Unlocking the Value in Applications Agenda Environment is Right - - PowerPoint PPT Presentation

Honeywell is Making Industrial Wireless Real Unlocking the Value in Applications

Agenda

• Environment is Right for Industrial Wireless
• Exciting Opportunities/Benefits from Wireless
• Choosing a Wireless Solution
• Why Honeywell?

Environment

• Growing Demand in the Following…

– Economic need to further optimize the plant – Make government compliance easier – Make plants safer – Easier equipment health assessments

• Wireless Technology is….

– Advancing – Becoming cost-effective – Standardizing Environment is Right for Industrial Wireless

Proven Products and Applications

• Wireless Worker Solutions deploy applications

and valuable plant information in places where they were not previously available utilizing mobile and wireless technologies.

– IntelaTrac PKS – Automates field operator activities – Mobile PKS – Brings the control room to the field

• Wireless Transmitters provide real-time, accurate

and reliable process and asset data at lower cost than traditional wired sensors

– XYR5000 – Senses field measurements wirelessly – XYR Gateway - Wireless IO for TDC/TPS

• Wireless Services provides site assessments and

implementation for wireless offerings at your site. State of the Art Offerings Delivering Value Today

Agenda

• Environment is Right for Industrial Wireless
• Exciting Opportunities/Benefits from Wireless
• Choosing a Wireless Solution
• Why Honeywell?

Unlocking the Value of Wireless-enabled Applications

Reliability

• Continuous Equip Health Monitoring
• Automated Field Operator Rounds

Safety & Security

• Safety Shower Monitoring
• People/Asset Tracking

Compliance

• Emissions Monitoring
• Leak Detection & Repair

Optimization

• Wireless I/O & Tools
• Better Data for Advanced Apps

Enabling Multiple Applications in One Wireless Cloud

New Applications on the Horizon

Reliability - Tank Farm

Issue:

• Wiring cost prohibitive $250K+
• Explosion-proof area
• Volume at high customer demand
• Spills are frequent and costly
• Current Measurement:
• Poly tube-style site glass
• Readings are visual with error
• Safety to Personnel
• Inventory management impossible

Solution:

• Wireless pressure transmitter
• Saved $230K first year

Ethanol Plant Application - Tank Level in Explosion Proof Area “We have not had a single spill or safety violation since the installation!”

~Production Mgr

Acoustic Measurement Leak Detection

• In Acoustic applications the sensor will notice a noise detection

deviation from threshold conditions on a leak.

• Each valve has unique characteristics. A baseline must be

established by viewing normal ambient noise and then the baseline identifies;

– deviations as leaks (12-20 Ultrasound Value (UV) Typical) – major deviations indicate possible line rupture (100-140UV) – minor deviation may indicate leak in close proximity to valve

• I.e. elbow, union, control valve, etc
• Savings Comparison

– 109 Points – 500Ft/Run @ $40/Ft – Wiring $2,200,000

• XYR - $120,000

Reliability - Compressor Application

• 7 Large Rotary Compressors
• Distant locations with no available wiring
• Trenching or suspended wiring required
• Wiring costs alone 200 –1,000 ft runs/$120/ft =$800K/min
• Existing instrumentation inadequate

– Each Compressor equipped with local indicator – Operators monitor by clipboard hourly & some units are non-accessible

• Installation needed to be completed immediately
• Cost to plant significant upon failure - Est. loss $1,000,000/day

Solution:

• Wireless temperature transmitters
• Installed cost = $76K -2 days

Refinery Application – Compressor Bearing Temperature Monitoring

Low Cost Temperature Monitoring – Potentially Saved Millions

Compliance - LDAR Applications

• Most applications have no existing wiring
• Costs typically required for plant operations and may have no ROI
• Wiring runs from $30-120/ft – Hazardous Classified Areas
• Energy Savings – Return Emissions for Fuel
• Fugitive Emissions

– Acoustic – Leak Detection, Full Release – Pressure – SRV release, filter blockage, replacement – Switched/Discrete – Rupture Disc, Valve Status – Temperature – Flare Stack Temperature, pilot status – Repeater – Gas & analytical sensors for sniffing.

Simpler Way to Comply

Compliance - Butane Spheres

• Customer Need: pressure

measurements from top of sphere for level estimating

• Specific cost is undetermined

for area - Est. $80/ft = $500,000(+)

• Longest shot 1,200 feet
• Shortest is 600 feet
• Installation time for field devices minimal
• 7 Tanks
• $12,000 total project cost

Simpler Way to Comply – Instant Savings of ~$.5M

Spent Alcohol Tanks

Current Result –Clipboard Measurement

• Safety – 10,000gal spill of pharmaceutical used isopropyl alcohol.
• Major safety
• Major fines
• Expensive clean-up

Situation

• 1,400 foot runs @ $50/ft
• Trenching
• 12 tanks
• Est. – $300,000

Wireless Solution

• Static Pressure
• $15,000

Optimization - Rotary & Mobile Equipment

Measurements on Rotary Equipment

Application

• Rotating Dryer

Issue:

• Requires ad-hoc designed electro-mechanical

links to transmit the signal

• Readings are not available (Temperature & Vacuum)
• Adding measurement points is expensive
• Current Method was inferred

Solution:

• Provided Wireless field device to give constant

process data

• Cost $5K/Dryer

Better Alternative for Rotating Application

Safety - Safety Showers

• OSHA is driving new requirements on shower

monitoring for all new installations! Operator must alert in 5-10 seconds.

• Flow switch indication on all Safety Showers
• Cost to run wire @ $120/ft. Average run over 600’

this equates to about $75,000 per run.

• 26 Showers
• 26 Wireless = $32,000 with XYR
• Simple Economics

Safer Plant & Saved $1M+

Deployment: Pipeline & Process Fence line Applications

Safety & Security - People/Asset Tracking

• Active RFID tracking

– Using Active Ultra Wide Band (UWB) RFID tag technology – Real-Time tracking with ranges up to 1000’ – Track 1000’s of tags – 2D and 3D tracking with up to 1’ resolution. – Coverage of large areas

• Integrated with Honeywell Experion PKS and/or EBI solutions

– Integrated with Process Control and Physical Security Work Processes

• Wireless integration option

– Can augment “or” replace current Access control solution – Improved Safety by integration into process operations – Active Real-Time Mustering Solution. – More effective method of meeting OSHA Process Safety Management Standards (PSM) safety standards. – High Value return and integration to unique customer SOP People and Asset Location Becomes Data For Your Process Knowledge System

Agenda

• Environment is Right for Industrial Wireless
• Exciting Opportunities/Benefits from Wireless
• Choosing a Wireless Solution
• Why Honeywell?

Choosing a Wireless Solution

• Applications

– Safety & Security – Reliability – Compliance – Optimization

• Architecture
• Services
• Experience

The Right Consideration Set

Key System Requirements

Important Wireless Customer Requirements *

• ARC Users Survey 2005
• Honeywell VOC 2003/2004/2005

“A Wireless Zone” Meeting all Requirements Concurrently Customer Architecture Requirements*

• 10. Multi-protocol
• 9. Quality of Service
• 8. Global Usage
• 7. Scalable
• 6. Multi-functional
• 2. Reliable Communication
• 7. Scalable
• 6. Multi-functional
• 2. Reliable Communication
• 5. Multi-speed Monitoring
• 4. Open
• 3. Good Power Management
• 5. Multi-speed Monitoring
• 3. Good Power Management
• 11. Control Ready
• 1. Security
• 4. Open
• 1. Security

• Alarms

– Any class (human or automated action)

Usage classes of wireless data networks

Safety

Class 0 : Emergency action

(always critical)

Control

Class 1: Closed loop regulatory control

(often critical)

Class 2: Closed loop supervisory control

(usually non-critical)

Class 3: Open loop control

(human in the loop)

NOTE: Batch levels* 3 & 4 could be class 2, class 1 or even class 0, depending on function *Batch levels as defined by ISA S88; where L3 = "unit" and L4 = "process cell"

Monitoring

Class 4: Alerting

Short-term operational consequence (e.g., event-based maintenance)

Class 5: Logging & downloading/uploading

No immediate operational consequence (e.g., history collection, SOE, preventive maintenance)

Importance of message timeliness increases

Where does it fit?

Safety

Class 0 : Emergency action (always critical)

Control

Class 1: Closed loop regulatory control

(often critical)

Class 2: Closed loop supervisory control (usually non-critical) Class 3: Open loop control (human in the loop)

NOTE: Batch levels* 3 & 4 could be class 2, class 1 or even class 0, depending on function *Batch levels as defined by ISA S88; where L3 = "unit" and L4 = "process cell" Monitoring Class 4: Alerting Short-term operational consequence (e.g., event-based maintenance) Class 5: Logging & downloading/uploading No immediate operational consequence (e.g., history collection, SOE, preventive maintenance)

For industrial control this level of security requires authentication, ciphering, redundancy, high speed, encryption and a FHSS inherently secure hop sequence. (SP-100 & XYR-6000 Goals) For industrial control this level of security requires authentication, CRC encryption and a FHSS inherently secure hopping sequence. (XYR-5000 today)

Hybrid Mesh Topology

Gateway I-Node/Router Leaf-Node 802.11device

What is the architecture? Applications for the real world!

Wireless Infrastructure Network Wi-Fi Clients Network Management Network Monitoring & Management Tools Client Applications DCS Client or other Client (OPC DA/AE, Modbus Serial, Modbus TCP) TCP  Serial Converter

Authentication Device Wireless Server Tools (Security, DCT/NMT & OPC Server)

Wireless Devices Safety RFID Location System Remote DA Applications

….and more

Second Generation Wireless - Terminology

• iNode (WiFi, 802.11, 2.4GHz FHSS)

– Router/Repeater – iNode Gateway

• Leaf node 2.4 GHz FHSS

– Transmitter

Leafs to iNode, iNode to system……..its that easy.

DSSS Strengths & Weaknesses

1 Watt of power “spread” across wide bandwidth 1 Watt 0 Watt Bandwidth (GHz)

Transmit Power (Watts)

Interference 1/10th

• 1. Security XYR Today
• Security is achieved with 4 methods

– Proprietary protocol – FHSS – Password Protection – CRC checking Time/mSec Power Watt 1 2 3 4 5 6 7 8 9 10 11 12 13 1 4 14 15 1 6 17 18 19

A Secure Wireless Architecture Providing….

– Confidentiality – Message Integrity – Source authentication – Replay protection – Resistance to denial-of-service attacks – Convenient key management

Passive listener Active Attacker Active Attacker Active Attacker

• 1. Security – Next Generation

Comprehensive, Easy to Use, End-to-End Integrated Security System

• 2. Reliable Communications
• Frequency Hopping Spread Spectrum

– Tolerates Wireless Interference – Tolerates Multi-Pathing

• Built-in Redundancy
• Mesh Networking
• Flexible Channel Allocation
• Receiver with High Selectivity
• Protocol Tolerant to Missing Packets

– Automatic Repeat Request Reliability More Than Mesh – Need a Tolerant System Honeywell Offering Contains “Tolerant System” Characteristics – Gets the Job Done While Co-Existing with Other Systems

• 3. Good Power Management

Sensor Battery Life is a Complex Function of: Transmitter Type, Ambient Temperature, Analog Conversion Rate, RF Transmit Rate, Number of Analog Inputs

Estimated Battery Life for Process Sensors Broadcasting One Analog Measurement With Honeywell Technology

Assumptions:

• Measurement rate and transmit rate are the same.
• Tadiran TL-2300 battery with an assumed switching regulator efficiency of 90%
• Worst case loading for sensor

Ambient Temperature Measurement Rate (seconds) 1 5 10 30

0ºC (32ºF) 4.9 yrs 10 yrs 10 yrs 10 yrs 25ºC (77ºF) 4.5 yrs 10 yrs 10 yrs 10 yrs 50ºC (122ºF) 4.0 yrs 10 yrs 10 yrs 10 yrs 72ºC (162ºF) 3.3 yrs 8.1 yrs 9.3 yrs 10 yrs

Self-Contained, Designed for ~10 Yr Battery Life (Rain or Shine)

Minimum Expectations For Wireless

• Ability to transmit data once per second continuously or in the

event of a alarm condition (SmartRate)

• Ability to sleep when process variable remains stable. (Preserve

Battery Life)

• Standard commercially available lithium batteries for replacement
• Smart Technology at sensor for diagnostic purposes
• Multiple protocols for gateway (TDC integration, 4-20mA modules,

ModBus, Management tool kit, etc.)

• Vendor should have several years of wireless experience
• 1,000-2,000 (+) feet of RF transmission per device.
• Antenna options to allow greater distances (1-2 miles)
• 10 Year Battery life

– (3-5 at once per second reporting)

• All the units should be field configurable

• 4. Open – Via PKS Advantage Program
• For Wireless…..
• Adding Radio Companies to Provide

Open Sensor Communication Kits

• Radio Companies will work with

PKS Advantage Partners to integrate their products into Honeywell Wireless System

• Multiple Radio Companies

Supporting – Aerocomm, Cirronet, LS Research, Omnex The PKS Advantage Program is a Honeywell-sponsored technology effort where 3rd party automation solutions suppliers, collectively aspire to deliver

• pen, integrated process knowledge solutions.

Honeywell’s Open Program for Field Device Integration – Utilizing for Wireless

Choosing a Wireless Solution

• Applications

– Safety & Security – Reliability – Compliance – Optimization

• Architecture
• Services
• Experience

The Right Consideration Set

Services

• Wireless assessment - Evaluate the site for wireless implementation
• Design a solution - Meet requirements and adhere to assessment

findings and best practices

• Implement the design - Meets customer requirements and adheres to

best practices

• Manage the network - Provide sustaining services for the network and

existing infrastructure ensuring wireless coverage and secure operation.

Assess Design Implemen t Manage Not Just a Product Supplier – Experience on the Ground Where You Need It

Choosing a Wireless Solution

• Applications

– Safety & Security – Reliability – Compliance – Optimization

• Architecture
• Services
• Experience

The Right Consideration Set

Proven Field Experience

• Over 200 customer sites have already installed Honeywell’s

wireless technology.

• Markets include:

– Oil & Gas/Refining – Chemical – Energy – Power Generation – Pharmaceutical Market – Pulp & Paper Market – Metals, Minerals and Mining Market – Consumer Goods Market

What does experience tell us?

• In most projects 60-70% of the process points are simple

monitoring points. (XYR 5000 Solution is a perfect fit!)

• Customers need critical loop monitoring and redundant

communications remainder of points(XYR-6000 fit)

• Customers want standardization. (SP-100 & XYR-6000)
• Customers need multiple frequency zones for signal robustness.

(900MHz & 2.4 GHz)

• Customers want proven Gateways –XYR

Agenda

• Environment is Right for Industrial Wireless
• Exciting Opportunities/Benefits from Wireless
• Choosing a Wireless Solution
• Why Honeywell?

Wireless Industrial Network Alliance

Promotes adoption of wireless technologies in industrial applications Promotes wireless standards for Home and Building automation and monitoring

Committee to establish standards and procedures for implementing wireless systems in the industrial environment.

HART Communications Foundation

Wireless HART Committee to establish standard for wireless control and process measurements

Why Honeywell?

• Market Expertise

– 35 Million Wireless Sensors Installed Honeywell-wide – Industrial Wireless Products Available Since 2002 with over 200 customers

• Technology Expertise

– Selected by US Department of Energy in 2003 for Industrial Wireless Research and Solution Development – 300+ Wireless Patents Published or Pending – 50+ Design/Implementation Engineers

• Standards Expertise

– Charter Members of ISA SP100, Wireless HART, WINA, and ZigBee

Wireless Expertise - Market, Technology, & Standards