WirelessHART Applications ARASU THANIGAI PEPPERL+FUCHS ASIA PTE LTD
So what is WirelessHART? WirelessHART: Is an open & interoperable standard Is based on the established HART protocol Uses known tools and procedures for configuration, maintenance, & diagnosis Requires minimal training Allows wireless access to existing field devices Can be used worldwide without any license 2
A Network that works The WirelessHART network is a mesh network where each sensor acts as both a router and repeater. The range of the network doesn t depend on the location of the central gateway, allowing set up of large distributed network structures. sensor gateway 3
Mesh Network: How it Works 25-Apr-2017 page 4
Mesh Network: How it Works 25-Apr-2017 page 5
Mesh Network: How it Works 25-Apr-2017 page 6
Essential Components WirelessHART GATEWAY WirelessHART FIELD DEVICE ADAPTER WirelessHART Devices Serial RS485 & Ethernet interface Modbus & HART protocol Redundant power supply Upgrade installed field devices Battery powered Powers the transmitter Operates as a router in a larger installations single of dual channel converter Inputs for AI,AO, DI, DO Battery powered LED & pushbuttons for status & set up The WirelessHART gateway is the core element of a wireless mesh network. It serves as the interface between the mesh network and the plant s process control or asset management. The WirelessHART adapter can be connected directly to the interface of any field device. This can be a conventional 4 20 ma or an intelligent HART device. The WirelessHART devices offers multiple ways to connect physical variables. They are designed to transfer measurements directly to the network. 5
New Connectivity to existing Devices Retrofitting Application for existing infrastructures that do not support HART communication today 25-Apr-2017 page 9
Wireless Devices for Measurement & Control 25-Apr-2017 page 10
Typical Applications Heavy Industry Extraction, Refining Conveying, Processing Manufacturing, Storage Water/Wastewater Municipal, Rural Environmental Pump Control Tank Levels Flow Measurement Preventative Maintenance 25-Apr-2017 page 11
Product Applications Tank Farms Oil Refineries Rotational Equipment Mobile Equipment Ad hoc Monitoring Pipelines 7
Measuring & Monitoring Temperature Corrosion Level Control A simple WirelessHART temperature sensor can be used to detect & diagnose problem situations long before they result in failures & influence plant availability. Ideal Applications or Locations Motors Pumps & cooling devices Resources that need monitors WirelessHART monitoring instruments can be placed at important measurement points along pipelines in places that previously couldn t be reached. Ideal Applications or Locations Long pipelines located in remote locations Plants with moving vehicles & changes in location WirelessHART makes it easier & more cost effective to monitor the levels in process & storage tanks by eliminating the need to manually take & record the measurements. Ideal Applications or Locations Storage vessels Process tanks 6
Process Monitoring & Control Hard to reach locations Process efficiency calculations Better insight into process Ad-hoc measurements Additional measurements from mult ivariable devices Calculated variables in devices
Equipment Monitoring Bearing temperatures Vibration Corrosion Oil pressure Air flow
Application Examples Environmental monitoring: Corrosion 25-Apr-2017 page 16
Application Examples Storage: Continuous Level Measurement 25-Apr-2017 page 17
Application Examples Storage: Discrete Level Measurement 25-Apr-2017 page 18
Application Examples Monitoring: Valve Lever Positioning 25-Apr-2017 page 19
Application Examples Monitoring: Temperature 25-Apr-2017 page 20
More applications.. Tank Level Monitoring / Control o 4-20 ma output on oil tanks Railroad o Rural railroad signal control - 2 DI o Yard switch control Refineries / chemical plants Steel / metal plants 25-Apr-2017 page 21
Hwy. 61 Quarry Dredging 25-Apr-2017 page 22
Mining Installation Worked with customer on antenna installation to provide reliable communicati ons 25-Apr-2017 page 23
Other Applications Health and Safety Safety showers Gas detectors Environmental Steam traps (energy usage) Water / Discharge Treatment Flow ph Stack emissions Relief valves
Other Applications Asset Management Maintenance Calibration Record valve signatures Radar echo Diagnostics Valve position feedback Device health (status)
Application examples with pictures
Fence Line Gas Detection Gas Detection Skid with 5 MACTek Bullets ~ 140 meters From Gateway; 4 analog transmitters and 2 HART Tank Level 4-20 ma Transmitter; scaled Engineering Units and Multidrop with HART Transmitters
Portable Gas Monitoring Place meters within reach of any WH Device or Gateway; use battery controls to conserv e power; transmit PV and Battery Voltage fo r Analog 4-20 non-hart transmitter Portable Mixing Tanks - (Pharmaceutical) Everything wired from one AC power connection; Analog output for Drive Speed, Pressure, Temp, PH, Level
Portable Boiler Efficiency Testing Budget ~$50,000; Savings using Bullets: Project Approved with a savings of $78,000 ( 78%) due to multidrop. Valve monitoring Paper Machine (Wet End); Dirt and moisture, no problem (IP68)
Multidrop Used on a wireless remote IO Application 34 transmitters with 10 Bullets!
Multidrop Bullet Direct Power, Multidrop Temperature Solution Puck Temperature Transmitters 24 Measurements ~ PV = Average or Difference ~ SV = Temp 1 ~ TV = Temp 2 Easily Repairable 1Second update per transmitter G G R R Y Y B B W W G 1 2 3 4 5 WirelessHART for less than $3 3 per measurement. 6 7 8
Battery Box Powering Two Devices Pressure and Temperature used on Rotating Digester
Tank Farm Monitoring GPB, Mexico Objectives o Reduce cost o Reduce time to implement Installation o 10 Level transmitters o 10 WirelessHART Adapters o 1 Gateway o HMI Software via OPC
Rotating Catalyst Driers at BASF The Netherlands Objectives o Eliminate manual sampling o Improved quality o Increase throughput with short er cycle times Installation o Pressure and Temperature Tra nsmitters o WirelessHART adapters o Gateway with Modbus output o Modbus to Profibus converter
Rotating Catalyst Driers at BASF Adapters provide: - Power and wireless connectivity to pressure and temp transmitters - A communication path from the rotation equipment to the gateway - Communication to a Siemens PLC via a Modbus to Profibus converter
Wellhead Monitoring for Heavy Crude Oil Extraction Objectives o Reduced installation time (from 15 days t o 3 days) o Eliminate expensive cabling and remote I /O Installation o 800 Instruments o 800 WirelessHART Adapters o 43 Gateways Pacific Rubiales Energy, Colombia
Wellhead Monitoring for Heavy Crude Oil Extraction
Burner Monitoring in Steel Production Stahl Gerlafingen AG Objectives o Improve reliability of the measu rement systems Installation o Flow measurement of cooling water o Flow measurement of ingot mol d water o Oxygen supply to burners o Temperature of shaft and ventu ri nozzles o Level of the dust silo Adapter connections to any HART or Analog Device
Burner Monitoring in Steel Production Stahl Gerlafingen AG Oxygen Flow to Burner Dust Silo Level The adapter can be connected anywhere in the 4-20ma loop enabling it to be hundreds of meters from the installed device.
Energy Efficiency Improved at Duke Energy Objective o Improve cost and speed of conducting efficiency tests o Leverage existing investment in HART instrumentation o Improve reliability by replacing m ultiplexers with gateways and less cabling Installation o WirelessHART adapters with multidrop wiring topology o WirelessHART Gateways Results o 100-150 man-hour savings enabling more tests, more often
Temperatures in Railcars at Croda Objective o o Installation o o Monitor temperature of highly reactive and flammable chemicals in moving rail cars Maintain wireless temperature measurement as rail c ars move throughout facility Wireless temperature transmitters installed on each r ailcar as they arrive at plant Temperature measurements communicated from gat eway back to the control system Results Improved safety and Reduced costs o Eliminated employees climbing to the top of railcars e very day There are savings of $14,000 per year in reduced operations and maintenance costs, but, the incalculable savings were in safety. Denny Fetters, I&E Designer
Filter Monitoring in Refining Objective o o Installation o Customer needed low cost method to monitor pump filters Existing pneumatic pressure transmitters wer e error prone, required manual gauge reading s and frequent maintenance Installed WirelessHART dp transmitters and a Gateway on Coker unit pumps Results Improved reliability o Eliminated pump damage and process upsets caused by loss of suction [Insight] from predictive wireless filter plugging alerts prevented a shutdown. Operators were able to shut down the pump, clean the filter and get it back on line in a matter of hours. If the alert were not present, the filter pump would have been damaged, and would have needed to be completely replaced Project Manager, Major Refining Company
Wireless Benefits at Technochem in Singapore Objective o Automated level measurement needed on tanks to support inventory, process management and accurate documentation for customers Installation o Wireless pressure transmitters are monitoring 14 tanks Results o Automated inventory management o Some of the fourteen wireless pressure transmitters are moved from place to place to aid in troubleshooting and new process development o Elimination of clipboard rounds, more accurate realtime data for process efficiency, documentation 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. The flexibility of (the) self-organizing wireless technology makes it much easier to troubleshoot problems as well as evaluate new applications. Jan Huijben, Incineration Manager
Conclusion The benefits of WirelessHART are: WirelessHART networks are flexible, intelligent solutions for the requirements of the process industry WirelessHART components eliminate wiring & integrate conventional field devices into wireless structures Measuring & monitoring have never been more flexible or efficient, especially in remote locations WirelessHART technology is here to stay, and those who adapt early will reap the benefits