'Wireless Now - Think Beyond the Wire' (Issue #1)

'Wireless Now - Think Beyond the Wire' (Issue #1)
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M AKI N G THE POS S IBLE R E A L
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MAK I N G T HE POS S IBLE R E A L
Think Beyond
the wire INNOVATIVE first movers gain
competitive advantage, even as last
barriers to widespread adoption fall
PLUS: 3 Ways to Put
Wireless to Work Today
Measure and Gather
New Process Data
Boost Your
Workforce Productivity
Better Manage
Your Business, Your Plant
Supplement to
“Better information from difficult-to-reach areas
of the mill is helping our personnel prevent
unscheduled downtime, meet customers’
quality requirements and optimize productivity.”
—Gary Borham, Wheeling-Pittsburgh Steel
Think Beyond
the Wire
Innovative first movers gain competitive advantage,
even as last barriers to widespread adoption fall.
New technology has historically brought disruptive change in the process automation field—not because
of the technology itself, but because of the capability it
enables that brings new value to the fore.
This happened as the introduction of microprocessors
and digital communications led to distributed control
systems and the migration of intelligence into field
devices. These technology changes enabled users to gain
more insight into their plants—not only about process
variables, but also about the current and future health of
the devices and the process. The additional information
enabled them to make a step change in the performance
of their business through more flexible operations,
increased safety, decreased operations cost, reduced
downtime and decreased cost of change.
However, even with these innovations and the
benefits of a digital plant, there are still untapped opportunities to reach new levels of process and business
performance. Valuable information that can enhance
productivity may still be out of reach because accessing it
would be cost-prohibitive or technologically impractical.
For example, what if you could immediately detect
leaks and releases before they lead to environmental problems and potentially millions in fines? Pinpoint corrosion
inside piping and vibration or temperature excursions that
are attacking equipment life? How much more productive
could your workers be if they had access to process and
control information even when they’re not in the control
room or maintenance shop?
Early adopters of wireless technologies already
are “thinking beyond the wire,” addressing these and
JUNE 2008 ● Special Advertising Supplement
other challenges. And with the recent completion of
the WirelessHART standard, the floodgates of newly
interoperable wireless instruments and systems are
poised to open further.
“It has been exciting to see how in-plant wireless
functionality has captured the imagination of managers, engineers and operations personnel,” says John
Berra, president of Emerson Process Management, of
the company’s Smart Wireless products. “Once they
started using the technology, they were able to envision
additional applications. These innovative first movers are
already confident and are well down the path to broader
implementation of wireless. We are pleased that, thanks
to them, our Smart Wireless products have a track record
of success in installations across industries and worldwide.
As a result, we’re expanding—adding to the industry’s
broadest wireless solution set.”
Today, much discussion of the potential for wireless
focuses on quickly adding a transmitter for a difficult-toreach process parameter, or on the ease with which a new
measurement point can be added to a current installation. But wireless, like Foundation fieldbus before it, also
promises to reduce the cost of routine instrumentation
tasks significantly—and ultimately has the potential to
revolutionize control system strategies.
Whether retrofitting a current system or designing a
greenfield project from scratch, wireless now gives system
designers out-of-the-box access to multiple instrument
variables and a wealth of onboard diagnostics. Who
can say what creativity that will unleash? Additional
new project benefits come from reduced physical space
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requirements and from the increased flexibility and ease
of expansion inherent in a wireless system.
What Can Wireless Do for You?
In past technology shifts, it wasn’t the technology itself
(such as microprocessors or digital communications) that
drove the shift; it was applications that took advantage of
the technology to deliver value. Similarly, the adoption
of wireless technology is being driven by the ability to
extend and manage the flow of information around the
plant more easily and cost-effectively.
Wireless technology is not a complete replacement for
wires, at least not for a while. But it is already enabling new
tools that give you the freedom to solve problems you could
not address cost-effectively in the purely wired world. The
possibilities are limitless. Imagine a plant where:
• Safety relief valve emissions are monitored for more
effective regulatory compliance;
• Safety showers are monitored 24/7 so help can be
dispatched immediately;
• Wireless vibration sensors give you a real-time indication of equipment reliability every day, not just
once a month/quarter/turnaround;
• The status of previously unmonitored plant equipment such as on-off valves is known and historicized
in real time, providing a safer, more productive
operating environment;
• Operators don’t have to make “clipboard rounds” to
collect data;
• Diagnostics in HART devices—including those
that couldn’t be accessed before—are available for
asset management;
•W
orkers can access desktop applications and perform tasks—including viewing and responding to
alarms from the field—wherever they are;
• The locations of personnel and physical assets in the
plant are tracked at all times;
• You can broadcast messages to specific groups of
workers wherever they are;
• Security systems track and ensure authorized plant
access;
• Video systems not only patrol the fence line, but
keep a cost-effective eye on the process;
• Corrosion in equipment and piping is monitored by
wireless sensors.
Many of these applications are possible without wireless, but wiring costs or technical limitations make them
impractical. Today’s cost-effective and easy-to-integrate
wireless technology overcomes these barriers, enabling
you to gain better insight into your plant—and ultimate-
WIRELESS ARCHITECTURE INTEGRATES SEAMLESSLY WITH EXISTING INFRASTRUCTURE
Emerson Process Management’s Smart Wireless solutions operate on an integrated wireless architecture for plant- and field-level
communications. A complete set of technical documentation, online tools and information about the newest additions to the
Smart Wireless portfolio is available at www.EmersonProcess.com/SmartWireless.
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Special Advertising Supplement ● JUNE 2008
EVERYTHING YOU NEED TO GO WIRELESS, RIGHT OUT OF THE BOX
Emerson Process Management’s Wireless SmartPack™ Starter Kit consists of SmartStart™ services; from 5 to 25 wireless devices from
Emerson; Smart Wireless gateway; and AMS® Suite software application for access to predictive information. Completely pre-engineered,
checked out and configured, the network will form right out of the box, with no additional user input or setup. More details are available
at www.EmersonProcess.com/SmartPack.
With traditional wired technologies, distance or
complexity can make connecting the measurement point
to a control, asset management or maintenance system, or
data historian impractical or cost-prohibitive.
Wireless technology removes the barriers of traditional wired solutions and gives you unprecedented access
to data that was previously out of economic or technical
reach. Imagine, for example, the benefits of additional
temperature measurements to detect cool spots in steam
lines, or the advantages gained by cost-effectively instrumenting a remote tank farm.
ly make your workforce more productive.
“We are building an infrastructure that opens up
opportunities for more applications,” says Gary Borham,
operations manager at steelmaker Wheeling-Pittsburgh
Steel Corp., where wireless transmitters measure cooling
water flow and monitor grease system health in the congested, hot steel-mill environment. “The result is better
information from difficult-to-reach areas of the mill,”
Borham says, “and this is helping our personnel prevent
unscheduled downtime, meet customers’ quality requirements and optimize productivity.”
REMOTE infrastructure?
“Especially important was the easy,
flexible self-organizing wireless
network that could be installed and
operational in a very short time.”
At Milford Power, a 500-megawatt plant on the
Connecticut coastline in the U.S., wireless transmitters monitor temperatures in 11 remote buildings
that house infrastructure equipment, including water
circulation pumps. In the winter, small heaters in
each building prevent pump systems from freezing,
knocking that pump out of commission for three days
and costing up to $20,000 to repair. A wired solution
would have been cost-prohibitive, so temperatures were
checked when operators made rounds to perform their
visual checks of the pumps.
But wireless saved $75,000 in installation and capital
costs, making automatic monitoring possible. “It only
took two hours to place the eleven devices in the pump
buildings and have them communicating to each other,”
says Cliff Esmiol, maintenance supervisor. “They easily
communicated around buildings and other obstructions.”
In fact, when a new steel and concrete building
was constructed in the plant, it completely blocked a
transmitter from the other transmitters in the mesh. The
signal, however, was unaffected.
And wireless isn’t just opening access to tradi-
—Cliff Esmiol, Milford Power
Easily Tap Plant and Process Information
The more you know about the process, physical assets
and overall operations of your plant, the safer and more
profitable your business can become. More (and better)
measurements mean more opportunities for reducing
operational costs and improving quality, throughput and
availability. In addition, new environmental and safety
requirements have been established after many of today’s
facilities were built, and plants have struggled to get
access to measurement and diagnostic information that
could ease compliance.
So, why aren’t more plants “measuring up”? Too
often, the cost or difficulty of adding new measurements
has outweighed the perceived value.
JUNE 2008 ● Special Advertising Supplement
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Start Anywhere, Start Today
Emerson Process Management’s approach, called Smart Wireless, is neither a top-down nor bottom-up model. You can begin
at the plant level and work down to the field, or at the field and work up. Start anywhere based on what your highest priority needs are. You’re not required to invest in an expensive wireless infrastructure throughout your facility to try out a simple
monitoring application. The company’s gateways, devices, access points and software use wireless communication standards
and have gone through rigorous coexistence testing. This ensures that wherever you start in the architecture, you can seamlessly and easily expand later as your budget and confidence in the technology evolve.
For example, would additional process measurements help you improve product quality or reduce energy usage?
Build a self-organizing sensor network at the field level starting with just a single gateway. Need to provide mobile
access to plant information? Set up plant-level wireless access points so workers can get the information they need wherever they are. Are both types of applications important? Implement both at once, using the plant-through-field strength
of the unified Smart Wireless architecture.
In short, flexibility and scalability mean you can start wherever it makes sense for you—without investing in more
infrastructure than you need. The products and knowledge are in place and the value clear for starting wireless
now. By picking an application—even a small one—you’ll join early movers enjoying the satisfaction of application
improvements they could only imagine before wireless. And you’ll gain confidence and knowledge in the use of
wireless, a technology set to make broad inroads industry-wide because of the significant improvements in efficiency and performance it delivers.
“Five minutes after
installing it, the network came to life. It’s
been there ever since.”
the wired connection.
The possibilities are almost
limitless. Just think of all the things
you’ve always wanted to measure,
but couldn’t justify the investment.
Chances are that now you can.
Indeed, the ease with which new
measurements can now be implemented has proven to be a gamechanger for early adopters. “When
Emerson approached me with their
industrial wireless solution, they said
‘We’re plug-and-play,’” says Tim
Gerami, a senior design engineer at
PPG Industries’ Lake Charles, La.,
facility. “I gotta admit, I kind of
laughed. Nothing I’d seen so far was
that easy,” he continued. “But I’m a
believer now. Five minutes after installing it, the wireless network came
alive. It’s been there ever since.”
Enable a Mobile Workforce
tional measurements, such as
temperature and pressures, but to
instrument and equipment information as well.
For example, millions of smart
HART-based devices in the field
today have some level of diagnostics
capability. Unfortunately, many
plants don’t have the infrastructure
to receive HART data into the
appropriate system. Since only a
fraction of these devices are digitally
monitored, the potential gain from
accessing such “stranded” diagnostics
is significant.
— Tim Gerami, PPG
With wireless technology, the
data doesn’t have to be stranded
anymore. Existing wired HART devices can be upgraded with a wireless
adapter to transmit diagnostic information back to the control room or
maintenance shop, where appropriate
personnel can take corrective action
as needed. Process control signals
continue to be communicated over
In an era when an aging workforce
and loss of experience are among
the most pressing business problems
process manufacturers face, wireless
technology can empower nextgeneration plant workers, just as cell
phones and PDAs have empowered
the mobile business person today.
Even during normal operations,
it’s not uncommon for a large plant
to have hundreds of people working
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NOT TOO LATE TO ENTER INNOVATORS CONTEST
Nominations for the Smart Wireless Innovators Contest, seeking to recognize engineers and companies
for their leadership in applying technology for plant
improvements, are open until July 31, 2008. A panel of
customer peers will judge entries and designate two
winners who will be awarded a crystal plaque, cash
reward, and expense-paid trip to the 2008 Emerson
Global Users Exchange in Washington, D.C., where they
will be formally honored. More information is provided
online: www.EmersonProcess.com/SmartWireless.
Special Advertising Supplement ● JUNE 2008
throughout the plant, often far from
their control rooms, maintenance
shops or offices. The new wave
of wireless tools are dramatically
improving their productivity by providing instant access to information
they otherwise would have had to
cover considerable distance to get, or
take valuable time from other plant
personnel to find out.
For example, although technology has enabled operators to perform
many of their control and monitoring
duties from the comfort and safety of
the control room, there are still times
when they have to go out into the
field. Some companies routinely have
their operators make rounds to see
firsthand how the plant is running.
By providing remote access to control
and asset-management systems, a rugged, wireless PC can greatly enhance
operators’ efficiency, as they will be
able to immediately relate what they
see to what is happening to the process and take quick corrective action.
When operators are in the field,
there may be no one in the control
room watching for alarms. But with
wireless access points throughout the
plant, operators can use these PCs or
similar tools to access critical process
information, historical data, graphics and other key functions that
normally reside in the control room
or elsewhere in the plant.
Improve Business
and Process Management
Wireless applications, such as personnel and asset locating, as well as
wireless video surveillance for security
and safety, have changed the way offices, hospitals, warehouses and retail
stores operate. These applications can
also address business needs such as
improving safety and security inside
process environments.
Many plants already are using
wireless technologies to improve security. Wireless closed-circuit television
cameras and RFID-equipped access
badges enable intelligent security
monitoring and control from restricting access to specific areas based on
levels of security, to tracking attempts
to violate security protocols and
helping security managers identify
potential vulnerabilities.
Wireless location technologies allow you to find and track inventory
and valuable assets—even workers—
moving inside and outside the plant
quickly. Time spent looking for
assets can be reduced dramatically,
which can have significant benefits
during major turnarounds, emergencies and new construction projects.
Being able to locate each worker
quickly also offers safety and productivity benefits.
WIRELESS IMPLEMENTATION
STARTS WITH EDUCATION
In order to begin to take full advantage
of the promise of wireless, a basic
understanding of how wireless works—
and how it can be used to improve
plant, process and project performance—is needed. And Emerson Process Management’s online PlantWeb
University is a great place to start.
PlantWeb University features
a broad range of online engineering and business training and now
includes a new 21-course wireless curriculum encompassing an introduction
to wireless technology, how wireless
can help you solve common problems
and access information that was previously out of economic and technical
reach, as well as practical advice on
implementing wireless solutions.
“The new PlantWeb University
courses will help users understand the
basics of wireless technology, what it
can do for them and how they can put it to work in their own operations,” says Jane Lansing, vice president, marketing, for Emerson Process Management. Join 60,000 other registered learners at www.PlantWebUniversity.com.
JUNE 2008 ● Special Advertising Supplement
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Measure and Gather
New Process Data
Wireless transforms the economics of what’s feasible
and the physics of what’s possible.
“We made a strategic choice to start where customers could get the fastest and easiest return,” says
Bob Karschnia, vice president of wireless for Emerson Process Management, referring to the company’s
release a couple of years ago of wireless, self-organizing
solutions at the instrumentation level. “This is because
field sensor networks can be easily installed and deliver
significant value without the need for investing in a
plant-wide wireless infrastructure,” he says.
But a wireless field device isn’t just a different kind
of transmitter; it is the product of a real breakthrough
in technology and practice that is just now being seen
for what it is, according to Peter Zornio, chief strategic
officer for Emerson Process Management. “The adoption of wireless technology,” Zornio explains, “will be
driven by the ability to extend and manage the flow of
information around the plant truly without limits. This
will drive work process and operational practice change
as this new capability is utilized. That’s the definition
of a technology discontinuity.”
Indeed, the implementation of process control
strategies has long been constrained by a simple set of
instrumentation costs: the transmitter itself, the time
and labor required for engineering and implementing
the installation, the running of wire back to a central
control room and the distributed control system input/
output (I/O) hardware itself. Over the years, the cost
of transmitters has steadily decreased, as has the cost of
I/O. It is the middle part the installation and the wiring of the device to the control system that continues to
be the limiting factor.
“Wireless devices typically take two
hours to install compared with two
days for a wired device.”
—Geir Leon Vadheim, StatoilHydro
And what a limiting factor it is! Because of the
high cost of wiring, many secondary process variables
go unmeasured, and large pieces of process equipment
go uninstrumented. Today, however, wireless is giving
users low-cost access to additional measurements and
process variables that were previously economically
infeasible. Estimates range up to 90% savings in installation cost per measurement using wireless.
First Movers Off and Running
Early adopters of wireless have been able to access many
such measurements, and not all of them have been
traditional analog process variables. For example, one
early adopter uses wireless to advise in real time when
pressure relief valves open and close. This minimizes
ADD NEW MEASUREMENTS QUICKLY AND EASILY
At StatoilHydro’s Grane offshore platform (pictured above), wireless transmitters install easily and perform well despite an environment
crowded with metal. “Following a short training program, our instrument engineers are very confident about adding more wireless devices to our installation as required. These typically take about two hours to install, compared with up to two days for a conventional wired
unit,” says Geir Leon Vadheim, StatoilHydro instrument lead. (Image copyright Jo Michael, StatoilHydro.)
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Special Advertising Supplement ● JUNE 2008
Typical process measurement
● Materials
● Installation
● Engineering
● Adminstration
Wired
Wireless
0
$5,000
$10,000
$15,000
Wired
Wireless
Installed cost
Wired or Wireless
▲
Benefit provided by data
WIRELESS SLASHES MEASUREMENT COSTS
With total installed costs reduced by up to 90%, wireless technology is dramatically changing the cost/benefit
equation for incremental measurements. To see how much you could save, access Emerson’s wireless savings
calculator: visit www.EmersonProcess.com/SmartWireless.
heim, StatoilHydro instrument lead. “Following a short
training program, our instrument engineers are very
confident about adding more wireless devices to our
installation as required. These typically take around
two hours to install compared with up to two days for a
conventional wired unit.”
the fines from regulatory agencies for accidental environmental discharges.
Another early adopter uses wireless to annunciate
activation of emergency stop buttons, pressure and
temperature switches and other alarms to the centrally
located operator.
Other early adopters are monitoring water temperature and pressure at eye-wash stations and the actuation
of safety showers remotely. With the addition of peoplelocating applications, operators are even able to tell
who it was that actuated that safety shower or eye-wash
Get That Stranded Data
There are an estimated 26 million wired HART devices
installed and in service around the globe. But fewer
than 25% of the installed HART devices have their
digital data, including diagnostics, connected to the
control system or to an asset management system. For
years, it was difficult to connect the digital information
stream to controllers and systems that were designed to
only see analog data streams.
But with WirelessHART adapters, like Emerson’s
soon-to-be-released Smart Wireless THUM™ Adapter,
all this will change. The THUM adapter is a device
that sits on the 4-20 mA DC loop and is typically
“No matter where a tank car is
positioned on-site, the quality of
the transmissions is unaffected,
and the signals integrate seamlessly
into our control system.”
— Denny Fetters, Croda
station and route the appropriate assistance to the scene
faster and with greater efficiency.
Early adopters also are monitoring additional process variables for process optimization. Temperatures,
pressures and flow rates that were far too expensive to
monitor at the operator console can now be brought
there wirelessly.
On StatoilHydro’s Grane offshore platform, wireless transmitters are being successfully used to monitor wellhead and heat exchanger pressures, providing
100% reliability and stability in a crowded metal
wellhead environment. “We are delighted with the
performance of the Emerson Smart Wireless network
in these challenging conditions,” says Geir Leon VadJUNE 2008 ● Special Advertising Supplement
WIRELESS ADAPTER TO LIBERATE HART DIAGNOSTICS
Called the “THUM” in part for its familiar looking form-factor,
this innocuous device is designed to be retrofitted onto existing HART devices. It extracts instrument diagnostics and other
information from the 4-20mA signal and transmits them via
WirelessHART to the host system.
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screwed into the unused conduit port on the
transmitter. It draws its power from the loop, extracts the HART digital data from the field device
and communicates via WirelessHART protocol to
a gateway and, thence, into the host system.
measuring the immeasurable
Croda Inc., an international specialty chemicals
manufacturer, uses wireless temperature transmitters from Emerson mounted on chemical tank
cars to send minute-by-minute readings to a
central host, improving process performance and
boosting overall safety.
Because the tank cars are moved frequently,
hard-wiring of temperature sensors was impractical. Previously, an employee had to climb
to the top of each car once a day to check the
temperatures and record each reading. This was
a time-consuming procedure that, during wet or
icy conditions, presented a fall potential. With
wireless, operators are alerted to any unexpected
temperature rise in the tank cars, while saving
about $15,000 per year in reduced maintenance.
“The wireless solution not only saves us time
and money, since plant personnel no longer
have to monitor those tank cars daily, it has also
greatly enhanced the overall safety of the plant
and our personnel,” says Denny Fetters, instrument and electrical designer for Croda. “No
matter where a tank car is positioned on-site,
the quality of the transmissions is unaffected,
and the signals integrate seamlessly into our
control system.”
Self-Organizing Mesh
Networks vs. Point-to-Point
Emerson Process Management’s Smart Wireless field networks
use self-organizing mesh technology that is tried and tested and
the basis for the recently approved WirelessHART standard. Each
wireless device in a self-organizing network can act as a router for
other nearby devices, passing messages along until they reach
their destination.
This capability provides redundant communication paths and
better reliability than solutions that require direct, line-of-sight
communication between each device and its gateway. Whenever there’s a change in the network or in conditions that affect
communications, the devices and gateways in a self-organizing
network work together to find and use the most efficient path for
each message a path that optimizes data reliability while minimizing power consumption.
Self-Organizing
Mesh Topology
Obstruction
● Gateway
● Device
Wireless link
Point-to-Point
Star Topology
Isolated device
Obstruction
● Gateway
● Device
Wireless link
Making the Infeasible Practical
Self-organizing network technology also reduces the effort
At PPG Industries’ Lake Charles, La., facility,
and infrastructure needed to set up a successful wireless network.
wireless temperature transmitters monitor the
One of the difficulties of setting up the traditional point-to-point
temperature profile of the plant’s steam headwireless network is the requirement to do a site survey to be
ers. The applications had always been desired,
certain that every node in the system has a line-of-sight path. This
but difficult to implement, according to Tim
survey work is expensive. Plus, the resultant point-to-point netGerami, PPG senior design engineer. PPG engiwork may require as many as five times the number of infrastrucneers also wanted to use wireless for some of the
ture nodes as a self-organizing network.
redundant measurements they really needed for
Another advantage of self-organizing networks is that they
plant optimization and asset management.
are dynamic. As new obstacles are encountered in a plant, such
PPG-Lake Charles formed a wireless commitas scaffolding, new equipment or moving vehicles, the networks
tee to look at wireless systematically throughout
can reorganize around them. All of this happens automatically,
the plant, from both an IT and an instrumentawithout any intervention by the user.
tion/process control perspective. The team chose
Emerson’s Smart Wireless and now all WirelessHART self-orTypical process measurement
Emerson Smart Wireless for the in-plant measureganizing networks use IEEE 802.15.4 radios with channel-hopping
ments, not only because of its familiarity with
as the physical layer. They are designed and tested to be tolerant
Wired
Rosemount® transmitters, but also because of the
to almost all interference and can co-exist with other wireless
architecture of the Smart Wireless network.
networks in your plant. The networks are also highly scalable and
“There were others where the wireless part
capable of one-second scanning with low latency. Emerson’s
Wireless
looked good,” Gerami notes, “but it was just
wireless devices based on this technology have been proven in
point-to-point, rather than mesh. It would
use to demonstrate greater
than 99% data reliability.
0
$5,000
$10,000
9
Wired
Special Advertising Supplement ● JUNE 2008
Wireless
Control
Class 0: Emergency action
(always critical)
Class 1: Closed-loop regulatory control
(often critical)
(usually noncritical)
Class 3: Open-loop control
(human in the loop)
Class 2: Closed-loop supervisory control
Note: Batch levels 3 (unit) and 4 (process), as defined by ISA S88, could be class 2, 1 or 0 depending on function.
Class 4: Alerting
Short-term operational consequence (e.g., event-based maintenance)
Monitoring
Class 5: Logging and downloading/uploading
No immediate operational consequence (e.g., history collection, sequence of
events, preventive maintenance)
Importance of message
timeliness
Appropriate for Wireless
Safety
WIRELESS IS RIGHT CHOICE FOR MANY APPLICATIONS
The application list for wireless is large and expanding. The ISA100 committee has defined the use classes as shown above. Based
on proven experience, Emerson recommends that users now consider wireless for the control and monitoring applications indicated,
focusing on adding measurements previously impossible to cost-justify, thereby improving safety, reliability, efficiency and environmental
compliance.
tion. Indeed, one gateway installed on the third floor
maintains communication with all the field devices on
all four floors and on the roof of the building.
work, but it limited the number of devices in a given
plant—maybe 50 per radio, 16 channels. That would
be difficult in a plant. You need more than a hundred
transmitters and several hundred eventually. A mesh
network has the potential to be virtually unlimited.”
‘An Era Well Begun’
“Looking to the future was one of the reasons to try
out the use of wireless sensors,” says Ruud van Dijk,
TAQA Energy engineering manager, of his company’s successful test of Emerson Smart Wireless technology at its natural gas production site in Alkmaar,
The Netherlands. “Basically, there was no room for
more wires at the site in Bergermeer, and connecting
new sensors would have entailed breaking open some
hundred meters of paving to install extra wires. This
is expensive and time-consuming.”
“Of course we already have years of experience
with wireless data transfer in office environments,”
adds John Pietersz of TAQA’s metering and control
department. “But it is a different matter on the
processing level. This world is very reluctant when it
comes to introducing new technology.”
The TAQA team determined that it needed the
flexibility and robust reach of the self-organizing
mesh network architecture of Smart Wireless. “In
the case of the Smart Wireless system, this radius is
200 meters,” Pietersz says. “It already leaves a lot of
elbow room, but what is special about the solution
is that the sensors can pass on each other’s signals.
This means that you can apply sensors far outside the
initial radius of 200 meters without having to install
extra base stations. Future expansions will then only
require the purchase of a transmitter, which will
naturally also yield economic advantages.”
“We have also bought an Emerson AMS asset management system,” Pietersz adds. “Currently we only manage the wireless sensors with it, but we will be putting
other instrumentation into the system in the near future.
In short, the wireless era has begun well for us.”
“Future expansions will require
only the purchase of a sensor or
transmitter, which will naturally also
yield economic advantages.”
— John Pietersz, TAQA Energy
Gerami makes the game-changing nature of
wireless clear. “It’s an enabler for things you wouldn’t
ordinarily do,” he says.
A Revolutionary Plant Design
To respond to an increasingly competitive marketplace,
pharmaceutical and life-sciences companies around
the world are striving to become more flexible
in their manufacturing capabilities. But they’ve
struggled for years to integrate process information
with their laboratory information and plant business
systems effectively.
Wireless instrumentation, together with Emerson’s DeltaV™ digital automation systems, now
are making it possible to do exactly that—provide
a wireless-enabled, united information system on a
unified network throughout the plant. This capability makes possible entire plant designs not feasible
just a few short years ago.
One major life sciences company designed a
multi-story plant in a building with twelve-inch thick
reinforced concrete floors and walls. Modular process
equipment can be moved around and reconfigured
at will, and because instrumentation communicates
wirelessly, reconfiguration requires no re-instrumentaJUNE 2008 ● Special Advertising Supplement
10
Boost Your
Workforce Productivity
Mobile connectivity keeps workers in
touch with the information they need.
When it comes to enhancing overall workforce
productivity, wireless technology delivers in another
important way. Upfront, wireless can slash the time
and effort necessary to add a new measurement point or
integrate a formerly isolated PLC or tank farm.
But once up and running, wireless technology goes
beyond the streamlining of engineering, integration and
installation to provide an ongoing boost to the productivity of plant workers by giving them mobile, instant
access to needed information wherever they might be.
Today operators can perform many of their duties from
the comfort and safety of the control room—but there are
still times when they have to go out into the field to collect
data, check on equipment or just see firsthand how the
plant is running. How can you stay in touch with operators
and maintenance technicians working throughout the
plant—and keep them in touch with the information they
need to do their jobs most efficiently?
Put a ruggedized, wireless PC in workers’ hands,
and now they can access control and asset-management
systems remotely and immediately relate what they see to
what’s happening in the process—and respond as needed.
That includes viewing and acknowledging alarms no matter where the operator is.
WHO SAYS YOU CAN’T TAKE IT WITH YOU?
With wireless PC or PDA in hand, roaming operators can now access control and asset-management systems to relate immediately what
they see to what’s happening in the process—and respond as needed.
11 Special Advertising Supplement ● JUNE 2008
Communications improve, too. A plant-wide wireless broadband network with VoIP technology can extend communication reach while also enabling “smart”
communications—broadcasting, for example, different
messages to specific teams based on the IP address of
each worker’s radio.
Maintenance workers also benefit. Wireless tools such
as hand-held communicators let them access maintenance
work orders, instructions and other information, and track
or report inspections, tests and repairs immediately.
This Stuff Really Works
PPG Industries’ Lake Charles, La., facility is among
those early adopters of wireless technology that already
are reaping the benefits of mobile data access—as well
as the speedier installation time afforded by wireless
instrumentation.
“We’re currently using wireless tablet PCs in our
operational units,” explains Tim Gerami, PPG senior
design engineer. “Operators can go around and look at
the DCS on the tablet PC. The PCs can also be used
for calling up operational procedures, looking up information on an existing valve or transmitter or using
AMS to calibrate a transmitter.”
At StatoilHydro’s Grane offshore platform, wireless
has eliminated the need for daily visits to the wellhead to record gauge readings manually. Further, this
increased process visibility already has led to operational improvements and allows unusual readings to
be identified earlier.
At yet another major refinery, operators once visited the
calcining unit monthly, manually logging motor-bearing
temperatures, pump-casing temperatures, differential pressure across water filters and in-line pressures on chemical
injection lines to detect plugging. Today, the operators still
make rounds, but without an infrared gun and a manual
log. Instead, they use a wireless PDA to interrogate their
wireless instruments and connect to the data historian to
check trend histories.
The operators’ focus is now on solving problems
instead of manually reading, logging and entering data.
With higher resolution to the process and more accurate
measurements, the plant has improved the availability of the coking operation, streamlined maintenance
activities, moved the plant to predictable turnarounds
and minimized unplanned failures of expensive pumps
and motors.
MOBILE ACCESS MEANS GREATER PRODUCTIVITY
Maintenance workers are among those plant employees who can
get more work done with wireless information access. Tablet PCs
and other hand-held tools let them access maintenance work
orders, instructions and other information, and track of report
inspections, tests and repairs immediately.
JUNE 2008 ● Special Advertising Supplement
12
“Operators can go around
and look at DCS displays
on wireless tablet PCs.”
The Emerson Mobile
Worker Offering
Emerson Process Management
has been providing wireless remote operations and
maintenance products since
2001. The company’s products
and technologies designed to
enhance the productivity of
mobile workers include:
For mobile operators:
DeltaV Remote Operate,
PlantWeb Alerts and Plant
Messenger for PDAs.
For mobile maintenance
workers: AMS Suite: Intelligent
Device Manager Wi-Fi client, CSI
2130 Machinery Health Analyzer,
CSI 9800 Machinery Health
Imager, CSI 7100 Machinery
Health Scanner, 375 Field Communicator.
For workers in dangerous
areas: A number of Class I/Div
2 and intrinsically safe handhelds in various form factors to
run these applications.
Emerson’s mobile-worker
applications rely on rugged,
wireless access points from
Cisco to provide Wi-Fi coverage. The Cisco® Aironet 1520
Series Outdoor Wireless Mesh
Access Points are Class I, Div
2-certified and support dualband radios compliant with
IEEE 802.11a and 802.11b/g
standards. Visit www.EmersonProcess.com/SmartWireless
for more details.
—Tim Gerami, PPG
13 Special Advertising Supplement ● JUNE 2008
Better Manage
Your Business, Your Plant
Plant-level wireless networks are already ensuring physical
security and tracking people and assets.
In-plant wireless technology isn’t just about communicating and integrating process information flows. It’s
also about enabling a broad range of business and plant
management applications—some well-defined and already
at work, and some as yet to be imagined.
“In a plant,” explains Bob Karschnia, vice president
of wireless for Emerson Process Management, “there are
a number of self-organizing wireless field devices, such as
pressure, temperature, and vibration transmitters, wireless
discrete switches and wireless adapters to extract diagnostics from wired devices. All these devices are networked
through our Smart Wireless gateway in a self-organizing
network based on WirelessHART. That’s the first application space where Emerson provides a complete solution for
our customers.”
“But for business and plant management applications,”
Karschnia continues, wireless coverage is provided through
hardened Cisco outdoor access points that are also meshed
together. “This infrastructure allows the plant to deploy applications such as Voice over IP (VoIP), video surveillance
and people location, and to use tools such as the DeltaV
Remote Client and AMS Device Manager Wi-Fi Client to
improve workforce productivity.”
By teaming with Cisco, Emerson provides a plant-level,
wireless mesh network that is open-standards-based as well
as scaleable, manageable and secure—all with a low total
cost of ownership.
YOUR MOST IMPORTANT Assets
One especially powerful application enabled by a plantENTERPRISE-WIDE
PLANT ASSET
INFORMATION DRIVES
DECISION-MAKING
Capturing powerful, realtime predictive diagnostics
in a secure web browser
gives a comprehensive
view of asset health.
Wireless devices bring visibility to even more assets,
enabling fast, accurate
decisions to impact your
plant’s bottom-line results.
JUNE 2008 ● Special Advertising Supplement
level wireless network is for locating employees and visitors.
“Wireless technologies can now help you track everything in a plant, but the most important assets in any plant
are its people,” says Karschnia. “A plant now can have a
real-time people location system to locate all employees and
visitors during emergencies.”
For example, wireless sensors can be mounted on
safety showers. “Field network wireless technologies
allow customers to cost-effectively install wireless flow
switches on all safety showers,” Karschnia says. “This
saves them thousands of dollars in wiring costs. These
flow switches are integrated in the control system and the
people location system.”
Wireless can help you track
“
everything in a plant, but the most
important assets are its people.”
—Bob Karschnia, Emerson Process Management
With this new wireless technology, Karschnia points
out, “A plant can meet OSHA requirements for initiating
an alarm five seconds to 10 seconds after a safety shower
is activated. Hard-wiring every plant safety shower or eyewash station back to the main plant annunciator system is
simply cost-prohibitive.”
Because of the plant-wide wireless network, an operator
can see the location of every employee’s RFID-enabled
identification card. “We can then use the wireless location
system to see who the closest first responder to that location
is,” Karschnia says.
Voice, Video Boost Safety, Security
Many plants already are using wireless technologies
to improve security. Wireless closed-circuit television
cameras and RFID-equipped access badges enable
intelligent security monitoring and control from
restricting access to specific areas based on levels of
security to tracking attempts to violate security protocols and helping security managers identify potential
vulnerabilities and improve systems. Wireless applications also enable you to monitor hazardous applica14
AN INTEGRATED APPROACH TO FIELD AND PLANT WIRELESS
Emerson Process Management’s Smart Wireless solutions operate on
an integrated, architecture of WirelessHART for field-level wireless
communication and Wi-Fi for plant-level applications.
tions in order to reduce risk to plant personnel.
High-bandwidth video surveillance systems can use
Cisco wireless mesh Wi-Fi networks to move data from
the fence lines and other remote plant locations into the
control room. This allows plant operators to have realtime video feeds from nearly every location in the plant.
And this, in turn, permits operators to be more productive by making some types of operator rounds unnecessary. Operators can decide whether to take their wireless
communication tools out into the plant after they know
where they need to go, because they have already seen a
problem or situation on a video feed.
High-bandwidth video is also helpful when used
in combination with RFID-based personnel monitoring. Personnel safety is greatly enhanced when
the responders know right from the beginning of the
incident whether the “person down” is in a dangerous situation, and when two-way communications
are enabled via VoIP portable communications
devices, responders can coordinate their actions and
maintain a high degree of safety at the same time.
Peter Zornio, Emerson Process Management chief
strategic officer, summarizes the disruptive, gamechanging potential of today’s wireless technology as
“measuring the immeasurable”—including inaccessible
process readings, people and asset locations and security data. Further, wireless presents the opportunity to
extend Emerson’s PlantWeb architecture and predictive
technologies to places where they were previously cost
prohibitive— including unmonitored valves, rotating
equipment, vessel and pipe health, and stranded smart
devices, he says.
Wireless is a more cost-effective
“
alternative to wired for newly
mandated environmental and safety
applications–and for applications we
don’t even know about yet.”
—Peter Zornio, Emerson Process Management
“It’s as immediately straightforward as a more costeffective alternative to wired for newly mandated environmental and safety applications—and as potentially gamechanging in the future as to enable applications we don’t
even know about yet,” Zornio adds. “It’s all the information on the move, anywhere.”
15 Special Advertising Supplement ● JUNE 2008
FEAR
WIRELESS
SAFETY.
Smart Wireless goes places so your people don’t have to.
You now have the means to make your safety practices even safer. Emerson Smart Wireless lets you cost-effectively
add automated monitoring and measurement points in hazardous areas, so personnel are kept out of harm’s way
while critical assets are still continuously monitored and protected. And when workers are on the move, Smart
Wireless helps you wirelessly monitor their whereabouts and maintain continuous communication through open,
industrial Wi-Fi technologies. From the plant-at-large to the worker himself, Emerson Smart Wireless looks out for
what’s important to you.
Discover your plant’s limitless potential
at EmersonSmartWireless.com
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2008 Emerson Electric Co.
HART® is a registered trademark of the HART Communication Foundation
D351567X012 / 20K / 6-08
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