Mumbai - India September 2013
© 2013 Fieldbus Foundation
WirelessHART Integration
2
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
3
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
+
Mumbai - India September 2013
© 2013 Fieldbus Foundation
The ABC of Application Classes Areas where wireless technology is applied
5
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
6
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
7
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
8
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
9
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
10
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
11
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
12
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
Mumbai - India September 2013
© 2013 Fieldbus Foundation
WirelessHART meeting plant needs
14
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
15
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
16
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
17
Mumbai - India September 2013
© 2013 Fieldbus Foundation
Same Tools – Devices Work Consistently 4-20 mA/HART
FOUNDATION fieldbus
WirelessHART
mA
No mA
18
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
19
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
20
Mumbai - India September 2013
© 2013 Fieldbus Foundation
Gateway of Wireless A WirelessHART gateway connects your existing
DCS to WirelessHART transmitters from different manufacturers
Mumbai - India September 2013
© 2013 Fieldbus Foundation
IP and Ethernet Refresher For every fieldbus there is an Ethernet
How does all the wireless data get into the system?
22
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
23
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
24
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
25
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
Mumbai - India September 2013
© 2013 Fieldbus Foundation
Wireless gateway integration today and tomorrow WirelessHART gateways support multiple industrial Ethernet protocols
27
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
28
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
29
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
30
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
Mumbai - India September 2013
© 2013 Fieldbus Foundation
HSE today! Integrated operations of remote applications
32
Mumbai - India September 2013
© 2013 Fieldbus Foundation
Centre of Operations
RTU with HSE for SCADA Applications
FF-H1 FF-H1
FF-HSE Operation Device Management
Mumbai - India September 2013
© 2013 Fieldbus Foundation
HSE for package unit integration
34
Mumbai - India September 2013
© 2013 Fieldbus Foundation
Package Unit Integration with HSE
Linking Device
FF-HSE
FF-H1 Operation
Device Management
Mumbai - India September 2013
© 2013 Fieldbus Foundation
Conclusion
36
Mumbai - India September 2013
© 2013 Fieldbus Foundation
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
+
37
Mumbai - India September 2013
© 2013 Fieldbus Foundation
Learn More www.fieldbus.org www.hartcomm.org www.eddl.org