Triplex Chapter of Vibration Institute Wireless Monitoring of Critical Assets Jim Girardeau Uptime Solutions jgirardeau@uptime-solutions.us www.uptime-solutions.us January 14, 2014 1 Uptime Solutions 2013
Agenda • Goals of Wireless Monitoring • Radio Technology • Case Study - Field Deployment 2 Uptime Solutions 2013
Part 1: Goals of Wireless Monitoring 3 Uptime Solutions 2013
Wireless Monitoring • Supplements route based analysis for critical machines. • Critical areas or problem areas analyzed continuously. • Analysts spend more time analyzing data, and less walking routes. • Higher Reliability with more accurate data. 4 Uptime Solutions 2013
Wireless Monitoring Goals • High capability Full spectrum analysis Real time signals, dwell on asset Automated fault detection • Historian and trending; access “anywhere” • Easy to install and flexible to expand • Reliable and cost effective 5 Uptime Solutions 2013
Wireless Network How does it work? • Monitoring Sensors- Sensors are connected to the wireless transmitter unit via • BNC/Pin Point connectors Radio- Data is sent via radio from the wireless node unit to the Base Station • (transceiver) Mesh Network-allows the nodes to talk to one another • Software- Displays Spectrums, Waveforms, Trend Data, Temperature Display and • stores data Main Office Power- 24 v DC / Battery • Bearings Base Pod Reliability Computer Station Motors Node Office Pumps Process Home Office Office 6 Uptime Solutions 2013
Part 2: Radio Technology 7 Uptime Solutions 2013
Wireless Soup 2.4GHz WLAN Standards A,B,G,N ISA Wireless HART 400/800/900M Hz GPRS ISM 8 Uptime Solutions 2013
Radio Fundamentals • Range Power Frequency Antenna gain • Capability/bandwidth • MAC Protocol, TDMA, Mesh, Star • Deployment 9 Uptime Solutions 2013
Power Output Coverage Area vs. Power TX 0dBM 64 times larger coverage TX 24dBm 10 Uptime Solutions 2013
Propagation Lost vs. Wavelength 900MHz 24.Ghz 5Ghz 0.00E+00 1.00E+00 2.00E+00 3.00E+00 4.00E+00 5.00E+00 6.00E+00 7.00E+00 8.00E+00 11 Uptime Solutions 2013
Antenna Gain Ideal Antenna 12 Uptime Solutions 2013
Typical Bit Rates Wireless Hart 900MHz WLAN 802.11B WLAN 802.11AG WLAN 802.11N 0.00E+00 1.00E+08 2.00E+08 3.00E+08 4.00E+08 5.00E+08 6.00E+08 7.00E+08 13 Uptime Solutions 2013
Deployment Considerations • Deployment on WLAN is a well know process, and involves site maps and placement of base stations. • Deployment of 900MHz is similar, but requires less infrastructure. • Deployment of Mesh type systems, seems easy due to their self adjusting properties and redundancy, but has difficulties in practice. 14 Uptime Solutions 2013
Example Deployment of Wireless Hart • Wireless Hart foundation “fundamental rules” --- The Rule of 5 – “Every Wireless Hart network should have a minimum of 5 Wireless Hart devices” The Rule of 3 -- “Every Wireless Hart network should have a minimum of 3 neighbors” The Rule of Percentage – “Every Wireless Hart network with greater than 5 devices should have 25% within range of the gateway” 15 Uptime Solutions 2013
Putting It All Together WLAN Low ISM WHart type Power Med High Low (mesh) Range Med High Low (mesh) Bit Rates High Low Low Deployment Ease Well known Long Range Radio Restrictions Support of Full Good Good Low Spectral resolution Real time Good Low Not possible Streaming Dwell on Single Good Good Not Possible Node Standard Worldwide Country by country Yes, some uncertainty Strong Point Flexible, well Long range, full Dense networks; supported, high spectral analysis deterministic data capacity sampling 16 Uptime Solutions 2013
Part 3: Field Study 17 Uptime Solutions 2013
Site Overview - Flyover 18 Uptime Solutions 2013
Site Overview - Schematic 19 Uptime Solutions 2013
Single Machine 20 Uptime Solutions 2013
Lots of Metal in the Way… 21 Uptime Solutions 2013
Wireless Performance 22 Uptime Solutions 2013
Time Domain Wave Forms 23 Uptime Solutions 2013
Frequency Domain 24 Uptime Solutions 2013
Gauges – Trend Values 25 Uptime Solutions 2013
Results • Multiple points were monitored reliably over a period of years. • The system was expanded after the trial to cover a large area of the mill. • Multiple defects were identified. • Key problem areas were put on 24/7 watch with email/text alerts 26 Uptime Solutions 2013
Q&A 27 Uptime Solutions 2013
Backup Slides 28 Uptime Solutions 2013
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