HART - Control Global

HART - Control Global
AN Advertising supplement to
Se p t e m be r 2O 11
Wired & Wireless
HART Communication
Get Connected
Now
INside...
Getting Connected:
Why and How
HART — The Premier Tool for
Asset Management
Get Connected with
WirelessHART
CTHart1109_01_v1.indd 8
8/26/11 9:51 AM
ta
Bridging the gaps in your plant.
How well do you know your plant? What is its current status? If there are gaps in your process monitoring,
Endress+Hauser’s innovative WirelessHART™ solutions will help you join the wireless world. Remote sites,
mobile equipment, in fact anywhere the cost of cabling is prohibitive: simply add WirelessHART™ and access
the process information you need. WirelessHART™ helps you measure, monitor and maintain more efficiently:
a cost-effective means of increasing productivity. www.us.endress.com/wireless
Endress+Hauser, Inc
2350 Endress Place
Greenwood, IN 46143
[email protected]
www.us.endress.com
CT1109_Hart.indd 2
Sales:
888-ENDRESS
Service: 800-642-8737
Fax:
317-535-8498
8/26/11 9:36 AM
taNK FaRM MONitORiNG • ReMOte i/O • ROtatiNG eQuipMeNt • asset MaNaGeMeNt
Need MORe
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Measurement and Control Technologies
ORDER ONLINE AT WWW.MaCteKCorp.CoM OR CALL 609-801-0039
HART and WirelessHART are registered trademarks of the HART Communication Foundation.
CT1109_Hart.indd 3
©2011 MACTek Corporation All Rights Reserved
8/26/11 9:37 AM
5”
Unlock Your Smart HART®
Device’s Hidden Secrets
HART Loop Interfaces:
• Convert HART to 4-20mA Signals
• “Break Out” Up to Three Analog Signals
• Provide High/Low Process
Alarm Trips (Contact Closure)
• Convert HART to MODBUS RTU
• Monitor HART Instrument
Diagnostics
• Work with Every HART-Compatible
Transmitter and Valve
• Set Up in Minutes Using FREE
Configuration Software
Control System
HART Digital Signal Carrying
Primary, Second, Third and
Fourth Variable Process
Data and Instrument
Diagnostic Information
4-20mA Representing
the Primary Variable
(Mass Flow)
4-20mA Proportional to 2nd Variable (DP)
4-20mA Proportional to 3rd Variable (P)
HART
Communicator
can be Connected
Anywhere Along
the 4-20mA Loop
4-20mA Proportional to 4th Variable (T)
High Alarm in Response to 4th Variable (T)
HART Transmitter Diagnostics Fault Alarm
or Additional Process Alarm
HIM Smart HART Loop Monitor
"Breaks Out" Data from
Smart HART Instruments
Smart HART
Multivariable
Mass Flow Transmitter
Flow
Flow
www.miinet.com/HART
United States • [email protected]
Tel: (818) 894-7111 • FAX: (818) 891-2816
Australia • [email protected]
Tel: (02) 8536-7200 • FAX: (02) 9525-7296
CT1109_Hart.indd 4
Belgium • [email protected]
Tel: 03/448.10.18 • FAX: 03/440.17.97
The Netherlands • [email protected]
Tel: (0)344-617971 • FAX: (0)344-615920
China • [email protected]
Tel: 86-21-62491499 • FAX: 86-21-62490635
United Kingdom • [email protected]
Tel: 01293 514488 • FAX: 01293 536852
8/26/11 9:37 AM
contents/index
EYEBROW
6
Getting Connected:
Why and How
Save time, increase profits and
productivity with HART.
12
ART — The Premier Tool
H
for Asset Management
HART and WirelessHART are
your best maintenance tools.
19
et Connected with
G
WirelessHART
IEC62591-WirelessHART works
and plays well with all systems—
including wired HART.
ADVERTISERS
Emerson Process Management . . . . 9
ifak system . . . . . . . . . . . . . . . . . . . 18
Phoenix Contact . . . . . . . . . . . . . . . 17
Endress + Hauser . . . . . . . . . . . . . . . 2
MACTek . . . . . . . . . . . . . . . . . . . . . . . 3
ProComSol . . . . . . . . . . . . . . . . . . . 22
Fluke . . . . . . . . . . . . . . . . . . . . . . . . 22
Moore Industries . . . . . . . . . . . . . . . 4
Siemens . . . . . . . . . . . . . . . . . . . . . 23
HART Communication Foundation . 24
Pepperl+Fuchs . . . . . . . . . . . . . . . . 11
Yokogawa . . . . . . . . . . . . . . . . . . . . 15
Get Connected! What Are You Waiting For?
By Ron Helson, Executive Director, HART Communication Foundation
H
ART Communication is working 24/7,
but if you aren’t “getting connected” to
continuously access the valuable information from your HART devices, then you are
not taking full advantage of all your HART assets:
moving from scheduled to predictive maintenance,
optimizing your processes and avoiding unscheduled shutdowns. So what are you waiting for?
Get connected to maximize the benefits
of your intelligent measurement and control
assets. Having your plant control, safety
and asset management systems communicate full-time with your wired and wireless
HART devices unlocks all their real-time diagnostics and intelligence. Getting automation systems continuously connected to your HART
devices is an important step to a culture change
that will impact how you manage measurement
devices, maintenance policies, plant operations and,
ultimately, your bottom line.
Here are compelling, real-world examples that
demonstrate the benefits of getting connected:
At the MOL Danube Refinery in Hungary,
using HART reduced operating and maintenance
costs nearly $900,000 by providing actionable information on device and control valve health and
preventing unscheduled shutdowns.
Using HART, Evonik Degussa Chemicals in Shang-
hai cut loop check time and costs by 25%. Daily
troubleshooting of instruments is now mainly done
from the safety and convenience of the control room.
At the largest nuclear power plant in North America, HART enabled the move from preventive maintenance toward true predictive maintenance: a more
effective way to address valve and process problems.
At a Northstar Bluescope steel mill, a WirelessHART solution eliminated almost
100% of cable and conduit, reducing
maintenance costs by $200,000 annually.
Users worldwide are sending a clear
message to industry suppliers by purchasing and deploying HART-enabled products
in overwhelming numbers each year. They
choose HART Communication because it is a
simple, reliable, secure, low-risk, feature-rich and
cost-effective intelligent communication protocol
that delivers significant value and rapid ROI. Suppliers are responding with cost-effective products,
many of which are described in this supplement.
Even a relatively small investment to get connected
provides actionable information that will improve
operation and lower costs. Join other users who
are gaining significant, high-value benefits for their
companies when you get connected to the intelligent
information in your HART devices. So what are you
waiting for?
This issue is our 11th HART Supplement in Control magazine. We thank you and everyone
involved for continued interest and support of this valuable resource.
For more on HART ® and WirelessHART® go to www.hartcomm.org or www.controlglobal.com.
90635
.com
6852
HART® and WirelessHART® are trademarks of the HART Communication Foundation.
Advertising supplement to CONTROL S-5
CT1109_Hart.indd 5
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Eyebrow
get Eyebrow
connected with hart
Getting Connected: Why and How
Save time, increase profits and productivity with HART.
M
ore than 30 million HART-enabled
devices have been installed in process plants around the world. In fact,
according to a recent market study released by
ARC Advisory Group, there were 32 million
installed HART devices, growing to 35 million in 2011, and the report projects growth to
continue to 37.3 million devices in 2012. Many,
if not most, of the instrumentation and final
control element vendors in the world provide
HART connectivity with their field devices. The
HART protocol has become the standard for
fieldbus communication in the world.
More and more, companies are seeing the
benefit of doing more than being temporarily connected to the instrument or valve with
HART communicator or PC communicator
software for commissioning or calibration.
They have seen that using HART to its fullest
capabilities is an area of optimization, lowered
cost and increased profitability.
Why Get Connected?
For the past 15 years, manufacturing theorists
such as ARC Advisory Group have been talking
about the benefits of implementing real-time
decision making from the plant to the executive
suite. Especially in the “high-cost” manufacturing countries, such as the United States, Canada
and all of Western Europe, keeping plants open
means showing increasing ROI to corporate
planners. There are really few ways to do this.
The two increasingly useful approaches are
both about increasing productivity. The first
is asset management. The second is advanced
process optimization.
“Collaborative process automation and a
continuous improvement plan utilizing per-
formance feedback and the benefits associated
with automation are the keys to automation’s
contribution to increasing manufacturing productivity, not the latest and the greatest technology,” an ARC study reports.
Performance feedback is the key. Most plants
have HART-enabled field instruments and
final control elements. Simply connecting those
instruments digitally to the control and computerized maintenance management systems
(CMMS) provides much of the feedback that
the ARC report is talking about.
Downtime is a key culprit. An ARC study
done in 2007 reports that downtime still represents a significant percent of production lost.
In oil refining, for example, downtime can be
from 1% to 8%. In petrochemicals as a whole,
downtime ranges from 2% to 5%, and in the
food and pharmaceutical industries, downtime
ranges from 1% to 10%.
It is easy to tie ROI into reducing downtime.
So how do you reduce downtime? The answer has been clear for years: better and more
predictive maintenance systems. But no maintenance system is any better than the sensors
that feed information to it. If you are collecting
information from those sensors about their sensor health and the processes they are monitoring by hand, the maintenance system is always
behind. The quality of that hand-collected data
taken off operator and technician clipboards is
usually poor to unreadable, and says things like
“didn’t work—fixed it.” State-of-the-art asset
management systems need real-time data—realtime sensor readings and real-time diagnostics.
Evonik Degussa Specialty Chemicals Company
in Shanghai, P. R. China, decided that HART
technology would be used to connect field instru-
S-6 Advertising supplement to CONTROL
CT1109_Hart.indd 6
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Get Connected with hart
ments to the distributed control system (DCS)
as well as to the asset management and safety
systems. There are more than 2000 HARTenabled instruments connected to the central control system, while the remote HART connection
simultaneously feeds data to the integrated asset
management and safety instrumented systems.
“As a direct result of this implementation,”
says Luc Sterck, Project Manager Instrumentation for Evonik, “we cut loop check time and
costs by 25 percent, and daily troubleshooting
of instruments are now mainly done from the
safety and convenience of the control room.”
The plant’s predictive maintenance program
How to Get HART Connected
Figure 1: All the ways you can use HART to make your plant run more profitably.
Connection Type
HART Field Devices – all
HART 5, 6 and 7 devices
including IEC 62591 /
WirelessHART
Temporary HART Connection – for device
set-up, commissioning,
configuration, diagnostics
and maintenance troubleshooting
Permanent HART Connection – full-time access,
use and integration of
intelligent device information with control, safety
and asset management
systems. Includes Temporary Connection capabilities from above.
Permanent HART Connection - Application
Specific – products
used to facilitate full-time
connection to HART
information
Product Type
Function
Suppliers*
Measuring instruments, valve
positioners, gateways, repeaters,
adapters, etc.
Full range of intelligent process
measurement and control devices
for: pressure, temperature, level,
flow, valve positioning (control),
discrete, signal converters, diagnostics, alerts and more.
Emerson, E+H, MACTek, Moore
Industries, Pepperl+ Fuchs, Phoenix
Contact, Siemens, Yokogawa and
Others
Handheld Communicator or Field
Calibrator
Temporary connection to single
HART device. Connect at device
or anywhere on the wire.
E+H, Emerson, Fluke, Yokogawa
& Others
PC-based HART configuration software with HART interface (modem)
- connection to device.
Temporary connection to single
HART device. Connect at device or
anywhere on the wire.
E+H, Emerson, ifak system,
MACTek, ProComSol, Siemens,
Yokogawa & Others
Loop Converter / Monitor – communicates full-time with a single
HART device. Reads and converts
HART digital signal from a device
into select analog signals for use
by non-HART capable control
system.
Provides multiple 4-20mA signals
and/or contact closures outputs
representing process variables
or diagnostic data from a HART
device. May also provide alarms,
Modbus RTU or digital display for
process status or faults.
Emerson, Moore Industries,
Pepperl+Fuchs, Yokogawa &
Others
Multiplexer – HART capable I/O
system for communication with
multiple HART devices. Provides
remote access to HART device
information for centralized asset
and device management.
Provides path for PC-based asset
management software to communicate with HART devices while
4-20mA signals continue to nonHART control system. Connect to
PC via RS-485, OPC, Ethernet, etc.
E+H, ifax system, Pepperl+Fuchs
& Others
Remote or Distributed I/O – HART
capable I/O system for communication with multiple HART devices.
Provides remote access to HART
device information for centralized
asset and device management.
Concentrates, communicates and
connects multiple HART devices
and their information to control
or asset management systems via
digital communication link like
Modbus, Ethernet, Profibus, etc.
E+H, Emerson, MACTek,
Pepperl+Fuchs, Phoenix Contact,
Siemens, Yokogawa & Others
DCS/PLC with integrated HARTcapability – full-time, fully integrated
analog plus HART digital communication with connected devices.
HART data fully integrated into
control system and operator display
for real-time use of intelligent device
information and diagnostic alerts.
Emerson, Phoenix Contact, Siemens, Yokogawa & Others
Protocol Converters – used in
applications where systems cannot
directly accept HART data.
Converts HART signals to Ethernet,
Profibus, Modbus or Foundation
fieldbus systems
Emerson, ifak system, Siemens &
Others
WirelessHART Gateway – component of WirelessHART network that
communicates to WirelessHART
devices and to the control system.
Interface between WirelessHART
field device network and control,
asset management or monitoring
system
Emerson, E+H, Pepperl+Fuchs,
Phoenix Contact, Siemens & Others
WirelessHART Adapter – component of WirelessHART network that
provides a wireless communication
connection to a wired HART device
The adapter attaches to a wired
HART device (or anywhere on the
wire) to provide wireless communication of PV, diagnostics and
other HART information between
the device and the WirelessHART
Gateway interface
Emerson, E+H. MACTek,
Pepperl+Fuchs, Phoenix Contact,
Siemens & Others
* Note: Companies listed are sponsors of this supplement. Check HART Product Catalog at hartcomm.org for a complete list.
Advertising supplement to CONTROL S-7
CT1109_Hart.indd 7
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get connected with hart
MACTek bullet
Figure 2: This adapter can upgrade up to eight devices to be
able to send wireless diagnostic and process data.
Emerson’s CHARM Input/Output Modules Have HART
Figure 3: Each module contains HART I/O and HART digital data is extracted automatically.
is expected to reduce the total number of hours
spent by maintenance teams. “We strongly
believe,” Sterck says, “that our plant’s commitment to implement predictive device diagnostics
on all HART instruments will bring comprehensive and pertinent operating information to
key personnel and therefore assure better plant
availability by predicting unexpected failures
and avoiding associated downtimes.”
The logic solvers of Evonik Degussa’s plant
use HART technology to connect with the sensors for loop check and safety instrumented
function (SIF) interlock validation. Some of the
logic solvers are used in complex online flammability calculations (SIL3).
Interoperability Gets YOU Connected!
You don’t need to radically revise your plant’s
instrumentation schemes. Operators and maintenance techs already have all the data they
need—right in their HART devices. Each HART
device is designed to be interoperable—it starts
in the HART specification, using EDD in every
device, and then it is tested and registered by
the HART Communication Foundation.
Since 2007, there has been a new way to get
connected with HART. In 2010, the IEC approved IEC62591-WirelessHART, the first
international open standard for wireless field
devices. As data gathering needs expand, both
for asset management and plant optimization,
new devices and new functions can be added to
the control system without the major expense
and downtime of pulling new wires. And WirelessHART is designed to be backward-compatible and interoperable with wired HART devices.
“Because IEC 62591-WirelessHART is
completely backward-compatible with any
registered installed HART devices, using adapters such as the MACTek Bullet can easily get
the diagnostic and secondary process variable
information from existing HART transmitters
without the cost, expense and time associated
with new wiring. And, since the Bullet can support up to eight devices in a HART multidrop
application, it makes the case for the adapter
even more cost-effective,” says Thomas Holmes,
CEO of MACTek Corporation.
There has been an explosion of devices and systems that you can use for connectivity with HART
devices. Almost all the major DCS vendors have
S-8 Advertising supplement to CONTROL
CT1109_Hart.indd 8
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The Eme
Escaping steam means lost energy
and lost profits. If only I could monitor
my steam traps without running all
over the plant.
YOU CAN DO THAT
Capture elusive energy savings with real-time automated steam trap monitoring.
Knowing the status of every steam trap could enable you to save up to 20% of steam loss and $4 million dollars
a year in lost energy. With the Rosemount 708 Wireless Acoustic Transmitter, you’ll have instant visibility to all your
critical steam traps through a non-intrusive, WirelessHART® monitoring system. Backed by Emerson’s proven
experience in Smart Wireless field instrumentation, the Rosemount 708 will enable you to effectively and easily
capture significant energy cost savings without running all over the plant. Talk to Emerson. We’re the experts
in wireless so you don’t have to be.
rosemount.com/stopsteamloss
The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2011 Emerson Electric Co.
CT1109_Hart.indd 9
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GET CONNECTED WITH HART
Each HART device is designed
manner in which mobile technology is changing the
way people live and work. DevCom2000 Mobile
uses the registered DD files from the HART Comto be interoperable—it starts in
munication Foundation for complete access to all
the HART specification, using
features of the instrument including Methods.”
Like many mobile apps, DevCom2000 can be
EDD in every device, and then it is
had on a try before you buy basis. “The enhancements in Rev 1.6 enable potential customtested and registered by the HART ers to try the DevCom2000 Mobile software
for 10 days before deciding to purchase. They
Communication Foundation.
can experience the power of the DevCom2000
desktop version with the convenience of mobile
technology,” Dobos says.
now provided native HART digital data gateways
Staying connected is simple. All HART devices are
directly into the control system. There are quite
designed with both interoperability and interchangea few companies that make HART digital multiability in mind. “Process industry users have very
plexers that route the data to the control systems.
high expectations when it comes to interoperability,”
Every tested and registered device is interoperable
says Ron Helson, executive director of the HART
with any other, right out of the box.
As the chart in Figure 1 shows, there are numerous Communication Foundation. “To them, interoperability is much more than devices sharing the same
vendors for every type of HART device, including
network infrastructure. Devices must integrate with
calibration and configuration devices. “Our compathe system in the same way without the need for
ny offers products for temporary use like our isHRT
multiple gateway types, special drivers and differUSB communication modem as well as solutions
ent system configuration methods. Similarly, devices
for permanent parameter acquisition, “ says Tobias
should be commissioned, set up and calibrated the
Thobaben of ifak system. “The modular [email protected]
same way, and device diagnostics information should
RT gateway provides parallel access to up to 40
HART lines, thus making it a real enabler for HART be consistent. HART, including WirelessHART technology, meets all these user requirements.”
based asstet management solutions. Our free HART
The standard HART command set and the
starter pack delivers real added value, allowing
vendor-specific commands return data values that
generic access to HART 5, 6, and 7 devices within
are easily integrated into the
FDT based applications,” Thobaben
And
Now
There’s
an
App
for
That!
control and asset managecontinues, “and our isHRT USBeX
ment systems. In the control
intrinsically safe communication
system, this additional digimodem allows users to work on
tal data improves the ability
HART devices without shutdown
for the operator to optimize
or hot work permits.”Thobaben’s
the process. In the asset
company is not alone in providmanagement system, the
ing generic access. ProComSol has
diagnostic data provides the
been a leader in providing PC-based
information to predict mainsoftware for commissioning, calibratenance requirements that
tion and troubleshooting HART
techs and managers simply
devices. CEO Jeffrey Dobos says,
cannot get from clipboard“our popular DevCom2000 Smart
based rounds.
Device Communicator Software is
Getting connected is
now available for communicating
not rocket science. It will
with HART instrumentation from
improve productivity, reduce
Mobile devices such as PDA’s and
maintenance and mainteSmartphones. Moreover, the name
nance costs, and signifiof the software has been updated
Figure 4: HART meets mobility. Here’s
cantly reduce downtime. So
from DevCom2000 PDA to Devthe first Windows Mobile app for HART
commissioning from ProComSol.
what are you waiting for?
Com2000 Mobile to reflect the
S-10 Advertising supplement to CONTROL
CT1109_Hart.indd 10
8/26/11 9:42 AM
R
RIDE THE WAVE
Wireless transmission – on 2.4 GHz waves
Historically, industrial wireless communication has
not been used in process automation applications;
however, WirelessHART™ will change this trend.
WirelessHART saves cabling costs and can be used in
applications considered impossible using traditional
installation methods. The technology is based on
the proven HART protocol, so implementation and
training is easy and straightforward. Even better,
the wireless field devices integrate easily into the
highly-available and stable mesh network generated
by components from Pepperl+Fuchs.
Learn more at: www.pepperl-fuchs.us/wirelesshart
Pepperl+Fuchs, Inc.
Twinsburg, Ohio
330.486.0002
www.pepperl-fuchs.us
CT1109_Hart.indd 11
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Eyebrow
get Eyebrow
connected to your assets
HART — the Premier Tool
for Asset Management
Cut downtime and improve profits with the tools you already have.
D
o more with less. That’s the mantra of
many industries today in North America or anywhere else around the globe.
Companies no longer have employees that aren’t
fully utilized—nobody has a couple of hours to
grab a clipboard and some test equipment and
go out in the plant to check the condition of
field devices and final control elements.
Besides, plants require hot work permits,
safety information, workarounds and other
time-consumers, making it highly unproductive
to grab that clipboard and go.
Companies around the world have begun formal programs to use the diagnostic data in their
HART-smart instruments and control valve
actuators and positioners by directly connecting
them to the asset management systems in the
maintenance department.
“HART technology has saved both time and
money,” says Todd Gordon of We Energies in Milwaukee, Wis. “We have also used the HART signal
from digital valve controllers (DVCs) or positioners to provide valve position to our DCS control
system with the use of a HART converter module.”
Why was this important? “Actual position
feedback was not available with the original plant equipment, and we couldn’t tell if a
valve was sticking without physically looking
at it,” Gordon says. “With this HART signal
converted to 4-20 mA for an input to DCS, we
then added a deviation alarm to tell the control
operator when the DCS command signal deviated from the actual valve position more than
5% for more than five seconds. This HART
feature alone saved the plant from tripping offline on several occasions. We have been able to
adjust valve packing on valves when they were
in service, which is a huge benefit. We have
also prioritized maintenance work based on the
friction calculations of the HART smart positioners. The dampers with the highest friction
numbers were repaired first.”
Chart of HART Diagnostic Information
Figure 1: Get connected to all of this valuable diagnostic data
that you already own.
S-12 Advertising supplement to CONTROL
CT1109_Hart.indd 12
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get connected to your assets
Hiren Choksi, of Krishak Bharti Cooperative
Limited in Gujarat, India, agrees. “Benefits are
quite huge in terms of the monetary aspect, as
well as it has helped by increasing the overall
productivity of the plant. Let’s say, in an ammonia plant, one unplanned breakdown shortens
the life of reformer tubes by 7% due to thermal
shocks. Using the HART protocol, faults and
errors are able to be identified and rectified
well in advance.”
Tina Lockhart, director of engineering for
Moore Industries International, says, “Every
HART field device response contains information regarding the device’s health. This information consists of device and variable status,
such as device malfunction or primary variable
out of limits. Having this data sent with every
message provides the operator with confidence
in the integrity of the process measurement and
with immediate notification of a problem. From
a maintenance perspective, a whole plant can
be monitored from a single location, and fault
diagnosis can often be performed remotely.
Many instruments provide additional status
information that can be used for predictive
maintenance and replacement of equipment
on an as-needed basis. This results in reduced
maintenance trips, fewer process disruptions
and high system availability.”
Eddie Saab of Lakeside Process Controls in
Ontario, Canada, talks about the use of HART
diagnostics to correct serious problems at the
Bruce Nuclear Power Station. “This is the largest nuclear power plant in North America,” he
says.“Bruce Power had a history of feedwater
heater operating problems. When a comprehensive root-cause analysis was initiated in 2001, it
pointed to two main causes for the problems: an
inverted loop in the saturated drains that allowed
liquid to collect (which was corrected), and
inadequate heater level control, which was solved
using HART-enabled smart instrumentation.”
Saab continues. “The Bruce Power/Lakeside
process controls team decided to carry out what
it called “smart utilization of smart equipment.”
Solenoids and junction boxes were integrated
onto the valve assemblies. An interlock was
tied in so that if power was lost to the solenoid,
the positioner air supply was blocked, and the
valve actuator used its spring to get the valve to
the fail-safe position. The team used the HART
signal inherent in the Fisher DVC6000 digital
positioner to detect the solenoid trip. And, finally, the team set up the Fisher DVC6000 digital positioner on the valve to provide a direct
signal for valve position and to enable on-line
valve diagnostics.”
Moving to Predictive Maintenance
“This approach uses two-way communication
between the control room and the valve for online troubleshooting,” Saab continues. “On-line
troubleshooting is looking for advance signs
of problems that could impact process performance. This allows the plant to move away
from preventive maintenance, typical within
the industry, and toward true predictive maintenance, a more effective way to address valve
and process problems.”
Kenneth Marse, of Galata Chemicals LLC
in Taft, La., puts the value of HART for asset
management simply. “The plant converted to
contract instrumentation/electrical maintenance
in 2007, and staffing was significantly reduced.
Instrument reliability suffered, and calibration
compliance declined. Using HART and the AMS
system [from Emerson Process Management],
the site has improved instrument reliability
and has returned to full calibration compliance
while maintaining a reduced staff.”
AMS is just one of the asset management
software packages that easily uses both HART
process and diagnostic information. Nearly all
of the major CMMS (computerized maintenance
Moore’s HART Health Monitor
Figure 2: Online fault diagnosis made easy with HART
Advertising supplement to CONTROL S-13
CT1109_Hart.indd 13
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GET CONNECTED TO YOUR ASSETS
“On-line diagnostics provided
by the HART instruments does
something more than preventive
maintenance. [They] ensure the
stable operation of the system and
increase the precision of control.”
— József Bartók, MOL Danube Refinery
management software) and automation-vendorbased packages provide native support for
HART devices.
We know, from talking to our customers,”
says Kaoru Sonoda of Yokogawa Electric Corporation, “just how much time and money can
be saved with good predictive maintenance systems. With the widespread use of HART instruments, connecting existing and future HART
devices into both the control system like our
CENTUM and the asset management system
like our PRM (Plant Resources Management)
can be critical to realizing those benefits.” Sonoda adds, “And the FieldMate Device Management Tool allows for easy device configuration
and troubleshooting”
INTEROPERABILITY AND
BACKWARD COMPATIBILITY
We Energies’ Todd Gordon notes, “Valley Power Plant has been using HART smart instrumentation since the late 1980s. The transmitter loop
test function has been used for troubleshooting
and insurance compliance testing of the boiler
trip functions. HART smart valve positioners
have been used since 1999, and they have provided valuable diagnostic capabilities that have
allowed us to troubleshoot problems while the
valves are in operation. It also helps to pinpoint
problems before mechanics start taking valves
apart. A leaking valve diaphragm that has
been identified with diagnostics can be replaced
without removing the valve, which saves time
and money. We have found numerous problems
before they affected plant operations.”
Gordon adds, “Other power plants in our company have adopted HART technology over the
years. The older Oak Creek Power Plant added
an AMS on-line system when they installed wireless transmitters on their feedwater heaters for
performance monitoring. Pleasant Prairie started
using digital valve controllers in 2003, has an
online AMS system and recently added some
WirelessHART transmitters to their systems.”
Gordon says HART interoperability is transparent. “Two new plants were built in the last
few years by two different contractors (Washington Group & Bechtel),” he says, “and both
plants came standard with on-line HART technology to communicate with the HART smart
instrumentation in the plant.”
SAVE TIME AND MONEY
ON CALIBRATION AND DIAGNOSTICS
Galata’s Marse says, “Our plant is using AMS
Intelligent Device Manager and HART to
monitor diagnostic alerts and for calibration
management to reduce maintenance time and
maintain calibration compliance. The central
system links real-time HART data and instrument documentation in a single system which
provides a single source for the I/E technician.”
Without the ability to enter calibration data
directly into the asset management system, the
data that is collected about the actual condition of the instruments other than the HART
diagnostic data is suspect.
Jim Shields, product manager for calibrators
for Fluke, points out, “Several surveys have
shown that paper-and-pencil documentation
Documenting Calibrators Speak
HART and CMMS
Figure 3: Documenting Calibrators with HART connectivity
make calibration rounds easy.
S-14 Advertising supplement to CONTROL
CT1109_Hart.indd 14
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GET CONNECTED TO YOUR ASSETS
produces and perpetuates errors. Further, as
maintenance and operations departments have
less and less time and fewer employees, much
of the data collected on clipboards will just be
filed and not used. In addition, entering this
manually collected data into CMMS systems
is also a manual operation, taking time, costing money and usually far down the list of
things that must be done to keep the plant
operating and producing revenue. That’s why
the new Fluke 754 Documenting Calibrator
has HART connectivity. Both sets of data can
be documented and uploaded directly to the
CMMS.”
Just how much money can you save using
HART diagnostics? “On-line diagnostics provided
by the HART instruments does something more
than preventive maintenance,” says József Bartók,
automation engineer at MOL Danube Refinery
in Hungary, adding that this “ensures the stable
operation of the system and increases the precision
of control.” Beyond fixing what breaks or keeping the plant running, a reliable, stable operation
contributes to bottom-line profitability.
On-line and off, HART has proved its mettle
according to Bartók.
In one case, the head pressure control was
slow on one unit leading to the assumption that
a valve was stuck and in need of removal and
Emerson’s AMS Snap-In Network Manager
Figure 4: WirelessHART device networks can be designed
easily with this visual network manager
HART-supplied diagnostic data
saved the MOL Danube Refinery
at least two days of unscheduled
downtime, or approximately
€637,000 ($897,790 USD).
repair. But technicians with on-line diagnostic
tools used HART-supplied data to interrogate
the valve and find current-to-pneumatic damage
only in the intelligent positioner–not the whole
valve.
Operators put the valve in manual, and
the fix took a half hour of instrumentation
work. This saved the plant at least two days
of unscheduled downtime, or approximately
€637,000 ($897,790 USD).
Savings, increased throughput, reduced downtime—spell it any way you want. You already
have all the data you need to gain savings like
MOL did—in your HART instruments.
WIRED OR WIRELESS—HART’S THE SAME
Engineers and operators who are familiar with
how to connect HART to their control and asset management systems are finding IEC62591WirelessHART a breeze to add to their systems.
Each WirelessHART transmitter behaves exactly like its wired counterpart. This is thanks
to the interoperability and interchangeability
specifications designed into the HART and
WirelessHART specification from the beginning. The biggest difference between the two is
that there are no wires.
We Energies added an asset management system (Emerson’s AMS Suite) and WirelessHART
sensors, according to Gordon, “when they installed wireless transmitters on their feedwater
heaters for performance monitoring.” The AMS
Suite has what is called a “snap-in” module
that performs network management and device
site selection for wireless instruments and final
devices.
No matter what vendor’s brand of HART or
WirelessHART devices you use, you can be assured of a simple and easy way to improve your
asset management—with tools you already have.
So get connected with HART right now!
S-16 Advertising supplement to CONTROL
CT1109_Hart.indd 16
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UNLEASH YOUR ASSET!
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More flexibility: Mobile HART devices
The isHRT USB is a replacement
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used in process automation. It also
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which satisfies the required timing
constraints of the HART bus regardless of PC performance.
For the use in hazardous areas we
offer an intrinsic safe, ATEX certified
version: isHRT USBeX.
It is functionally equivalent to the
standard type.
The [email protected] BluePack supports
wireless (Bluetooth) and wired
(USB) access to a HART network
and runs an embedded HART
master stack. This guarantees
compliance with the HART timing requirements regardless of
the speed of the PC host application or the data transmission
quality between the host and the Bluetooth device.
The interface can be powered via the USB connection or
3 replaceable AAA cells. It can be powered down by an
on/off button. To increase the life span of the batteries the
device switches to sleep mode if no Bluetooth communication takes place.
Visit www.ifak-system.com/HART for more information.
CT1109_Hart.indd 18
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EYEBROW EYEBROW
GET CONNECTED WITHOUT WIRES
Get Connected with WirelessHART
The only international open standard for wireless sensor networks takes
charge, so get connected now.
I
n August 2011, IDTechEx published a survey,
“Wireless Sensor Networks 2011-2021.” In it, the
researchers claimed that wireless sensor networks
will grow from $0.45 billion in 2011 to $2 billion by
2021. Most of that growth will be in smart homes,
smart grid and other non-industrial applications.
Raghu Das, CEO of IDTechEx says, “In 2011,
industrial wireless sensor networks account for
approximately 6% of the total $0.45 billion. In
2021, they will account for approximately 28%
of the estimated $2 billion market.”
“In 2011 I’d estimate WirelessHART to be 60%
of that market segment that is industrial only,”
Das continued. It is difficult to predict its use in
the future—the choice of standards is a problem.”
A recent survey by Control magazine indicates
that the prediction may well be easier than Das
thinks. According to the survey, published in the
August issue, end users have stopped waiting for
the standards to be hashed out and have begun selecting WirelessHART over other standards. Part of this is undoubtedly true because
WirelessHART is now the only international
open standard for wireless sensor networks:
IEC62591-WirelessHART.
As a further insight, the Control study showed
that 18% of respondents said they didn’t need
wireless networks—any variable they needed badly
enough was worth running cable to. If you remember that HART Communication is both wired and
wireless, this is an important advantage to end users and asset owners. You can continue to use your
wired HART systems and when there is a need, a
WirelessHART network will fit right in.
INTEROPERABILITY MAKES WirelessHART WORK
A unique feature of WirelessHART is its integration with the wired HART specification. Just as all
HART instruments—including WirelessHART—
have been interoperable and backward-compatible. You already know how to commission
and calibrate the wireless versions, because you
already have HART smart devices in your plant.
There is no run-up learning curve.
“From the E+H perspective we support
all standardized communication protocols
which of course includes WirelessHART”says
Endress+Hauser (www.endress.com) wireless
product manager Jason Knuteson. “Our customers are continuing to ask for robust and
flexibility solutions for difficult process applications they experience, and WirelessHART is a
great answer to their needs!”
What does interoperability really mean? It
means that any HART device of any kind will
work seamlessly with all other certified and
registered HART devices. Further, for its basic
functions at least, any certified and registered
HART device can be interchanged with any
other similar device. So every HART temperature transmitter is interchangeable, and
so forth. For WirelessHART, it means that any
WirelessHART gateway can be used with any
manufacturer’s devices, and all devices can be
used with any gateway.
The Growth of WirelessHART
Wireless Sensor
Networks
2011
2021
All Wireless Networks
$450,000,000
$2,000,000,000
Industrial Sensor
Networks
$27,000,000
$560,000,000
WirelessHART
$16,200,000
$336,000,000
Figure 1: Data from IDTechEx and Control predicts that
WirelessHart will grow exponentially over the next 10 years.
Advertising supplement to CONTROL S-19
CT1109_Hart.indd 19
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get connected without wires
Network Manager and More!
and WirelessHART is well-suited to
provide diagnostic information on
measured process values.”
What this means for you is that
you have much less risk selecting
WirelessHART for your wireless
sensor network than in selecting any
other system. It means that WirelessHART is “future proof.” You can
be certain that the HART Communication Foundation will maintain the
full backward compatibility that has
become its hallmark.
So Who’s Waiting?
You may not be waiting at all. According to the wireless study published
in Control’s August 2011 issue, 43%
Figure 2: Phoenix Contact’s Network Manager also includes a Wireless
of respondents said they already had
Network Planner.
wireless field networks, while another
27% said they were planning to install
The WirelessHART Ecosystem
them in the next 1-3 years. If that’s the case, the
Proprietary wireless systems and even some
next step is to learn how to design, configure,
so-called standard systems generally have only
manage and operate IEC62591-WirelessHART
one vendor. This can be very worrisome for the
sensor networks.
operator when selecting a wireless network for
the plant. Since 2007 when it was introduced,
Setting Up WirelessHART
the number of vendors producing registered and
“The WirelessHART standard is built on proven
certified WirelessHART devices (the HART “Eco- industry standards,” Executive Director Ron
system”) has been climbing—now numbering
Helson says. “The radio uses the IEEE 802.15.4
around 20. These vendors include the manufacstandard and requires extremely low power,
turers of at least 80% of all transmitters, control
enabling the battery to last as long as 10 years
valves, and online analysis equipment, such as
in some applications. The radio operates in the
Siemens, Endress+Hauser, Moore Industries
same license-free 2.4 GHz band as Wi-Fi and
International, Emerson Rosemount and Emerson
many other wireless technologies. WirelessHART
Fisher.
uses channel-hopping and channel black-listing
“Siemens is continuing to see a strong demand
to prevent interference and enable coexistence
for our WirelessHART products and soluwith other wireless networks, and a combination
tions,” says Michael Cushing, product marketing
of star and mesh topology networking to ensure
manager for Siemens Industry, Inc. (www.sea.
robustness in the presence of noise.”
siemens.com) “and our SITRANS products are
Helson continues, “WirelessHART uses the
the cornerstone to our portfolio. Cost and efElectronic Device Description Language (EDDL)
ficiency is driving this demand, as WirelessHART (IEC 61804-3) to simplify system integration as
users eliminate significant costs of cabling and
well as enabling setup, calibration and device
installation, and realize the convenience of faster
diagnostics using graphical interface software
commissioning and easier maintenance. We also
applications.”
have the ability to interface WirelessHART with
WirelessHART was designed to operate reliother Siemens process instruments through our
ably in a process plant environment that is full
SITRANS AW200 adapter. Customers will conof structural steel, metal vessels and pipes using
tinue to have the need for easy access to inforindustry-accepted mesh topology. WirelessHART
mation from plant applications and operations,
mesh networks are easily deployed without the
S-20 Advertising supplement to CONTROL
CT1109_Hart.indd 20
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get connected without wires
need for installing a wireless infrastructure of
backbone routers in many plant areas and providing power for them.
What you need to get started is a scale drawing
or photo of your plant. Several companies make
wireless sensor network management equipment
that allows you to overlay the physical location
of the sensors on the scale drawing, and tell you
whether you need repeaters, more sensors or
more gateways. For an example of this, see the
Emerson AMS snap-in component in Figure 4 of
the previous article on page S-16.
“BASF has a number of good applications for
wireless communication, and we are putting them
to good use,” Kranendonk says.
This application shows another unique feature of
IEC62591-WirelessHART. A wireless adapter can
be retrofitted to an existing HART wired transmitter
to turn it into a fully functional wireless transmitter.
Like the rest of the HART ecosystem WirelessHART
adapters are being made by several vendors, including Endress+Hauser, Emerson (www.emersonprocess.com) and Pepperl+Fuchs (www.pepperl-fuchs.
com). MACTek (www.mactekcorp.com ) produces a
“Bullet” WirelessHART adapter that permits up to
eight wired HART transmitters to operate wirelessly.
Some of these wireless adapters provide their own
power supply or can be used to power the transmitter, and some get their power from the current loop
connected to the wired HART transmitter.
“WirelessHART easily scales to support large
applications with separate networks for each
plant area aligning with DCS structures and
division-of-work responsibilities that make it
easy to manage and more secure,” Helson says.
Northstar Bluescope Steel had a real problem.
The steel mill has water-cooled electric arc furnaces,
with water-cooled burners and cooling panels that
keep the furnace walls from melting and deforming—and blowing out the panels. If that happens,
Real World, Real Answers
from WirelessHART
BASF had a real problem. Technicians needed to
measure the temperature in a rotating vacuum
dryer full of catalyst. Because the dryer rotated,
wired temperature sensors had been eliminated.
They were stuck with manual sampling and lab
testing. They needed something better and faster.
“We went in search of alternatives so that we
could dispense with the time-consuming sampling
process and free up the operators,” say Ramon
Kranendonk and Perry Stofberg pf BASF in DeMeern, the Netherlands. “On the Endress+Hauser
stand at a trade fair, we saw a demonstration
of a wireless system for measuring temperature.
The system used standard
transmitters and a module
Diagram of BASF’s Wireless Connections
with an antenna was used
to transmit the data signal to a host by means of
WirelessHART. For us, this
was obviously an excellent
solution.”
Kranendonk noted that
another criterion was the
straightforward integration
into the system. Control is via
Siemens PLCs and PROFIBUS. Their asset management
software is FieldCare. The
Fieldgate gateway has 24
VDC power, and two outputs: one Ethernet, and one
Modbus. The Modbus signal
is converted to PROFIBUS
DP and fed to the PLC. The
Ethernet signal is sent to the
Figure 3: Because they rotate, wired sensors were just not practical
FieldCare server.
Advertising supplement to CONTROL S-21
CT1109_Hart.indd 21
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get connected without wires
the furnace is seriously damaged, and just one
blown-out panel costs upwards of $20,000 to
repair. Then there is the lost production cost due to
the unexpected downtime. That can be as much as
an additional $200,000 per day or more.
“Between nine and 12 measurements per week
would fail due to high temperatures or physical
damage to sensors, cable or conduit,” says Rob
Kearney, maintenance supervisor of Northstar’s
mini-mill in Delta, Ohio. “And when a measurement point fails, the furnace must be shut down.
The new wireless solution eliminated almost
100% of the cable and conduit—which reduced
maintenance costs by $200,000 annually.”
The self-organizing WirelessHART network
collects the data used to control temperature on
the furnaces. Emerson provided 32 Rosemount
WirelessHART temperature transmitters, 28 for
control and four for monitoring. The transmitters
send their data to aWirelessHART gateway which
interfaces with the mill’s transformer-regulation
and burner-control system.
“Safety has also been improved,” Kearney
says. “The furnace’s cooling panels are operating
consistently at a safe temperature, and there is less
maintenance required around the hot furnace shell,
where ambient temperatures can be +140 ºF.”
Is HART Future-Proof?
The process industries, in fact, all manufacturing,
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are very conservative. Refineries and chemical
process plants especially don’t like trying new
things, because a failure generally makes something go boom. Pharma and biopharma plants
and other validated industries are similar in conservative application of new technologies.
But HART and its wireless capability, WirelessHART, aren’t new. They are both based on
the proven technology that has made HART the
standard for process fieldbus. And going forward, you don’t have to fear that suddenly the
devices will become obsolete. Endress+Hauser is
one of the world’s two largest field instrument
manufacturers. Here’s what Jason Knuteson,
E+H wireless product manager, has to say, “The
long-term investment and commitment into the
WirelessHART and other wireless communication is 100% from E+H. This is a decision made
at the top levels within our organization! We are
committed to the needs of our customers.”
David Skelton, Phoenix Contact’s (www.phoenixcontact.com) vice president Americas sums it up
well. “Process engineers around the world are using
WirelessHART as a way to easily obtain data from
their existing HART or newWirelessHART instruments. With this gateway, Phoenix Contact has
combined our competencies in wireless, networking
and process technologies to develop a product that
makes WirelessHART networks even more costeffective and flexible.”
1551A Ex and
1552A Ex “Stik” Thermometer
Finally, a digital substitute for
mercury-in-glass thermometers. Accurate and repeatable
to ± 0.05 °C over its full range,
the 1551A/1552A “Stik”
Thermometer is the new “gold
standard” of industrial temperature calibration. Whether
working outdoors in environments where potentially
explosive gases may be present
or on the floor of a processing
plant, the intrinsically-safe,
battery operated, portable reference thermometer is designed to go where
you work.
www.flukecal.com
S-22 Advertising supplement to CONTROL
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Screen Simulation
Working
all the time...
so you don’t
have to.
HART Communication is working – 24/7 – to identify
problems for corrective action to avoid a potential plant
shutdown – and help you move from scheduled to predictive
maintenance. For maximum benefit your plant control, safety
and asset management systems should “get connected” to continuously
communicate with HART-enabled devices and unlock their real-time
diagnostics and intelligent capabilities.
Wired and Wireless...GET CONNECTED!
Scan with red laser
®
HART is a trademark of the HART Communication Foundation.
5109hart-ControllMag-magGlass.indd 1
CT1109_Hart.indd 24
www.hartcomm.org
8/24/11 8:52:27 AM
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