1© ARC Advisory Group

Wireless in Process Automation

Trends and OutlookETSI Board #6713 June 2008

Wireless in Process Automation

Trends and OutlookETSI Board #6713 June 2008

Harry ForbesSenior Analyst, North America

ARC Advisory GroupHForbes@ARCweb.com

David HumphreySenior Analyst, Europe ARC Advisory GroupDHumphrey@ARCweb.com

2© ARC Advisory Group

Who Is ARC Advisory Group?Who Is ARC Advisory Group?

Strategic Advisory and Management Consulting Firm: The leader in manufacturing and logistics

• Supply Chain: Sourcing to Fulfillment

• Plant Systems: Production Management to Controls

• Product Lifecycle Management: Design to Service First-hand industry and application experience Technology trends and business forecasts Formed in 1986 – 22 years of growing knowledge

Enterprise to Plant Floor

3© ARC Advisory Group

Industrial Wireless Segmentation

• Which are the critical parameters?

Process Industries Wireless Market Forecast

Wireless Applications in Manufacturing

Wireless Standards organizations and efforts

AgendaAgenda

4© ARC Advisory Group

Device Power Model

• Replaceable battery (low-power)

• Rechargeable battery

• Mains power Manufacturing Process Type

• Continuous Process Manufacturing

• Discrete Manufacturing Wireless Network level

• Sensor level network

• WLAN level network

Industrial Wireless SegmentationIndustrial Wireless Segmentation

5© ARC Advisory Group

Manufacturing Process TypeManufacturing Process Type

Process AttributeContinuous Process

Manufacturing UnitDiscrete

Manufacturing Unit

Sensor types Predominately Analog Predominantly Discrete

Sensor count per unit 1000 100

Unit Physical Size 1000 Meter 10 Meter

Units per Plant 10s 100s

Production Cycle Length 100 Days 1 Day

Unit Startup Time Hours Minutes

Control Loop Time .1-1000 Sec .001-.5 Sec

Field Device Cost $1000 $100

Installation Cost/device cost 10 X 4 X

Automation Technology DCS PAC/PLC

Commonly Used Device Networks

HART,Foundation Fieldbus,Profibus-PA,Ethernet

Profibus-DP,DeviceNet, Interbus, AS-i,Ethernet

6© ARC Advisory Group

Wireless Network LevelWireless Network Level

ENG

OperationLevel 2

Server Server Server Server

ManagementLevel 3

ENGServer

DomainController

ControlLevel 1

APC History

Field Devices Level 0

HMI HMI HMI HMI HMI HMI

7© ARC Advisory Group

Process Manufacturing Wireless Market ForecastProcess Manufacturing Wireless Market Forecast

Size and Growth Wireless penetration into Process Field Device

Market

8© ARC Advisory Group

Wireless Market Growth in Process IndustriesWireless Market Growth in Process Industries

0

200

400

600

800

1,000

1,200

2007 2008 2009 2010 2011 2012Worldwide Market for Wireless Devices in Process Manufacturing

($Millions) ©2008 ARC Advisory Group

9© ARC Advisory Group

Wireless Impact on Field Device Markets?Wireless Impact on Field Device Markets?

10© ARC Advisory Group

Wireless Field Device Penetration Wireless Field Device Penetration

11© ARC Advisory Group

Current and EmergingProcess Wireless ApplicationsCurrent and EmergingProcess Wireless Applications

Bridging Field Process Sensing Equipment Condition Monitoring Advanced Metering Infrastructure (AMI)

12© ARC Advisory Group

Wireless Cable Replacement (Bridging)Wireless Cable Replacement (Bridging)

Many commercial products• E.g. Cooper (MTL/Elpro),

Phoenix Contact, ProSoft, others

Proprietary and Wi-Fi radioOptimized for longer rangeNot glamorous, but very

useful and economical

13© ARC Advisory Group

Wireless Process SensingWireless Process Sensing

Commercial products since 2003

Longer life now possible More reliable

communication Better security Becoming standards-

based• IEEE 802.15.4

• HART V.7 (WirelessHART)

• ISA 100

14© ARC Advisory Group

Equipment Condition Monitoring - Present Equipment Condition Monitoring - Present

These address assets that are NOT beingmonitored now, which is most plant assets

ECM Application Components• Specialized Mobile Computers• Vibration Sensors• Analytical Software• Historical Data Repository

Current suppliers include:• ABB• Emerson• GE/Bentley• Honeywell• SKF

15© ARC Advisory Group

PowerGeneration

Generation Switchyard

Transmission Substation

Distribution Substation

EndUser

Common Information Infrastructure

Advanced Metering + Demand Response

Advanced Metering:Integrates Devices at the Edge of the GridAdvanced Metering:Integrates Devices at the Edge of the Grid

16© ARC Advisory Group

WLAN ApplicationsWLAN Applications

Mobile Operator Support

• Process Operations

• Maintenance, Safety, Environmental operations Visibility During Planned Shutdowns

(“turnarounds”)

17© ARC Advisory Group

Mobile Operator Support Mobile Operator Support

Initially networked via cradles Applications

• Rounds and readings

• Data Capture

• Work Order Generation

• Condition Monitoring

• Process Operations

• Turnaround visibility Combines with AutoID,

and sensing Converged with voice

18© ARC Advisory Group

WLAN Infrastructure Trend:Discrete ManufacturingWLAN Infrastructure Trend:Discrete Manufacturing

Wi-Fi coverage becomes dense Multiple Wireless Applications

• Automation• Data• Voice• Location services

Manufacturers are moving to a unified WLAN network model• Common services• Wider coverage

RF Spectrum management will become a part of network management practices

19© ARC Advisory Group

WLAN Infrastructure Trend:Process ManufacturingWLAN Infrastructure Trend:Process Manufacturing

Layer 2WLANSegment

Layer 2WLANSegment

Bridgeor Router

.11s Mesh #1 .11s Mesh #2

MeshPortal

20© ARC Advisory Group

Discrete Manufacturing Sensor Applications: ABB WISADiscrete Manufacturing Sensor Applications: ABB WISA

Commercial Product Uses Bluetooth radio

• Radio only, not stack

Unique sensor power solution• No batteries• Rotating magnetic field induced around machine

Well thought-out requirements for discrete manufacturing sensor use-cases• Number of sensors, range, latency, reliability, etc.

FESTO has done related work using IEEE 802.15.4

21© ARC Advisory Group

Location TrackingLocation Tracking

Technology Decision Variables

• Technology

• Radio type

• RSSI vs. TDOA

• Required Precision of Location

• Cost ( installed cost, Total Cost of Ownership) Possible Radios for Location Technologies

• Wi-Fi (Aeroscout, Ekahau, Cisco, others)

• 802.15.4 (Innerwireless, others)

• UWB (Zebra/Multispectral Solutions, Nanotron)

22© ARC Advisory Group

Location System ArchitectureLocation System Architecture

Passive RFID Tags

Passive Readers

Enterprise Applications

Location Engine Appliance

Wi-Fi Tags, clients, integrated sensors

Dual-mode Wi-Fi /UWB Tags

UWB Readers

ExcitersWi-Fi

Network

23© ARC Advisory Group

Wireless Standards Organizations and InitiativesWireless Standards Organizations and Initiatives

24© ARC Advisory Group

WSN Standards and Technologies WSN Standards and Technologies

IEEE 802 ZigBee Alliance HART Communication Foundation IETF ISA TinyOS Alliance Bluetooth SIG Proprietary technologies (ANT, Z-Wave, others)

25© ARC Advisory Group

IEEE 802IEEE 802

802.15.4e• MAC amendment to the existing standard 802.15.4-2006 to

• better support the industrial markets • permit compatibility with Chinese WPAN

• Suppliers do not use standard 15.4 MACs• 15.4 TDMA (called GTS) network operation

• not completely specified

802.11n• Next enhancement to Wi-Fi

802.11s• Multi-vendor Wi-Fi mesh networking• Ballots have failed so far

26© ARC Advisory Group

ZigBee AllianceZigBee Alliance

Built over IEEE 802.15.4 standard ZigBee Scope

• Network layer, Security, Mgmt, Profiles• Network formation• RF Channel choice• Scope equivalent to TCP/IP Suite

• Too broad• Largely unsuccessful

Solved the low-power problem with:• Reduced function devices, RFDs• Mains-powered routers• Not a good fit

for manufacturingapplications

ZigBee Application focus• Began with building lighting (2003)

• Challenging performance requirements• Few commercial products

• Now has shifted to Advanced Metering/Home Automation Networks• AMI needs wireless access to home energy controls• Utilities will want secure end-end IP connections

27© ARC Advisory Group

HART Communication FoundationHART Communication Foundation

WirelessHART Part of HART Field Communication Specification, Revision

7.0 • Ratified September 2007• Allows for wireless transmission of HART protocol

Based on IEEE 802.15.4 PHY with modified MAC Layer

Full mesh network topology

Adaptive frequency hopping

Time-division multiple access (TDMA)

... ... ...

Time

Timeslot

Frame nFrame n-1 Frame n+1

28© ARC Advisory Group

HART Communication FoundationHART Communication Foundation

Network Manager• Critical• Makes all decisions• Devices can be “dumb”

Presently a sole-sourced technology• Dust Networks SoC and module products

2nd source of WirelessHART technology is possible• Client Device portion only, not network manager• Talk but no investment yet

29© ARC Advisory Group

ISA 100ISA 100

Instrumentation, Systems, and Automation Society (ISA)

ISA develops standards for ANSI ISA 100 scope includes all types of manufacturing ISA 100.11a is first standard. Due 2009 ISA Compliance Institute

• ISA began compliance function only in 2007

• Compliance work for 3 important ISA standards

• Wireless (ISA 100)

• Cyber-security (ISA 99)

• Enterprise Interoperability (ISA 95)

• ISA ability to execute is unproven

30© ARC Advisory Group

IETFIETF

RFC 4944 (6LowPAN)

• IPV6 over 802.15.4 ROLL Working Group

• Began May 2007

• Routing over low-power lossy nets

• Application areas:

• Industrial

• Home

• BuildingsSensor Network (Mesh, Star, or Tree)

Sensor Network Data Link Layer

IPV6 Services Layer

IPV4-IPV6 Routing

Sensor Network Gateway

IP V4 Network

IPV6 Network

31© ARC Advisory Group

TinyOS AllianceTinyOS Alliance

TinyOS is an open-source OS for WSNs

• Used for most academic WSN research

• Global collaboration among academics

• Not used in commercial WSN applications

RFM

Radio byte SensorSensor

Messaging Layer

clocksbit

byte

packet Radio Packet

Routing Layer

sensing applicationapplication

HW

SW

ADC

messaging

routing

UART Packet

UART ADC

32© ARC Advisory Group

Bluetooth SIG Bluetooth SIG

Low Power Bluetooth (formerly Wibree)

• Compatible with Bluetooth 7-device PANs ANT (Garmin) for non-Bluetooth applications

33© ARC Advisory Group

Summary: Things To RememberSummary: Things To Remember

Critical Industrial Wireless Segmentations• Power use model (replaceable, rechargeable, mains)• Process vs. discrete applications • Wireless Sensor Networks vs. WLAN

Industrial Wireless Market Will Grow Rapidly• But adoption cycles and service lives are long

Current wireless applications in process manufacturing:• Cable replacement• Process Sensing• Equipment condition monitoring• Mobile operator support• Location tracking – attractive, but far less mature

Industrial Wireless Standards• Many, many organizations are participating now

34© ARC Advisory Group

Thank You.Thank You.For more information, contact the authors at

DHumphrey@ARCweb.comHForbes@ARCweb.com

or visit www.arcweb.com