Application; DCS and PAM (Plant Asset Management) Anywhere– Mobile workers - Commissioning in the field requires access at varying locations– Maintenance requires asset management in the field for trouble shouting
Challenge;– Plant wide WIFI coverage in a plant with lots of steel barriers– Eliminate local control rooms (used for start-up only)
Field Wireless Solution;– Wireless backbone– Notebooks suitable for rough environments and approved for use in hazardous areas– Roaming - While walking around switch automatically between Access Points
Field Wireless Benefits; – Faster commissioning time
• Loop testing and tuning in the field• Monitor smooth start up in the field
– Local control room eliminated• Temporarily tents are used for commissioning and start-up• Single database through wireless DCS and PAM Anywhere
Application; Process Monitoring, Mobile Operator, Camera’s– Temperature, level, pressure, valve position and vibration monitoring (several WSN’s)– Mobile workers (operator and maintenance staff), surveillance and mobile camera’s
Challenge;– Integrate WON and WSN into existing and running DCS system – large geographic area – Different wireless technologies from different vendors
Field Wireless Solution; – Wireless Industrial Gateways (WSN):
• GW’s (x9) with connected sensors (x21) and repeaters for redundancy– Wireless Access Points (WON)
• APx14– System separation by Firewalls where “wireless meets wired”
Field Wireless Benefits; – Add measurement points without infrastructure (no power/no cables)– Transparent WON + roaming – Remote maintenance support from HQ– Flexibility (Mobile Worker)
Application; Maturing drum temperature monitoring– Replacement of mechanical temperature sensor/indicator– 150 seconds for one revolution; batch process duration is four hours
Challenge;– Temperature is monitored to maintain consistency of viscous fiber feed– Reliable temperature measurement in automation system– Wired temperature measurement is not possible - drum rotates
Field Wireless Solution; – Wireless temperature measurement on drum– Gateway and 2 repeaters– Repeater location carefully selected
– Radio signal path is changing continuously
Field Wireless Benefit; – Stable on-line temperature measurement– Robust wireless communication was confirmed
Application; Temperature and pressure monitoring – Temperature and pressure monitoring of natural gas well– Each well is surrounded by metal mesh/fence to prevent intrusion (security)– Area with heavy snow fall - snow builds on the mesh/fence
Challenge;– Replacement of aging existing optical cable network in the field– Low cost implementation– Concern that the metal mesh/fence and snow has effect on radio communication –
Wireless Solution; – Test conducted with temperature transmitter (3)– Transmitters located at the well inside the metal mesh/fence– Gateway to sensor distance is approximate 50 meter
Benefits; – Signal strength decreased due to shield by fence and snow– Robust wireless communication was confirmed
Application; Utilities Management– Oil Consumption and inventory management– Flow (3), level (5) and pressure (2) measurement
Challenge;– 2-3 measurement points per measurement zone - zones about 400 meters apart– Cabling costly and tedious for just 2 or 3 measurements 400 meters distant– Measurement points almost at ground level– Trees in the plant in between the measurement zones
Field Wireless Solution; – EJX110 x 8 pcs (level & flow), EJX530 x 2 pcs– 1 GW (positioned on top of water tank )– Repeaters (3) at suitable locations
Field Wireless Benefits;– Elimination of 1600 m cable– Reduced modification work– Time saving– Flexible for future expansion
Application; Temperature Monitoring on Heat Exchanger– Monitor the efficiency of heat exchanger which maintains LNG temperature
Challenge;– High cabling construction costs due to many monitoring points over wide congested plant
• 20 points each for inlet and outlet – Update time required 5 Seconds– Integration with third party DCS System and Asset Management System– Transmitter locations 25 Meters high – Long Battery life required
Field Wireless Solution; – Temperature Transmitter (40) and Gateway (2) – Fast update time time (5 sec).– Gateway with 13 meter extended antenna
increased performance / reliability
Field Wireless Benefits; – Eliminate wiring, construction and installation costs– Long battery life (5-10 years) – No interference with existing Wi-Fi system.
Application; Temperature and pressure monitoring– Implement 21 wireless transmitters in 7 locations - wired infrastructure not available
Challenge;– The buildings are relatively high and close to each other
Field Wireless Solution; – Temperature and pressure transmitters, Gateway and 6 repeaters– Repeaters at different locations (redundancy)– Locations carefully chosen for optimal network reliability– Gateway located 7 m high
– Remote antenna could be considered
Field Wireless Benefit; – Stable measurements– Robust wireless communication was confirmed
– Packet Error Rate is almost 0%
– Repeaters provide redundant radio path– Repeaters allow “on-line” battery exchange– Significant saving on cabling, time etc.
GHz radio is sensitive to the existence of obstacles
Wireless is not much affected by “the climate”
ISA100 WSN is not much affected by other wireless networks– Coexistence by channel hopping and propper CCA, network and join keys
– Separate frequency bands - e.g. WiFi 5 GHz, sensor network 2.4 GHz
Mesh network (more than two paths) offers reliability– The higher the number of the devices the higher the “robustness” of the mesh
– Introduces latencies, is not deterministic, not suitable for control, battery in-efficient
– Response time is a useful indicator for the radio transmission condition• Response time fluctuations due to communication re-tries and mesh routing change
Star network (redundant BBR’s) has superior built-in robustness– High speed updates, deterministic, redundancy, suitable for control
