Siemens: Running Smoothly Yokogawa: Beyond Process Control Emerson: Control Valves June 2014

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Catherine Palmer
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1 MCI (P) 127/07/2013 PPS 1627/11/2012 (022884) ISSN June 2014 Siemens: Running Smoothly Yokogawa: Beyond Process Control Emerson: Control Valves

Cover COVER cover STORY story The Evolution of Field Wireless Applications Masaaki Matsuzaki explains why wireless technology is an important first step toward the ideal factory.

2 Cover COVER cover STORY story The Evolution of Field Wireless Applications Masaaki Matsuzaki explains why wireless technology is an important first step toward the ideal factory. In today s industry, there is an urgent need to enhance operational safety and implement environmental measures, in addition to improving productivity. The underlying causes include aging equipment and dwindling number of skilled engineers. However, there are limitations on production management relying on the experience and expertise of people, and also on labor-intensive factory monitoring due to the shortage of skilled human resources and rising labor costs. Accordingly, there is a growing need for online monitoring of not only information on instrumentation directly related to production but also various other information on equipment diagnosis, safety, environmental conservation, and energy saving, in order to statistically analyze situations and trends to determine factors for preventing accidents, and to enhance the stable, safe operation of the entire plant. Wireless technology is attracting attention because it enables a large number of sensors to be installed and connected online. Wireless technology eliminates the need for space and design work for wiring, reduces the material and labor costs for wiring, and makes it easier to change monitoring points frequently. There has been reluctance to place the field online because the benefits to be gained did not match the wiring cost, but wireless technology can solve the problem and be an important first step toward the ideal factory. This article introduces Yokogawa s new concept of Wireless Anywhere which supports field innovation with wireless technology, and outlines practical measures to make the concept real. Some examples of promising applications are also described. Wireless Anywhere Yokogawa announced the Wireless Anywhere concept, as shown in Figure 1, in April 2013, stating that it would use wireless technology throughout plants for various applications as a basis for field digital innovation to enhance the productivity and safety of plants. To achieve this goal, we need to develop technology that can convert and integrate various existing communication protocols in the field into ISA100 Wireless and connect them flexibly to various host systems. Yokogawa also aims to place various excellent sensors online via ISA100 Wireless and integrate them. Figure 1: Wireless Anywhere concept. 16 CONTROL ENGINEERING ASIA June 2014

Cover Story Technologies for achieving Wireless Anywhere ISA100 wireless module with a built-in antenna Diverse sensor technologies support the complex, highly-developed society of today.

Likewise, various sensors monitor process parameters such as temperature, pressure, and flow rate in plants and transmit them online.

The management of safety, environment, and other factors throughout the entire plant must be integrated more systematically by sensing various data and transmitting them online, such as equipment

3 Cover Story Technologies for achieving Wireless Anywhere ISA100 wireless module with a built-in antenna Diverse sensor technologies support the complex, highly-developed society of today. Without sensor technologies which cover from consumer electronics to space development, society could not sustain itself. Likewise, various sensors monitor process parameters such as temperature, pressure, and flow rate in plants and transmit them online. The measurement results are used for feed-back control to ensure stable production. The management of safety, environment, and other factors throughout the entire plant must be integrated more systematically by sensing various data and transmitting them online, such as equipment diagnosis information (for Table 1: Main specifications of the communication module. instance, vibration and corrosion), safety detection information (gas and fire, to name a few), and environmental information (ph, conductivity, turbidity, and toxicity, among others). There are many sensor manufacturers with different technologies worldwide. If these sensors could work together in a single wireless network, it would help achieve the ideal factory. Yokogawa has therefore developed ISA100 communication modules with a builtin antenna. Figure 2 shows an external view and the configuration. This compact module has a chip antenna, ISA100 Wireless transceiver, protocol stack, a RS-485 serial interface for sensors, Multi-protocol wireless adaptor and other components integrated in a cylindrical case. As another measure to achieve Under a licensing contract, Yokogawa will disclose the interface Wireless Anywhere, Yokogawa and other information on this module and provide modules has developed a multi-protocol to sensor manufacturers, to enable them to make their sensors wireless adaptor (Photo 1). comply with ISA100 Wireless. This collaboration allows sensor This adaptor converts manufacturers to focus on developing their sensor technology, protocols for wired field rather than having to consider ISA100 Wireless communication communications such as including designing high-frequency circuits and ultra-low power Foundation Fieldbus, HART, communication control, obtaining certification for the ISA100.11a Modbus, and PROFIBUS into communication protocol and radio laws, and designing explosionproof specifications. developed adaptor is for the ISA100 Wireless. The first Yokogawa believes this approach will help many excellent sensor HART protocol. Many vendors technologies worldwide realize their potential in the ISA100 provide HART-compliant Wireless infrastructure. This will enable overall management devices and they are widely used in many plants. When the multi-protocol wireless adaptor is mounted on a HART device, the device is powered by the built-in battery of the adaptor, so there is no need for an external Figure 2: ISA100 wireless module with built-in antenna. including diagnosis, safety, and environment, in addition to traditional instrumentation, as well as a low-cost transition from control based on human expertise and experience to a more systematic and statistical management. A wireless network with various sensors reduces human errors, eliminates the need for workers to enter hazardous areas, and thus achieves the ideal factory. Table 1 lists the main specifications of the communication module with a built-in antenna. Photo 1: Multi-protocol wireless adaptor. power source. The adaptor then encapsulates the process values and diagnosis information which have been obtained by HART communication into ISA100 Wireless signals and sends them to a host system. The host system handles the data in the same way as data from conventional HART devices. Similarly, the device is managed by a device type manager (DTM) as a HART device in spite of the presence of the adaptor between them. Thus, this adaptor enables existing HART devices to operate as wireless devices, eliminating power lines. Yokogawa is also developing a Modbus-compliant model, which is compatible with Yokogawa s SENCOM (SENsor with CONTROL ENGINEERING ASIA 17

COVER STORY COMmunication) interface, and a SENCOM digital sensor can store data.

Meanwhile, the FU20F stores data such as calibration and electrode resistance, and so can be calibrated in advance in the laboratory and replaced in the field.

When the wireless adaptor is mounted on a ph/orp SENCOM sensor, the sensor acts as an ISA100 Wireless ph/orp analyzer.

4 COVER STORY COMmunication) interface, and a SENCOM digital sensor can store data. The FLXA21 two-wire liquid analyzer, FU20F SENCOM digital sensor, and SPS24 SENCOM PC software are used in combination. Conventional sensors are calibrated in the field. Meanwhile, the FU20F stores data such as calibration and electrode resistance, and so can be calibrated in advance in the laboratory and replaced in the field. This helps shorten the process downtime, improve the maintenance efficiency, and reduce the maintenance cost. When the wireless adaptor is mounted on a ph/orp SENCOM sensor, the sensor acts as an ISA100 Wireless ph/orp analyzer. Photo 2 shows an external view of a ph/orp SENCOM sensor mounted with a wireless adaptor. Photo 2: SENCOM Wireless Adapter. Wireless infrastructure supporting various sensing technologies For wireless technology to be used in various applications, highly reliable wireless communication is essential. Yokogawa has already released a wireless system characterized by large scale, high speed, and high reliability, which satisfies technical requirements for various applications. For example, detecting gas or fire requires high-frequency monitoring and a short alarm activation time (from detection by a sensor to alarm activation by the host system). In addition, a backup scheme in case of communication or instrument failure is necessary. To meet these requirements, Yokogawa ensures the reliability of wireless systems by adopting high-performance wireless physical layers, redundant network layers, and other technologies. Communication can also be delayed due to the topology of wireless networks. To address this issue, Yokogawa uses deterministic routing and other technologies. (For details, see The Safety Monitoring Solution with Large-scale, High-speed, High-reliability Field Wireless Technology, M. Matsuzaki, Measurement Technology, January 2014.) Figure 3: Image of the tsunami monitoring system. Figure 4: Example of drainage treatment facility. Application examples Wireless level measurement Level measurement is needed mainly in tank yards. Sensors are installed on the top of tanks that are distributed over a wide area, and it is usually difficult to connect signal cables and power cables to all sensors. This is why wireless communication is ideal for level measurement. Yokogawa offers a series of wired level sensors for various usages. For example, the PULS62 is a radar sensor for level measurement equipped with a 26-GHz horn antenna or parabola antenna. This is suitable for liquid measurement in storage tanks and reaction tanks, which are difficult to measure. These level sensors comply with HART communication. By mounting multi-protocol adaptors on them, they can perform ISA100 Wireless communication. Once adaptors are mounted, wiring is no longer necessary since the power is supplied from the battery of the adaptor. A unique example among these wireless level 18 CONTROL ENGINEERING ASIA June 2014

Cover Story measurements is a tsunami monitoring system, which is currently under evaluation.

Because a tsunami is usually preceded by a sudden ebb tide, detecting a sudden lowering of sea level may indicate a tsunami.

Figure 3 shows an image of the tsunami monitoring system. Wireless monitoring of drainage quality As mentioned above, Yokogawa is developing multi-protocol wireless adaptors for the SENCOM interface.

5 Cover Story measurements is a tsunami monitoring system, which is currently under evaluation. Level meters equipped with the wireless adaptor are installed on a storm surge barrier near the plant to monitor the sea level. Because a tsunami is usually preceded by a sudden ebb tide, detecting a sudden lowering of sea level may indicate a tsunami. By combining the warning and alert information issued by the Japan Meteorological Agency, this system is expected to offer reliable tsunami warnings. Figure 3 shows an image of the tsunami monitoring system. Wireless monitoring of drainage quality As mentioned above, Yokogawa is developing multi-protocol wireless adaptors for the SENCOM interface. Simply by mounting the adapter, the FU20F ph/orp SENCOM digital sensor can perform wireless communication. Figure 4 shows an example of a drainage treatment facility in a factory and required ph/orp analyzers. ph is the main target of measurement and requires many sensors. When treatment facilities or drainage ports are located in a distant or hazardous area, visiting the site with meters is time-consuming for monitoring staff. Wiring work for signal lines and power lines is often costly, and there is a risk of disconnection in the event of a natural disaster. In addition, wiring work is often not considered worthwhile for temporary monitoring. Wireless communication which does not require signal and power lines would be an ideal solution. Yokogawa s wireless system features long-distance communication of up to 600 m without a repeater as long as the line of sight is ensured. Even for longer distances, Yokogawa s wireless communication network can be established with the minimum number of repeaters, ensuring excellent cost-effectiveness. Conclusion Field wireless technology enables quick, low-cost introduction of measurement and monitoring at places which are difficult for other online and offline methods. When wireless communication technology expands its coverage from instrumentation directly involved in the production to the sensing of other information such as equipment diagnosis, field safety, environmental protection, and energy conservation, it will help make the entire plant more visible and intelligent. This will enable more advanced plant management that does not depend on human power or expertise, thereby boosting productivity and maintaining the equipment, protecting the environment, preventing accidents, eliminating physical and human damages, and thus reducing the total cost of plants. CEA Masaaki Matsuzaki is the Manager, Wireless Solution Division, of Yokogawa Electric International. Unmanaged Monitored Managed Advanced Managed Power over Ethernet IP67 Wi-Fi Radios Cellular M2M Routers Cellular RTUs Communication Converters uptime. anywhere. From factory floor to extreme outdoor applications, Red Lion understands every network is not the same. That is why our new N-Tr on and Sixnet industrial Ethernet switches Wi-Fi radios and cellular devices are designed to meet diverse networking environments. Built-in redundancy coupled with robust reliability ensures infrastructures like yours stay up and running around the clock. Red Lion provides uptime anywhere so you can get the most out of your network investment. Download our new Industrial Networking Guide or visit Red Lion, the trusted name in automation, now offers Ethernet and Cellular networking solutions. Connect, monitor and control virtually anything, anywhere Red Lion Controls Inc. All Rights Reserved I asia@redlion.net I better. redlion.net CONTROL ENGINEERING ASIA 19

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