WirelessHART Integration - Fieldbus...A wireless pressure transmitt對er has a basic accuracy of...

Mumbai - India September 2013

© 2013 Fieldbus Foundation

WirelessHART Integration

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1,000 Wireless Devices At Every Site – Beyond the P&ID

How we operate unmanned sites

How we maintain assets

How we operate in the

field

How we look at energy

consumption

Presenter

Presentation Notes

-I believe every plant and every field will have 1,000 wireless transmitters – the goal -Wireless changes how we do things, for the better: -- How we maintain assets -- How we look at energy consumption -- How we operate in the field -- How we operate unmanned sites – the “super puma” will go extinct -Get there first!

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Topics Covered The ABC of application classes WirelessHART meeting plant needs For every fieldbus there is an Ethernet Wireless gateway integration today and tomorrow HSE today! HSE for package unit integration

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The ABC of Application Classes Areas where wireless technology is applied

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Application Class

Description Remarks

A Functional safety Time-critical applications in the area of functional safety, process interventions and interaction with other applications and systems are governed by the requirements of critical safety applications.

B Process management/control

Time-critical, deterministic applications which must meet high requirements with regard to availability and reliability. Interactions with other applications and process interventions are included.

C Display monitoring Applications which are not time-critical and exclusively provide additional information. Interactions with other applications and systems are excluded.

NAMUR NE124 Application Classes - Do you know your ABC?

Most wireless applications are class ‘C’: – Reliability: Essential Asset Monitoring – Energy Efficiency: Energy Conservation Measures – Personnel Safety: Reducing operator rounds – Integrated Operations: Unmanned sites

Presenter

Presentation Notes

Example specification: Use wireless transmitters for monitoring in non critical services: • Loops which are not used as pre-alarm to an ESD • Loops which are not used as key indication for process operation • Loop which do not require an update better than 8 seconds • Loops which are not used for computation in DCS (flow compensation, etc.) or other system (OMS, BCS, APC, Mass balance calculations, etc.) Wireless transmitters shall not be used for Control loops.

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A “Second Layer” of Automation - for “Missing Measurements”; “Beyond P&ID”

Essential Asset Monitoring (EAM) Energy Conservation Measures (ECM)

• Heat exchanger • Pump • Blower • Air cooled exchanger (fin fan) • Unmonitored compressor • Cooling tower • Pipes & vessels • Filters & strainers

• Steam trap failure • Heat exchanger fouling • Steam consumption • Chiller water consumption • Filter & strainer blocking • Cooling tower fan

Health, Safety, and Environmental (HS&E)

Integrated Operations (iOps)

• Safety shower and eye wash station • Manual valve • Relief valve • Gauge, sight glass, variable areas

flowmeter, dip stick • Grab sampling • Vibration, temperature, acoustic tester • Stranded diagnostics • Control valves • Passing valves

• Production well • Injection well • Separator • Storage tank

Modernization User

Guide Available

Presenter

Presentation Notes

Focus on the broad categories, not the individual applications

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Wireless Essential Asset Monitoring - Process Equipment Diagnostics: Smart Assets

Heat exchangers Pumps Blowers Air cooled exchangers (fin fan) Unmonitored compressors Cooling towers Filters Pipes & vessels etc.

Pre-engineered packages using

WirelessHART and multiparametric

software algorithms for process equipment diagnostics

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Types of Diagnostics

Process equipment diagnostics is a new type of diagnostics for which WirelessHART is ideally suited

1. Signal Diagnostics • Communication Errors • 4-20 mA integrity • Wireless signal

strength

3. Process Connection Diagnostics

• Valve • Actuator • Impulse line

4. Process Equipment Diagnostics

• Heat exchanger • Pump • Blower • Air cooled exchanger

2. Device Diagnostics • Electronics (memory

etc.) • Internal mechanical

parts • Supply

ISA108

Presenter

Presentation Notes

Type 1 = Bus diagnostics / 4-20 mA integrity (“power advisory”) = By system interface card Type 2 = Device diagnostics = By device itself (self-diagnostics) Type 3 = Process connection diagnostics = By the device Type 4 = Process equipment diagnostics = By multiparametric algorithm based on multiple PV

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Intelligent Device Management

Intelligent Device Management (IDM) is one of many parts in an Asset Management System (AMS)

Plant Asset Management System

Machinery Health Management

Process Equipment Management

Intelligent Device Management

Rotating Machinery • Turbine • Compressor • Pump

• Heat Exchanger • Pump • Blower • Air cooled exchanger • Cooling tower • Compressor

Instrumentation • Transmitter • Analyzer • Control valve • On/off valve • Motor drive • Gas Chromatograph

ISA108

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Reduce Field Operator Rounds - Getting rid of the blind spots

Dial gauges Sight glasses Variable area flow meters Dip sticks Portable testers

– Vibration – Temperature – Ultrasonic (leak)

Grab samples

Presenter

Presentation Notes

Both dial gauges and wireless transmitters need no wiring and are therefore low cost to deploy since no wiring is required, and low risk of plant damage since no cable has to be laid. The price of a pressure gauge is as low as $100. However, the typical accuracy of a pressure gauge is only 1%. The typical temperature effect is 0.4% per 10 degC adding further inaccuracy. Add to this human factors such as parallax error when reading the gauge, mistakes writing the log sheet, error reading the log sheet, and typographical error when entering data into software. The measurement "update period" depends on how often the field operator makes the rounds in the plant which may be as infrequent as once per shift, day, week, or even month or longer. The more often the field operators have to make their rounds for timely data, the greater the risk to their personnel safety. In remote applications the cost of operation can be significant, as additional manpower has to make a car ride to well pad or helicopter transfer to satelite platform to collect the readings. Gauges have moving mechanical parts which will fail with time in spite of its simplicity, resulting in reliability which is only fair. A corroded gauge may get stuck, no longer responding to process changes, which may go undetected for long periods of time. The solution is to replace pressure and temperature gauges, level sight glasses, dip sticks, variable area flow meters, and portable testers etc. with wireless transmitters. A wireless pressure transmitter has a basic accuracy of 0.065% with a temperature effect as little as 0.14% per 28 degC. Since the data collection is totally automatic, human errors in reading, writing, and typing are eliminated. The measurement update period can be as fast as one second, a minute, or an hour. Console operators get the measurement directly in the DCS. Built-in device diagnostics detects sensor health validating the reading or flagging sensor failure or exceeded operating conditions, etc. Sensors have no moving parts and are therefore very reliable. The price tag is approximately $5,000 for a wireless pressure transmitter. Greater accuracy and stability results in better inventory control and ability to spot developing tendencies. Timely measurements provide a better understanding of the process for troubleshooting. Not having to send field operators into the plant improves personnel safety. Cost of operation is reduced, especially for remote field travels.

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Increased Operator Awareness - Other Monitoring not on the P&ID

Safety shower & eyewash stations

Steam trap failure Pressure relief valve release Manual valve position

feedback

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Integrated Operations (iOps*): - Unmanned Sites

Production wellhead – Casing/annulus pressure – Gas lift

– Water wash – Chemical injection

Injection wellhead – Gas – Water – Chemical – Steam

Separator Storage tank

• Pressures • Temperature • Differential

pressure • Valve position

• Central operation

• Optimization • Reservoir

modeling

* Also known as: Smart Fields, e-Field, i-Field, Digital Oilfield, Intelligent Oilfield, Field of the future and Intelligent Energy

Presenter

Presentation Notes

PRODUCTION WELLS Basic (many of these likely to already be monitored) Flowline Pressure Flowline Temperature Casing/Annulus Pressure Wellhead Pressure Bradenhead Pressure Gas lift (add) Gas Lift Pressure Gas Lift Temperature Gas Lift Differential Pressure Water wash (for gas lift) (add) Water Wash Pressure Water Wash Differential Pressure Chemical injection (add) Chemical Inj. Pressure Chemical inj. Differential Pressure Chemical inj. Flow INJECTION WELLS Gas injection Gas Inj. Pressure Gas Inj. Differential Pressure Gas Inj. Temperature Wellhead Pressure Casing Pressure Water injection Water Inj. Pressure Water Inj. Differential Pressure Chemical injection Inj. Pressure Inj. Temperature Inj. Flowrate Steam injection Steam Injection Pressure Steam Injection Temperature Water Injection Differential Pressure to monitor flow



WirelessHART meeting plant needs

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Wireless for Process

Applications

WirelessHART Technology - Based on User Requirements

NAMUR NE124 Availability /Reliability Real-time

Capability

Security

Coexistence

Interoperability

Transparent Integration Version

Management

Long Battery Life

Diagnostics

Industrial Grade

Familiar Tools

Certification

Mesh Topology

1 second – 1 hour •Encryption •Authentication •Verification •Channel hopping •Key Rotation •Sequence Number

•Ch. hopping •DSSS •Short messages •Ch. black listing •Low TX power

Independent Testing

Same tools as 4-20

mA/HART and fieldbus

Intrinsically safe • Comm. stats •

Adapters • Planning tools •

MB/Profibus/OPC • Conf. & diag. tool •

Comm. stats • 8 bit response code •

200 bits of MSA • Specific commands •

IEEE 802.15.4 radio • Sleep mode •

Status indication • EDDL

IEC 62591

•EDDL •Planning tool •Config. & diag.nostics tools

Presenter

Presentation Notes

3.1 Application Classes 3.2 Availability and Reliability 3.3 Real-time Capability 3.4 Security 3.5 Coexistence 3.6 Interoperability / Interchangeability 3.7 Transparent Integration in Systems 3.8 Version and Lifecycle Management 3.9 Power Supply 3.10 Self-Monitoring and Diagnosis 3.11 Equipment and Components 5.1 Configuration / Commissioning 5.2 Service and Maintenance 6 Certification

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Industrial Wireless - Unique Self-Organizing Full Mesh Topology

Redundant data pathways eliminate single points of failure – Actual installations consistently

demonstrate >99% data reliability – Dense plant environment

Routing at device-level – Unique full-mesh, 7 hops deep – No backbone router infrastructure – No hazardous area power required – True wireless: low cost, low risk

Unique automatic reconfiguration – No manual routing configuration

10 year battery life at 1 min update depending on sensor type

The difference between a home/office network and an

industrial network

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Unique HART Wire Terminals as Standard - Use Existing Common Tools

Using the same tools as for 4-20 mA/HART and FOUNDATION fieldbus devices – Handheld field communicator

– Zone 1 – Laptop software – Documenting calibrator

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Same Tools – Devices Work Consistently 4-20 mA/HART

FOUNDATION fieldbus

WirelessHART

mA

No mA

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Unique Ease of Adoption - Same Familiar Tools, Same Procedures

WirelessHART devices use the same tools as 4-20 mA and FOUNDATION fieldbus devices – Same handheld communicator – Same documenting calibrator

Same procedures – Configuration/setup – Calibration – Diagnostics – Viewing internal variables

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Multi-vendor Interoperability - IEC 62591

Native I/O Devices Adapters

Adapters only required for 4-20 mA/HART

devices on 4-20 mA systems

Fieldbus devices already digitally

integrated

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Gateway of Wireless A WirelessHART gateway connects your existing

DCS to WirelessHART transmitters from different manufacturers



IP and Ethernet Refresher For every fieldbus there is an Ethernet

How does all the wireless data get into the system?

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Ethernet and Wi-Fi are Just Media - What About the Protocol?

Just “Ethernet” or “Wi-Fi” is not sufficient for interoperability – Devices connect to the same

network, but they don’t “talk” IP “network protocol” is also not

sufficient TCP or UDP “transport protocols”

are also not sufficient To access the data, a common

“application protocol” is required There are thousands of different

“application protocols” for different applications...

Physical (Ethernet/FO/Wi-Fi)

Data Link (MAC)

Network (IP)

Transport (TCP or UDP)

Presentation

Session

A complete protocol requires several parts:

Application Protocol

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The Protocols are Standardized - One for Each Function

Standard protocols for network management functions: DHCP, SNMP, PING, DNS and NTP/SNTP, DSCP, 802.1p, 802.1Q, etc.

Protocol Application Standard HTTP Online Information Access IETF RFC 2616 FTP File transfer (document access) IETF RFC 959 SMTP Send email IETF RFC 821 POP Receive email IETF RFC 918 SIP Video conferencing IETF RFC 3261 RTP Video IETF RFC 3550 H.323 Voice (telephony / VoIP) ITU H.323

Laptop Tablet Voice/Video Voice/Video Tag Video Hand Held

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FF-HSE

FF-H1

Linking Device

Industrial Ethernet Application Protocols - Already Standardized

Fieldbus Indsutrial Ethernet PROFIBUS-DP PROFINET-IO FOUNDATION fieldbus H1 FOUNDATION fieldbus High

Speed Ethernet (HSE) Modbus/RTU Modbus/TCP DeviceNet EtherNet/IP 4-20 mA/HART, WirelessHART HART-IP

Modbus/TCP EtherNet/IP HART-IP

Modbus/RTU DeviceNet 4-20 mA/HART WirelessHART

Device Server

Linking Device

Multiplexer / Gateway

PROFINET-IO

PROFIBUS-DP

Proxy

HART-IP

For every fieldbus

there is an Ethernet

Presenter

Presentation Notes

For every fieldbus there is a corresponding and complementary industrial Ethernet application protocol PROFINET-IO IEC 61784-2 family 3, IEC 62411 PROFIBUS-DP FOUNDATION fieldbus High Speed Ethernet (HSE) IEC 61784-1 family 1, IEC 61158 type 5 FOUNDATION fieldbus H1 Modbus/TCP IEC 61784-2 family 15, IEC 62030 Modbus/RTU EtherNet/IP IEC 61784-2 family 2, IEC 62413 DeviceNet HART-IP IEC 61784-1 family 9, IEC 61158 type 20 HART, WirelessHART

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Sensors & Actuators

Process

Execution

Automation

Business Level 4

Level 3

Level 2

Level 1

Level 0

CMMS / MES

ERP

Control System

Level 1-1/2

Drive

Fieldbus H2 or Ethernet

Fieldbus H1

Gateway Remote I/O PLC Linking D.

Package Unit H1

System Architecture - Wireless, Fieldbus, and Ethernet Complement Each Other

Ethernet takes the place of H2 fieldbus H1 fieldbus takes the place of 4-20 mA and on/off Wireless takes the place of gauges, handheld testers, and doing nothing

Presenter

Presentation Notes

Purdue reference model / ISA95 Ethernet takes the place of H2 fieldbus H1 fieldbus takes the place of 4-20 mA and on/off WirelessHART takes the place of gauges, handheld testers, and doing nothing



Wireless gateway integration today and tomorrow WirelessHART gateways support multiple industrial Ethernet protocols

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Plant-Wide Applications Larger than the capacity

of a single gateway Plant-wide applications

require a gateway in each plant area

The gateways need to be integrated back to the DCS

System

PIB PIB

PIB

PIB

PIB PIB

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Modbus Register Mapping and Masking

Card-Port Baud rate Flow control Data bits Parity Stop bits Timeout Max Retries 1-1 1200 RTS/CTS 7 None 1 4 seconds 3 times 1-2 2400 8 Odd 1.5 2-1 4800 Even 2 2-2 9600 3-1 19200 3-2 38400

Tag Name

PLC Address

Register Number

Data Type

Bit Mask

Reverse Bits

Word Swap

Raw Counts

EU Range

Scan

00001 Boolean 10001 Boolean 30001 Integer

51-TT-101

2 30003 Unsigned Integer

−32768 to 32767

0 to100 degC

1 40001 Float / Real Normal

On/Off

4-20 mA

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Lots of Process and Device Information WirelessHART devices provide lots of

useful information: – Process information: DCS

– PV – SV, TV, and QV

– Device information: IDM part of AMS – Diagnostics – Setup/configuration – Identification – Internal variables

Mapping process and lots of device information for all devices is time consuming:

– Modbus: map to registers – EtherNet/IP: map to instance & member – OPC: map to group & items

Changes are error prone

Tag Parameter Type Register 51-PT- 101 PV Float 40000

51-ApHT- 101 PV Float 40004 51-ApHT- 101 SV Float 40008

51-TT- 101 PV Float 40012 51-TT- 101 SV Float 40016 51-TT- 101 TV Float 40020 51-TT- 101 QV Float 40024 51-LT- 101 PV Float 40028 51-FT- 101 PV Float 40032 51-ZT- 101 PV Float 40036

51-ACT- 101 PV Float 40040 51-ACT- 101 SV Float 40044

51-VT- 101 PV Float 40048 51-PT- 102 PV Float 40052

51-ApHT- 102 PV Float 40056 51-ApHT- 102 SV Float 40060

51-TT- 102 PV Float 40064 51-TT- 102 SV Float 40068 51-TT- 102 TV Float 40072 51-TT- 102 QV Float 40076 51-LT- 101 PV Float 40080 51-FT- 101 PV Float 40084 51-ZT- 101 PV Float 40088

51-ACT- 101 PV Float 40092 51-ACT- 101 SV Float 40096

51-VT- 101 PV Float 40100

Presenter

Presentation Notes

Modbus: map to registers EtherNet/IP: map to instance and member OPC: map to group and items

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F-ROM Gateway Integration - with HSE Hosts

Process variables and outputs as standard function blocks in DCS WirelessHART device diagnostics and setup/configuration through

HART transducer block or “pass-through” to intelligent device management (IDM) software

ZV-103

Gateway H TB

H TB

DI

AI

H TB DO

LSH-101

PIT-102

ZV-103

DCS PID

ARTH

DC

AI AO TRK_IN_D LSH-101

PIT-102

IDM Software

Presenter

Presentation Notes

FF-913 HART/WirelessHART transducer block HART pass-through: HART_CMD, HART_RESP, HART_IND or HART-IP on the same Ethernet cable



HSE today! Integrated operations of remote applications

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Centre of Operations

RTU with HSE for SCADA Applications

FF-H1 FF-H1

FF-HSE Operation Device Management



HSE for package unit integration

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Package Unit Integration with HSE

Linking Device

FF-HSE

FF-H1 Operation

Device Management



Conclusion

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Summary WirelessHART enables new applications WirelessHART meets plant needs For every fieldbus there is an Ethernet WirelessHART gateway integrate with existing

and future systems HSE for remote applications available today HSE for package unit integration available today

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Learn More www.fieldbus.org www.hartcomm.org www.eddl.org

http://www.fieldbus.org/

http://www.hartcomm.org/

http://www.hartcomm.org/

http://www.eddl.org/

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WirelessHART Integration - Fieldbus...A wireless pressure transmitt對er has a basic accuracy of...

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