[PPT] - WirelessHART Applications ARASU THANIGAI PEPPERL+FUCHS ASIA PTE LTD PowerPoint Presentation

SLIDE 1

WirelessHART Applications

ARASU THANIGAI PEPPERL+FUCHS ASIA PTE LTD

SLIDE 2

So what is WirelessHART?

WirelessHART:
Is an open & interoperable standard
Is based on the established HART protocol
Uses known tools and procedures for configuration,

maintenance, & diagnosis

Requires minimal training
Allows wireless access to existing field devices
Can be used worldwide without any license

2

SLIDE 3

3 sensor gateway

A Network that works

The WirelessHART network is a mesh network where each sensor acts as both a router and repeater. The range of the network doesn’t depend on the location of the central gateway, allowing set up of large distributed network structures.

SLIDE 4

page 4

25-Apr-2017

Mesh Network: How it Works

SLIDE 5

page 5

25-Apr-2017

Mesh Network: How it Works

SLIDE 6

page 6

25-Apr-2017

Mesh Network: How it Works

SLIDE 7

5

Essential Components

WirelessHART GATEWAY WirelessHART FIELD DEVICE ADAPTER WirelessHART Devices

 Serial RS485 & Ethernet interface  Modbus & HART protocol  Redundant power supply  Upgrade installed field devices  Battery powered  Powers the transmitter  Operates as a router in a larger installations  single of dual channel converter  Inputs for AI,AO, DI, DO  Battery powered  LED & pushbuttons for status & set up

The WirelessHART gateway is the core element of a wireless mesh network. It serves as the interface between the mesh network and the plant’s process control or asset management. The WirelessHART adapter can be connected directly to the interface

f any field device. This can be a

conventional 4…20 mA or an intelligent HART device. The WirelessHART devices

ffers multiple ways to connect

physical variables. They are designed to transfer measurements directly to the network.

SLIDE 8

page 9

25-Apr-2017

New Connectivity to existing Devices

Retrofitting Application for existing infrastructures that do not support HART communication today

SLIDE 9

page 10

25-Apr-2017

Wireless Devices for Measurement & Control

SLIDE 10

page 11

25-Apr-2017

Typical Applications

Heavy Industry
Extraction, Refining
Conveying, Processing
Manufacturing, Storage
Water/Wastewater
Municipal, Rural
Environmental
Pump Control
Tank Levels
Flow Measurement
Preventative Maintenance

SLIDE 11

7

Product Applications

Tank Farms
Oil Refineries
Rotational Equipment
Mobile Equipment
Ad hoc Monitoring
Pipelines

SLIDE 12

6

Measuring & Monitoring

Temperature Corrosion

A simple WirelessHART temperature sensor can be used to detect & diagnose problem situations long before they result in failures & influence plant availability.

Ideal Applications or Locations

WirelessHART monitoring instruments can be placed at important measurement points along pipelines in places that previously couldn’t be reached.

Ideal Applications or Locations

WirelessHART makes it easier & more cost effective to monitor the levels in process & storage tanks by eliminating the need to manually take & record the measurements.

Ideal Applications or Locations

Level Control

 Motors  Pumps & cooling devices  Resources that need monitors  Long pipelines located in remote locations  Plants with moving vehicles & changes in location  Storage vessels  Process tanks

SLIDE 13

Process Monitoring & Control

Hard to reach locations
Process efficiency calculations
Better insight into process
Ad-hoc measurements
Additional measurements from mult

ivariable devices

Calculated variables in devices

SLIDE 14

Equipment Monitoring

Bearing temperatures
Vibration
Corrosion
Oil pressure
Air flow

4-20 mA output on oil tanks

 Railroad

Rural railroad signal control - 2 DI
Yard switch control

 Refineries / chemical plants  Steel / metal plants

SLIDE 21

page 22

25-Apr-2017

Quarry Dredging

Hwy. 61

SLIDE 22

page 23

25-Apr-2017

Mining Installation

 Worked with customer on antenna installation to provide reliable communicati

ns

SLIDE 23

Other Applications

 Health and Safety

Safety showers
Gas detectors

 Environmental

Steam traps (energy usage)
Water / Discharge Treatment
Flow
pH
Stack emissions
Relief valves

SLIDE 24

Other Applications

 Asset Management

Maintenance
Calibration
Record valve signatures
Radar echo
Diagnostics
Valve position feedback
Device health (status)

SLIDE 25

Application examples with pictures

SLIDE 26

Fence Line Gas Detection Tank Level Gas Detection Skid with 5 MACTek Bullets ~ 140 meters From Gateway; 4 – analog transmitters and 2 HART 4-20 mA Transmitter; scaled Engineering Units and Multidrop with HART Transmitters

SLIDE 27

Portable Gas Monitoring Portable Mixing Tanks - (Pharmaceutical) Place meters within reach of any WH Device

r Gateway; use battery controls to conserv

e power; transmit PV and Battery Voltage fo r Analog 4-20 non-HART transmitter Everything wired from one AC power connection; Analog output for Drive Speed, Pressure, Temp, PH, Level

SLIDE 28

Portable Boiler Efficiency Testing Valve monitoring Budget ~$50,000; Savings using Bullets: Project Approved with a savings of $78,000 ( 78%) due to multidrop. Paper Machine (Wet End); Dirt and moisture,

no problem (IP68)

SLIDE 29

Multidrop

Used on a “wireless” remote IO Application – 34 transmitters with 10 Bullets!

SLIDE 30

Multidrop

Puck Temperature Transmitters
24 Measurements

~ PV = Average or Difference ~ SV = Temp 1 ~ TV = Temp 2

Easily Repairable
1Second update per transmitter
WirelessHART for less than $3

3 per measurement. Bullet Direct Power, Multidrop Temperature Solution G G R R Y Y B B W W 8 1 2 3 4 5 7 6 G

SLIDE 31

Battery Box – Powering Two Devices

Pressure and Temperature used on Rotating Digester

SLIDE 32

Tank Farm Monitoring – GPB, Mexico

 Objectives

Reduce cost
Reduce time to implement

 Installation

10 Level transmitters
10 WirelessHART Adapters
1 Gateway
HMI Software via OPC

SLIDE 33

Rotating Catalyst Driers at BASF The Netherlands

 Objectives

Eliminate manual sampling
Improved quality
Increase throughput with short

er cycle times  Installation

Pressure and Temperature Tra

nsmitters

WirelessHART adapters
Gateway with Modbus output
Modbus to Profibus converter

SLIDE 34

Rotating Catalyst Driers at BASF

Adapters provide:
Power and wireless connectivity to pressure and temp transmitters
A communication path from the rotation equipment to the gateway
Communication to a Siemens PLC via a Modbus to Profibus converter

SLIDE 35

Wellhead Monitoring for Heavy Crude Oil Extraction

 Objectives

Reduced installation time (from 15 days t
3 days)
Eliminate expensive cabling and remote I

/O  Installation

800 Instruments
800 WirelessHART Adapters
43 Gateways

Pacific Rubiales Energy, Colombia

SLIDE 36

Wellhead Monitoring for Heavy Crude Oil Extraction

SLIDE 37

Burner Monitoring in Steel Production

Stahl Gerlafingen AG

 Objectives

Improve reliability of the measu

rement systems  Installation

Flow measurement of cooling

water

Flow measurement of ingot mol

d water

Oxygen supply to burners
Temperature of shaft and ventu

ri nozzles

Level of the dust silo

Adapter connections to any HART or Analog Device

SLIDE 38

Burner Monitoring in Steel Production

Stahl Gerlafingen AG

Dust Silo Level Oxygen Flow to Burner

The adapter can be connected anywhere in the 4-20ma loop enabling it to be hundreds of meters from the installed device.

SLIDE 39

Energy Efficiency Improved at Duke Energy

 Objective

Improve cost and speed of

conducting efficiency tests

Leverage existing investment in

HART instrumentation

Improve reliability by replacing m

ultiplexers with gateways and less cabling  Installation

WirelessHART adapters with

multidrop wiring topology

WirelessHART Gateways

 Results

100-150 man-hour savings

enabling more tests, more often

SLIDE 40

 Objective

Monitor temperature of highly reactive and flammable

chemicals in moving rail cars

Maintain wireless temperature measurement as rail c

ars move throughout facility

 Installation

Wireless temperature transmitters installed on each r

ailcar as they arrive at plant

Temperature measurements communicated from gat

eway back to the control system

 Results – Improved safety and Reduced costs

Eliminated employees climbing to the top of railcars e

very day

Temperatures in Railcars at Croda

“There are savings of $14,000 per year in reduced operations and maintenance costs, but, the incalculable savings were in safety.” —Denny Fetters, I&E Designer

SLIDE 41

 Objective

Customer needed low cost method to monitor

pump filters

Existing pneumatic pressure transmitters wer

e error prone, required manual gauge reading s and frequent maintenance

 Installation

Installed WirelessHART dP transmitters and a

Gateway on Coker unit pumps

 Results – Improved reliability

Eliminated pump damage and process upsets

caused by loss of suction

Filter Monitoring in Refining

“[Insight] from predictive wireless filter plugging alerts prevented a shutdown. Operators were able to shut down the pump, clean the filter and get it back on line in a matter of hours. If the alert were not present, the filter pump would have been damaged, and would have needed to be completely replaced”

— Project Manager, Major Refining Company

SLIDE 42

 Objective

Automated level measurement needed on tanks to

support inventory, process management and accurate documentation for customers

 Installation

Wireless pressure transmitters are monitoring 14 tanks

 Results

Automated inventory management
Some of the fourteen wireless pressure transmitters

are moved from place to place to aid in troubleshooting and new process development

Elimination of “clipboard rounds,” more accurate real-

time data for process efficiency, documentation

Wireless Benefits at Technochem in Singapore

“If I see a problem in some part of our process, it is fairly simple for me to take a pressure transmitter and move it elsewhere. I can often determine what’s going

n in just five minutes, address the issue and quickly return the transmitter to its
riginal application. The flexibility of (the) self-organizing wireless technology

makes it much easier to troubleshoot problems as well as evaluate new applications.” — Jan Huijben, Incineration Manager

SLIDE 43

Conclusion

The benefits of WirelessHART are:
WirelessHART networks are flexible, intelligent solutions for the

requirements of the process industry

WirelessHART components eliminate wiring & integrate conventional

field devices into wireless structures

Measuring & monitoring have never been more flexible or efficient,

especially in remote locations

WirelessHART technology is here to stay, and those who adapt early will