wireless technology update - pharmout
TRANSCRIPT
Wireless Technology Update
Craig Abbott
Emerson Process Management
Emerson in 2015
Emerson’s Five Business Platforms
Solving the process
industry’s toughest
challenges with
predictable
success any time,
any place
Process Management
Revolutionizing
manufacturing to
operate faster,
more efficiently
and cost effectively
Industrial Automation
Optimizing and
deploying critical
infrastructure for
today’s mobile,
always-on world
Network Power
Innovating to help
improve human
comfort, safeguard
food and protect
the environment
Climate Technologies
Making projects
easier, safer and
more efficient for
professionals,
contractors and
homeowners
Commercial & Residential Solutions
Agenda For Today
1. The Different Flavours of Wireless
2. IEC62591
3. System Integration
4. Available Instrumentation
5. WirelessHART Solutions
6. Wi-Fi
7. System Integration
8. Wi-Fi Application Examples
Industrial Wireless Comes in Many Forms
Radio Satellite3G/4G/LTEWi-FiWireless
Instruments
Wireless Field Networks
WirelessHART Based Solutions
A Summary from PharmOut (Grant South, Senior Consultant)
• https://www.pharmout.net/wireless-sensors-in-a-gmp-environment/
Pros Cons
•Relatively well priced compared to a traditional
wired sensor
•No cabling, wall penetrations or other installation
difficulties
•Attractive option for retrofitting existing facilities
•Particularly suitable for sterile facilities where
cabling can cause cleaning and contamination
issues.
•Additional maintenance activities (e.g. scheduled
battery replacement)
•Signal propagation issues can be caused by
interference, and physical obstacles (walls,
personnel, equipment), particularly when changes
are made in facilities, such as installation of new
equipment
•Communication speed/reliability may not be
sufficient for sensitive or time critical applications
•Wireless sensors by different manufacturers may
not be interchangeable due to differing RF bands,
proprietary protocols, etc.
Connecting Devices Wirelessly
Point to Point
NetworkStar Network
Self Managed Mesh Network
Gateway
Control Room
Obstruction
Obstruction
Obstruction
Obstruction
International Standard IEC62591
CSI
Good Manufacturing Practice – If you don’t measure you can’t manage
Reliability & Maintenance Energy Efficiency & Loss
• Pump
• Blower
• Air cooled exchanger (fin fan)
• Non-process compressor
• Cooling tower
• Pipe & vessel corrosion
• Valve
• Instrumentation
• Vibration, temperature, acoustic tester rounds
• Steam trap failure
• Heat exchanger fouling
• Cooling tower fan optimization
• Relief valve seat leakage
• Unit-wise energy consumption metering: water, air
(compressed), gas/fuel, electricity, and steam
Health, Safety, and Environmental (HS&E) Process Operations Productivity
• Emergency Safety shower and eyewash
• Manual and bypass valve position
• Relief valve and rupture disk release
• Toxic / flammable gas release
• Hydrocarbon leak detection
• Effluent discharge
• Operator rounds: gauge, sight glass, VA meter
• Tank farm storage tank
• Wellhead
• Separator and test separator
• Dosing
System Complexity
Wired Projects Wireless Projects
Security
Integration Options via an Emerson Gateway
WirelessHART
Network
Serial Modbus
IP Modbus
IP Modbus
Ethernet/IP
DeltaV
HART/IP
RS485
Serial Modbus
Ethernet
SCADA/HMI/Workstation
SCADA/HMI/Workstation
SCADA/HMI/Workstation
SCADA/HMI/Workstation
PLC/RTU
PLC/RTU/DCS
PLC/RTU (typically AB)
SCADA/HMI
Asset Management Tools
Each gateway has one Serial Port (2 wire RS485) and two Copper Ethernet Ports (RJ45, 10/100 Mbit)
The Ethernet can be converted to run over Copper, Fibre, 3G/4G/LTE, Satellite, Radio or ADSL
DeltaV DCS
OPCSCADA/HMI/Workstation
Instruments
Gateway
Isolation Options
Process Control
DCS ESD
Process Operators Energy Management Asset Management
RS485 Modbus
Installation
• Low installed cost– Clamp-on
– Strap-on
– Bolt-on
– Stick-on
– Stud
– Magnetic
– Slip-in
• Low risk– No cut
– No drill
– No weld
– Self organising
Clamp-on
Strap-on
Stick-on
Screw-on
Magnetic
Bolt-on
LaySlip-in
Swap
Instrumentation Options
• Pressure
• Single Spot Temperature
• Multi-spot Temperature
• Differential Pressure
• Combined Pressure & Differential Pressure
• Flow (annubar / conditioned orifice plate)
• Level (Guided Wave Radar)
• Level (Hydrostatic)
• Level or Dry/Wet (Vibrating Fork)
• Oil/Water/Sand interface detection
• Digital On/Off feedback
• Digital On/Off output
• Low Speed Counter (<50Hz)
• High Speed Counter (<10kHz)
• Steam Trap Health
• Acoustic flow (PRV release / leak)
• Vibration (motion and PeakVue®)
• Bearing Temperature
• Valve Position (On/Off)
• Valve Drive (Pneumatic Open/Close)
• Valve Position (% Open)
• Corrosion Monitoring
• Sand detection (erosion)
• Wireless Conversion Kit (THUM)
17Emerson Confidential
Water
Gas
Electricity
Air
Steam
Cooling
Cleaning
Inert Blanketing
Mixing
Instrument Air
Energy Management Requires Measurement
Raw Material
Heating
Process Control
Pumping
Combustion
Every process is an energy consumer
Condition Monitoring
Water Consumption Management
Consumption can now be allocated to plant areas
Allocation of costs
Efficiency management
No measurement of existing water storage
No cabling available
No power available
Would need to trench
GSK – Cork, Ireland
“Whenever we look to improve the plant with new equipment, we are always looking to minimise
capital expenditure and Smart Wireless can help achieve lower costs.”
Emmett Martin, Site Services & Automation Manager, GlaxoSmithKline
CHALLENGE
Wireless Pressure
Wireless Level
Wireless Flow
30 second updates
SOLUTION RESULTS
HSSE
RESULTS
Instrumentation Reliability
• Issues with instrumentation
are detected and corrected
before they can impact
product quality
CHALLENGE
Required additional data to monitor performance and reliability of control system
Existing PLC did not have instrument diagnostics capability
A Pharmaceutical Facility in Australia
Approximately 60 wireless transmitters and THUMs to collect diagnostics data from instrumentation
SOLUTION
RELIABILITY
Continually Changing Processes
Improved accuracy of
documentation to verify
that specific chemical
wastes have been
destroyed
Treatment, incineration, and distillation of waste products for the pharmaceutical industry
Cost of monitoring, tracking in a constantly changing environment
Technochem Environmental Complex Pte Ltd
PROCESS
CHALLENGE
WirlessHART Network with pressure transmitters that can be moved and repurposed within minutes.
SOLUTION RESULTS
“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 on in just five minutes,
address the issue and quickly return the transmitter to its original application.”
Jan Huijben, Incineration Manager
Rotating Equipment
Greater reliability of
temperature measurement
leading to better process
control and improved
product quality
Carbon reactivation process uses a rotating kiln
Very difficult to accurately monitor temperature on the rotating equipment
Calgon Carbon
PROCESS
CHALLENGE
WirlessHARTtemperature transmitters connected to existing thermocouples to report data without the use of slip rings
SOLUTION RESULTS
“We used WirelessHART because of the ease of installing the network, the reduced cost of installation,
and the ability to communicate in spite of the constant rotation of the kiln. Non-wireless methods were too
expensive, and other wireless line-of-sight systems could not handle the kiln’s movement.”
Jeremy Dolan Site Manager, Calgon Carbon
Safety Shower Monitoring
Significantly increased
man-down awareness
Timestamped events
for inspection and
incident review.
Response times to safety events deemed too long
Need real time monitoring of safety showers and eye wash stations.
Monroe County Pure Waters
CHALLENGE
One WirelessHART digital transmitter per station.
SOLUTION RESULTS
WHSE
NaOH Leak Incident
“Although I was protected by the proper PPE, I still used a nearby emergency shower to dilute
the hypo. Despite my best efforts, the line continued to leak and I was unable to call for radio
help. I had to run to the solids control room for help.”
Jeff Helfer, Maintenance Manager, Montor County Pure Waters
Wireless Plant Networks
Wi-Fi Based Solutions
• Installed across all industries– Pharmaceuticals
– Food and Beverage
– Chemical
– Oil & Gas
– Power
• Supporting Multiple Applications– Mobile Worker
– Mobile Video
– Control System Bridging
– Field Device Backhaul
Hundreds of Wireless Plant Networks Globally
Wireless Plant Networks
• Star Network around Access Points
• May be meshed for backhaul
• High Speed Data Access
• IT Protocols and Applications
The Mobile Workstation
• Access to the control system at all times
– Laptop, Tablet, Mobile Desktop PC
– Thin or thick client
• Electronic Workbook
– Data sampling
– Digital rather than paper
– Timestamped records
• Online documentation
– Manuals, Procedures, Approvals processes
The Mobile Worker
• Integrated Hard Hat
– Video Camera
– Microphone
– Noise Cancelling headphones
• Two way communication with control room
– Expert sees what field tech sees
• Man Down
Mobility Tracking
• Location Triangulation from Wi Fi hotspots
• Proximity to Beacons
• Calculate direction
• Asset Tracking
• Personnel Tracking
• Proximity to Hazards
• Emergency Mustering
Security Enhancements
• Power And Comms Options
– Ethernet
– Wi-Fi
– POE
• Built in Video Analytics
• Built in Audio Analytics
Video Integration with the DeltaV DCS
• Live Video is streamed directly to the Operator Workstation
• Video can be embedded in the same display as the process data
• Full Pan, Tilt & Zoom control capability
Operator Mobility
Halved Workstations
Faster Calibration
New Production
Opportunities
Xolair® production
Localized control is essential
Three production levels
Geographically dispersed
Needed Mobile Workstations
Novartis
PROCESS
CHALLENGE
10 WiFi Hotspots
17 Mobile Operator Workstations
Cell cultivation, harvesting, purification and freezing
SOLUTION RESULTS
“Because of the wireless network, we do not need to systematically invest in new control stations, even if
the production of new products requires a change to the plant equipment or layout.”
Philippe Heitz, Head of Engineering, Novartis
Combined Wireless and Wi-Fi
• Emerson™ Smart Wireless Gateway 1552WU
• WiFi components
– 1550 Series Cisco Router
– 5GHz (an) WiFi for meshed backhaul
– 2.4GHz (bgn) WiFi for local data access
• WirelessHART components
– Embedded Rosemount 1420 Gateway
• Additional Wireless Applications
– Mobile Worker
– Safety Mustering
– Location Tracking
– Audio and Video support