma/hart and fieldbus Intrinsically safe Comm. stats Adapters Planning tools B/Profibus/OPC Conf. & diag. tool Comm. stats 8 bit response code 200 bits of MSA Specific commands Independent Testing Familiar Tools Industrial Grade Diagnostics Certification Long Battery Life IEEE radio Sleep mode Status indication Mesh Topology Availability /Reliability Wireless for Process Applications Version Management EDDL 1 second 1 hour Real-time Capability Security Transparent Integration Coexistence Interoperability EDDL Planning tool Config. & diag.nostics tools Encryption Authentication Verification Channel hopping Key Rotation Sequence Number Ch. hopping DSSS Short messages Ch. black listing Low TX power IEC 62591

15 15 Industrial Wireless - Unique Self-Organizing Full Mesh Topology Redundant data pathways eliminate single points of failure Actual installations consistently demonstrate >99% data reliability Dense plant environment Routing at device-level Unique full-mesh, 7 hops deep No backbone router infrastructure No hazardous area power required True wireless: low cost, low risk Unique automatic reconfiguration No manual routing configuration 10 year battery life at 1 min update depending on sensor type The difference between a home/office network and an industrial network

16 Unique HART Wire Terminals as Standard - Use Existing Common Tools Using the same tools as for 4-20 ma/hart and FOUNDATION fieldbus devices Handheld field communicator Zone 1 Laptop software Documenting calibrator 16

17 Same Tools Devices Work Consistently 4-20 ma/hart ma FOUNDATION fieldbus WirelessHART No ma 17

18 Unique Ease of Adoption - Same Familiar Tools, Same Procedures WirelessHART devices use the same tools as 4-20 ma and FOUNDATION fieldbus devices Same handheld communicator Same documenting calibrator Same procedures Configuration/setup Calibration Diagnostics Viewing internal variables 18

19 Multi-vendor Interoperability - IEC Native I/O Devices Adapters Adapters only required for 4-20 ma/hart devices on 4-20 ma systems Fieldbus devices already digitally integrated 19

20 Gateway of Wireless A WirelessHART gateway connects your existing DCS to WirelessHART transmitters from different manufacturers 20

21 IP and Ethernet Refresher For every fieldbus there is an Ethernet How does all the wireless data get into the system?

22 22 Ethernet and Wi-Fi are Just Media - What About the Protocol? Just Ethernet or Wi-Fi is not sufficient for interoperability Devices connect to the same network, but they don t talk IP network protocol is also not sufficient TCP or UDP transport protocols are also not sufficient To access the data, a common application protocol is required There are thousands of different application protocols for different applications... A complete protocol requires several parts: Application Protocol Presentation Session Transport (TCP or UDP) Network (IP) Data Link (MAC) Physical (Ethernet/FO/Wi-Fi)

23 The Protocols are Standardized - One for Each Function Protocol Application Standard HTTP Online Information Access IETF RFC 2616 FTP File transfer (document access) IETF RFC 959 SMTP Send IETF RFC 821 POP Receive IETF RFC 918 SIP Video conferencing IETF RFC 3261 RTP Video IETF RFC 3550 H.323 Voice (telephony / VoIP) ITU H.323 Standard protocols for network management functions: DHCP, SNMP, PING, DNS and NTP/SNTP, DSCP, 802.1p, 802.1Q, etc. Hand Held Tablet Voice/Video Laptop Video Voice/Video Tag 23

WirelessHART 24 Fieldbus Indsutrial Ethernet PROFIBUS-DP PROFINET-IO FOUNDATION fieldbus H1 FOUNDATION fieldbus High Speed

24 Industrial Ethernet Application Protocols - Already Standardized HART-IP FF-HSE PROFINET-IO Modbus/TCP EtherNet/IP HART-IP Linking Device Proxy Device Server Linking Device Multiplexer / Gateway FF-H1 PROFIBUS-DP Modbus/RTU DeviceNet 4-20 ma/hart WirelessHART 24 Fieldbus Indsutrial Ethernet PROFIBUS-DP PROFINET-IO FOUNDATION fieldbus H1 FOUNDATION fieldbus High Speed Ethernet (HSE) Modbus/RTU Modbus/TCP DeviceNet EtherNet/IP 4-20 ma/hart, WirelessHART HART-IP For every fieldbus there is an Ethernet

25 System Architecture - Wireless, Fieldbus, and Ethernet Complement Each Other Business ERP Level 4 Ethernet takes the place of H2 fieldbus Execution Automation Fieldbus H1 Sensors & Actuators Process 25 CMMS / MES Control System Fieldbus H2 or Ethernet Level 3 Level 2 Level 1-1/2 Gateway Drive Remote I/O Linking D. PLC H1 Package Unit Level 1 Level 0 H1 fieldbus takes the place of 4-20 ma and on/off Wireless takes the place of gauges, handheld testers, and doing nothing

26 Wireless gateway integration today and tomorrow WirelessHART gateways support multiple industrial Ethernet protocols

27 Plant-Wide Applications Larger than the capacity of a single gateway Plant-wide applications require a gateway in each plant area The gateways need to be integrated back to the DCS PIB PIB PIB PIB PIB System PIB 27

28 Modbus Register Mapping and Masking Card-Port Baud rate Flow control Data bits Parity Stop bits Timeout Max Retries RTS/CTS 7 None 1 4 seconds 3 times Odd Even Tag Name 51-TT- 101 PLC Register Data Bit Reverse Word Raw EU Scan Address Number Type Mask Bits Swap Counts Range Boolean Boolean Integer Unsigned to100 Integer to degc Float / Real Normal 4-20 ma On/Off 28

29 29 Lots of Process and Device Information WirelessHART devices provide lots of useful information: Process information: DCS PV SV, TV, and QV Device information: IDM part of AMS Diagnostics Setup/configuration Identification Internal variables Mapping process and lots of device information for all devices is time consuming: Modbus: map to registers EtherNet/IP: map to instance & member OPC: map to group & items Changes are error prone Tag Parameter Type Register 51-PT- 101 PV Float ApHT- 101 PV Float ApHT- 101 SV Float TT- 101 PV Float TT- 101 SV Float TT- 101 TV Float TT- 101 QV Float LT- 101 PV Float FT- 101 PV Float ZT- 101 PV Float ACT- 101 PV Float ACT- 101 SV Float VT- 101 PV Float PT- 102 PV Float ApHT- 102 PV Float ApHT- 102 SV Float TT- 102 PV Float TT- 102 SV Float TT- 102 TV Float TT- 102 QV Float LT- 101 PV Float FT- 101 PV Float ZT- 101 PV Mumbai Float - India ACT- 101 PV September Float ACT- 101 SV Float VT- 101 PV 2013 Float Fieldbus Foundation 40100

block or pass-through to intelligent device management (IDM) software IDM Software LSH-101

30 F-ROM Gateway Integration - with HSE Hosts Process variables and outputs as standard function blocks in DCS WirelessHART device diagnostics and setup/configuration through HART transducer block or pass-through to intelligent device management (IDM) software IDM Software LSH-101 Gateway H DI TB LSH-101 AI DCS PID AO TRK_IN_D PIT-102 H TB AI PIT-102 ARTH 30 ZV-103 H TB DO ZV-103 DC

31 HSE today! Integrated operations of remote applications

32 RTU with HSE for SCADA Applications Centre of Operations FF-HSE Operation Device Management FF-H1 FF-H1 32

33 HSE for package unit integration

34 Package Unit Integration with HSE FF-H1 Operation Device Management Linking Device FF-HSE 34

35 Conclusion

36 Summary WirelessHART enables new applications WirelessHART meets plant needs For every fieldbus there is an Ethernet WirelessHART gateway integrate with existing and future systems HSE for remote applications available today HSE for package unit integration available today + 36

37 Learn More

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