Using WirelessHART Technology in Process Industries

Using WirelessHART T h l U i Wi l HART Technology in Process Industries

IEC Approved Standard (IEC 62591Ed. 1.0)

Welcome
Extension of the HCFs HCF s Worldwide series of seminars Vendor neutral Clear away the wireless fog Seminar Sponsored by: Introduce WirelessHART as the first global standard
Technical and practical seminar

Understanding HART g The Standard for Instrumentation

30,000,000 Installed HART i stable is t bl and backward compatible Most widely used y Widest choice of product and suppliers Built upon standards HART 5 1998 HART 7 2007 Over 70% market share Major vendors and Over 245 Members IEC 62591 WirelessHART IEC 61804 - Device Description Lang. IEC 61158- Industrial Comms. Networks IEEE - R di 802 15 4 Radio 802.15.4 Protect your investment The momentum is here

Understanding HART g Building on HART HART has maintained backward compatibility

Do not remove feature Add features Maintain command structure
Time/Cond. Reporting PV Trending Security Mesh & Star All PV With Status Long Tags

HART 7

HART 6
HART 5

Use existing tools and knowledge Wireless adapters allow for installed instrument i t ll d i t t upgrade

Process Monitoring Diagnostics Configuration Remote Access

4-20mA Loop Wireless

Todays Topics Introduction What Can Wireless Do For You Understanding HART Wireless Building Blocks Using WirelessHART Host Integration Planning a WirelessHART Project y Summary

Today we will discuss .

WirelessHART Attributes
Battery life (power options) Range Control Mesh & Star topologies p g Radio / Antenna characteristics Co-existence Security Update rates

IEC Approved Standard

WHAT WIRELESSHART CAN DO FOR YOU

Contents

Designed for process Works with existing g systems Reduce installation cost Reduce project execution time Implement incrementally

Designed for Process g Applications Process Monitoring

Hard to reach / expensive to install locations Full access to multivariable devices
Type T Class Cl Description D i ti

Safety

0 1 2

Critical Closed Loop regulatory control Closed loop supervisory control Open loop control Alerting Al ti Data logging and Up/Download

Asset Management
Condition monitoring Configuration database
Control

3 4 Monitoring 5

Control
Open loop Closed loop

Designed for Process g NAMUR WirelessHART Field Test Report

Field test organized by NAMUR at BASF SE in Ludwigshafen, Germany Objectives
1. Identification and Assessment of added value with applications for Wireless Sensor Networks with regard to:
1. Mobility, 2. Flexibility and 3. Cable Replacement

2. Reflections (Comparison) of WirelessHART pilot application results against NE124 requirements i

Designed for Process g NAMUR WirelessHART Field Test Report

> 55 devices

Designed for Process g NAMUR WirelessHART Field Test Report Conclusions:

WirelessHART allows successful deployment of wireless sensor networks WirelessHART in principle is applicable for monitoring applications (NE124 Class C) Suppliers have improvement potential related to implementation supporting applications pp p g y WirelessHART offers opportunities despite legacy burdens

Designed for Process g NAMUR WirelessHART Field Test Report Recommendations

Gateway

A single standard Standardize Battery design and connection Configuration standardization and interface
Devices

Designed for Process g Process Monitoring Applications Access to hard to reach or previously uneconomical process measurements
Tank Farm Well head monitoring Rotating equipment (kiln) Solve process problems with temporary measurements

Elimination of operator rounds Full multi-variable device access

Designed for Process g Applications Process Monitoring & Control

Hard to reach locations Process efficiency calculations Better insight into process Ad-hoc measurements Additional measurements from multivariable devices Calculated variables in devices

Designed for Process g Applications Equipment Monitoring

Bearing temperatures Vibration Corrosion Oil pressure Air flow

Designed for Process g Applications Health and Safety

Safety showers Gas detectors

Environmental
Steam traps (energy usage) Water / Discharge Treatment
Flow pH

Stack emissions Relief valves

Designed for Process g Applications Asset Management

Maintenance
Calibration R Record valve signatures d l i t Radar echo

Diagnostics
Valve position feedback Device health (status)

Works With Existing Systems g y Traditional Wired System

Works With Existing Systems g y Remote I/O System

Works With Existing Systems g y Wireless Similar to Remote I/O

Reduce Installation Cost Material, Time and Labor

Conventional Analog Wiring
AnalogI/O

Systemterminations Multicoreterminations

Devicetermination Multicoreterminations

WirelessHART Network
Serial I/O

1 system connection

Gateway

Reduce Project Execution Time j Its More Than Just The Wire Savings Reduce engineering time
Loop diagrams Specification and purchase of field enclosures Specification and purchase of wire

Reduce installation time

No cable to pull No terminations to make No cable trays to install No scaffolding to erect

Implement Incrementally

Once the network is in place just:

Install the next field device Add an OPC/Modbus data point

Additional devices strengthens the network It s Its just that easy!

Summary
Designed for process applications
PV monitoring Control Asset management

Adaptor - upgrade path for existing installed instruments Works with existing systems y Lower cost installation Reduced project execution

UNDERSTANDING HART

Understanding HART g HART = Highway Addressable Remote Transducer

Allows local and remote access to instrument configuration Instruments have microprocessors
More sophisticated May not have a local display

HART data is available anywhere on the 4-20mA loop

Understanding HART g HART Communication Over Wire

Understanding HART g HART Commands There are three classes of HART commands
Universal
PV TAG Diagnostic

Common Practice
Calibration PV range

Device Specific
Linearization tables Technology specific

Understanding HART g Device Description (DD) All the information needed by the host to fully communicate with a field device. Handheld host
Simple instruments IS version for hazardous areas

PC-based host
Asset management Condition monitoring

Understanding HART g Communication Modes Master-Slave Mode: Master Slave

Communication is initiated by a master device
Point-to-point or multi-drop p p

Primary Master:
Control room (system)

Secondary Master:
Handheld

Burst Mode:
Master instructs the slave device to continuously broadcast a standard HART reply message (e.g. (e g PV) until instructed to stop stop.

Understanding HART g Multiplexer/Pass through Operation HART multiplexers

Monitor PVs Typically a PC (SCADA) acts as the host Can be added as retrofit
Analog + HART Data Control or Asset Management System

Remote I/O can pass p HART commands to the host

Connect to I/O as though it were a modem Read/write all data

Analog

HART Data

Understanding HART g Summary HART is the industry standard instrument communications protocol 90% use HART for only commissioning but are missing the real potential HART is supported by all major instrument and control systems suppliers HART is evolving to meet Users requirements Wireless is the next step p

WIRELESS BUILDING BLOCKS

Working With ISM Bands g Wireless Spectrum and ISM Band

Radio
Frequency
Unlicensed band ISM
(Industrial, Scientific and Medical)

2.4 to 2.5GHz Need to co-exist with other users -15 channels available Available worldwide

Readily available
Standard IEEE802.15.4 Radio

Low Power
Low power = longer battery life

Working With ISM Bands g Coexisting with Other Networks

Need to co-exist with other users of the ISM band

Good worker gets the message through Good neighbor works with alongside networks

Working With ISM Bands g Co-existence Channel hop to avoid busy channels (15 channels) Assess channels before you use them Blacklist channels which have heavy use Transmit for a short period of time (good neighbor) Vary transmit power (security benefit too)

Built into WirelessHART

Wireless Topologies e ess opo og es

Star & Mesh St configuration Star fi ti
Best for control Low data latency Plant unlikely to change

Mesh configuration
Best for reliability Multiple paths Adapts to changing plant

Star

Mesh

Main User Concerns

Make it Reliable
Manage power Process plants change P l t h Need to coexist

Make it Secure
Secure the data Authenticate data and devices

IEC Approved Standard (IEC 62591Ed. 1.0)

Make it Simple
As simple as 4-20mA

Make it Reliable Power is Everything!

High Speed Host Connection

Update rate affects battery life

Batteries will continue to improve p

Power options include

Battery External power Energy scavenging

Features are built in to extend battery life

Smart reporting

Make it Reliable Location in the Mesh and Power

Parents have to route data from children Children can have routing g feature switched off Radio is on for
Routing g Synchronizing Advertising

Pinch point

Make it Reliable Variable Transmission Rates

WirelessHART instruments are time synchronized
Time distribution Time slots

Allows different reporting rates within one mesh Synchronization allows channel h h l hopping i Access and timing is handled automatically! g y

Make it Reliable TDMA - Time Division Multiple Access

Source Now Listening

Ti Time Slot Sl t
1 Slot = 1 Transaction on an assigned channel Dedicated slot (PV update) Shared slot (alarm/events)

Transmission Starts

Transaction

STX ACK

Destination Listens for Start of Message

Destination ACK Starts

Time Synchronization
Common time When a slot begins What channel to use

Slots
Cycle n-1 Cycle n Cycle n+1

Superframe

TDMA Slot-based Communication Slot-

Time synchronization and time slots are handled automatically! y y

Make it Reliable Slot Timing

Start Slot Assessment Switch to Transmit Wait for Receive Acknowledge Acknowledge

Listen CCA

Message g 3 to 4 msec

Switch to receive

10 msec - 1 time slot - 1 channel

1 device can transmit up to 8 PVs plus status in 1 slot y Packet = 133 bytes 250kbit/s

Make it Reliable Smart Reporting - Threshold Triggered

Based on absolute process value
Define Min and Max rates Published on threshold crossing Can trigger on LowHigh Transition or High-Low Transition

PV is ti i time stamped t d Increases battery life

Make it Reliable Smart Reporting - Window Triggered

Windowed operation sends PV when
Dead band exceeded (i.e., (i e process change) Max time between updates exceeded

PV is time stamped Increases battery life

Make it Reliable MESH Network

Self building mesh
Simplifies commissioning Automatic features
Ti Time slot allocation l t ll ti Path selection

Self-healing mesh
Redundant communication paths (no ACK from message) More instruments = more redundant pathways

Make it Reliable Architecture Overview

Devices
Gateway
Builds network and provides host connection

Process connected
Instruments (pressure temperature flow)

Repeaters R
Extend the network

Adapters
Add wireless capability i l bilit

Handhelds / PC tool
Configures instruments to join network

Make it Reliable Gateway

Host interface to WirelessHART
One or more access points to WirelessHART High speed bus access to Host

Contains two vital WirelessHART functions

Network Manager Security Manager

Make it Reliable Network Manager Builds the MESH

Advertises network to new instruments Builds routing pathways
Looks for neighbors and best pathway

Builds communication schedule

Allocates slot times to instruments

Make it Reliable Network Manager Monitor/Report health

Collect performance information
Path statistics End-to-end reliability Signal strength

Collect device diagnostic information

Battery life Device status

Make it Reliable Network Manager

Manages the MESH
Manages complete list of network devices
Live list

Grooms the MESH

New devices M h condition Mesh diti
Network manager web server view

Make it Secure Introduction

WirelessHART ensures secure communications
Security is built-in and cannot be disabled Uses standard AES-128 bit encryption Ease of use (automatic functions) Only the final device can decrypt and utilize the data

Make it Secure Risk Assessment / Reduction WirelessHART networks have two main categories of protection: p
Data Protection
Confidentiality Integrity

Network Protection
Availability

Make it Secure Security Manager Responsible for:

Authentication
White list of devices Message integrity

Encryption
Di t ib t encryption Distributes ti keys
Join S Session i Network

Make it Secure Data Protection

Data Protection
Prevent eavesdropping by unauthorized devices
Secure join procedure Authenticate devices Encrypt messages

Message i t it M integrity
Encrypt the message Has the message been altered en route?

Make it Secure Data Protection Authenticate Instruments Secure network joining

AES 128-bit encryption keeps the joining process pri ate private Join Key
Can be unique to each device or common to the network Authenticates that the device belongs to the network Requires a local device connection

Make it Secure Data Protection Encrypt Messages

The WirelessHART Sensor Network provides:
Individual session keys session = end-to-end
Only the consumer can decrypt the message

Session S i Key A

Modify

Make it Secure Data Protection Check Message Integrity

The WirelessHART sensor network provides:
Message integrity checking
Message Integrity Code (MIC) is unique and is part of each message Receiving device checks data has not been altered.

Security Control

Counter

MIC

Data

Message

Make it Secure Network Protection Unauthorized Devices An unauthorized device tries to join the network Join Key management g
The join key can be changed Use an access control list

Make it Secure Network Protection Replay Attack

Keep the network busy handling data
Read data and repeat it onto the network

The message is ignored

The Counter at the network layer is time slot dependant
The replay has to happen in the same time Security slot (10msec) Counter MIC Data
Control

Message g

Make it Secure Network Protection Denial of Service

Keep the network busy handling data

Saturate the network with authentic looking data Join Requests

Join request ignored

The Network Manager has g list of authorized instruments Needs to be an authorized device d i A counter logs each failed join request alert site security

Make it Secure Network Protection - Monitoring

The network manager monitors unusual network activity
Failed join attempts Excessive retries MIC f il failures Authentication failures

Make it Secure Network Protection

Only the security manager is authorized to issue session, network and j i k d join keys WirelessHART does NOT use TCP/IP, making it safe from many i t internet attacks t tt k

Make it Simple
Reduce Maintenance

Self-Healing Mesh Network

Reduce Engineering

Built i S B ilt in Security it

Make it as Simple as 4-20mA

Self-Building Mesh Network

Reduce Engineering

HART Commands Universal Common Practice Instrument Specific I t tS ifi

Use existing tools and knowledge

Make it Simple
Same people & skill set
4-20mA Device Commissioning Similar work flow to 4-20mA Connect Connect Set Loop wire HHT Range Test Calibration procedure Instrument configuration Handheld and system WirelessHART Device Commissioning g
Power up Connect Set HHT Join Loop Test

Device Commissioning Work Flow is Similar

Summary
HART is the ideal basis for a wireless instrument network
Industry standard Based upon standards 30,000,000 installed devices

WirelessHART addresses Users concerns

Reliable Secure Sec re Simple

It is HART at the core Same Tools Same Instruments Same Same Know How Same people

Backing of major vendors g j

WIRELESSHART HOST INTEGRATION

Host System Communication

Industry Standard Protocols
Ethernet
Modbus TCPIP OPC FOUNDATION Fieldbus HSE ProfiNet Https XML VPN

Serial (RS232/RS485)
Modbus RTU Profibus DP HART/485

Host Data Capacity

Serial Data Capacity
Data telegram size may have a limit (244 bytes Profibus DP)

Controller I/O Capacity

May be based upon TAG limit or memory

Gateway Capacity
May be designed for specific network size

Accessing Cyclic Data

Mapping PV to registers Function blocks or modules

Wireless Cooperation Team - WCT

WirelessHART Mesh Network

Specifications in 2010

Accessing Data On Demand

Gateways may p y y provide separate p connections for cyclic and acyclic data HART configuration or asset management applications send requests to the device via the gateway in an identical manner as it does today using a modem or multiplexer interface.

Summary - Host Integration Host integration

Uses standard high speed networks Map process data at the gateway Cyclic d C li and acyclic i f li information ti available

PLANNING A SUCCESSFUL WIRELESS PROJECT WITH WIRELESSHART

Project Scope j p Network Planning

Organize networks in the same way as wired instruments
By process unit By plant area Usually within wireless range
Typically less than ~250m

76

Project Scope j p Plant Infrastructure Assessment

Walk through of the area Assume worst case for planning Traditional site survey i not is t required

Line of Site 225m Low obstructions 150m Medium Obstructions 75m High Obstructions 30m

85 meters

77

Network Planning 3 Dimensional g Environment

Line of Sight or Low Obstructions

High Obstructions Where many instruments are locate

78

Device Placement Design a Network Minimum 5 Devices

Place devices like wired
Self-Organizing will adapt wireless to process environment Plan to install like wired

Network Minimum of 5 devices

Based on experience Less will work Network becomes stronger with more devices Initial network is an investment in future network
79

Device Placement Field Device Connectivity Best Practice

Each field device has at least 3 neighbors
The 3rd neighbor will act as a backup if one of the two primary paths is obstructed or unavailable

D i Devices mounted >0.5m t d 05 from any vertical surface 1.5m Devices mounted >1.5m off the ground
Only 2 neighbors is okay but not best practice 80

Device Placement Vertical Placement of Devices

Omni-directional antenna Omni directional
Radiates the same power on any horizontal angle

L Less th 45 than

Same distances as horizontal plane

Rule of thumb
<15m high dont worry about it!

81

Device Placement Identify Line Of Sight (LOS) Height

Identify obstruction height
Most devices installed below this height

Identify LOS height

LOS Height = Obstruction Height + 2m Gateways and Repeaters get maximum range when mounted at LOS Height

82

Device Placement Repeaters

Repeaters Over or Around Obstacles Line of Sight
S-31 S-27

LT 100

LT 100
S-35

CY 100

Medium Obstacles
S-32

LT 100

S-33 S-26 S-28

S-30

I-5

LT 101

LT 100

S-29 S 29

LT 100

LT 100

E-16 Building 1

WirelessHART Network Gateway

E-18

E-15

E-11

High Obstacles

S-36

CY 200

83

Device Placement Gateway Location

Three Options
Easiest for Integration Center of Initial Network Center of Process Unit

Rule of Thumb
Plan for connection to 25% of devices communicate directly to gateway Ensures ample connectivity and eliminates pinch points

84

Device Placement Network Expansion

Existing Network is Foundation for Scalability
Add new devices to perimeter of existing network Add new devices to interior of existing network Self-organizing incorporates and expands without disruption

85

Device Placement This is a MESH network

Dont forget this is a mesh Don t network
Instruments do not need to be within the range of the gateway They just need to be close to another wireless instrument

86

Instrument Specification Sheet p Wired HART & WirelessHART

Optional Information: Keys can be preprogrammed or entered in the field. Keys can be changed after commissioning.

Device Specification p Adapter

88

Device Specification p Gateway Specification

Sheet

Wireless Gateway
NO. BY DATE REVISION

1 OF 1
SPEC.NO. SPEC.NO. REQ. BY P.O. REV. DATE

FIELD
CHKD APPR.

TAG: Wireless Protocol: WirelessHART Mounting: Enclosure Class: Flush

Surface

Rack Weather Proof

Other

____________

General Purpose

Explosion Proof Class ____

Operating Temperature Range: Power Supply: Antenna Radio Power

_________________ 220V 50Hz Other ac dc

117V 60Hz

___

volts

Omni-directional Extended Range Remote co-ax cable connection Minimum ___ Maximum ___ ____ devices ____ updates/second (per device)

Wireless field device capacity Minimum device update rate Host Protocols Modbus RTU OPC Other Data Connections: RS485

Modbus TCPIP Profibus DP

Modbus data format: ______________ FF HSE

________________
RS232C Ethernet 10baseT Ethernet 100base-TX

89

Co Commissioning ss o g Commissioning the Network

HART handheld or PC tool will allow you to join instruments to the network
Overlapping networks will have different network IDs

Steps p
Install and power Gateway Install devices one by one
Begin with closest to the gateway STAR or Point-to-Point Communica P i tt P i tC i 90

Commissioning Commissioning a WirelessHART Device

Steps
Install or activate the devices power source Enter the Network ID Enter the Network Join Key Set the refresh (update) rate Verify the device has joined the network
At the device using a handheld or other tool At the gateway

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Commissioning g Verify Device & Network Configuration

Verify Device Operation
Check device TAG Check device engineering units Check PV Update rate Check battery voltage TT-105 Deg C 4 sec 8.75 vdc

Verify Gateway
Check for minimum of 5 direct connections Check for 25% of devices with direct connections in large g networks
<10% add repeaters if necessary

92

Commissioning g Verify Network Operation

After all devices have been commissioned
Allow time for the network to optimize (>4 hours) Check each device for at least 3 neighbors Check path stability
60% minimum Increasing the elevation of the t th antenna can correct t many situations Add repeater if necessary

93

Documentation Wireless Symbols

Wireless Field Device Wi l Fi ld D i
TE 105 TT 105

Adapter with loop powered device p pp

TT 105 YO 105

Adapter Powering 4-20 device

TT 105 YO 105

Gateway
YG 5202 Network ID

Repeater
YA 5202-2

Y, G, A and O are User Defined symbols 94

Documentation Loop Diagram

Gateway Field Device with External g (RTD) ) Sensing Element ( Self-contained Field Device Analog Field Device with g Adapter

Planning a WirelessHART Project g j Summary

Segment your network like you Seg e you e o e would remote I/O Assess the potential communication ranges g Determine gateway and device locations Place repeaters if needed Documentation Commission and let network stabilize Establish security procedures

IEC Approved Standard (IEC 62591Ed. 1.0)

96

USING WIRELESSHART TECHNOLOGY IN PROCESS INDUSTRIES

SUMMARY

Today you discovered. discovered

What WirelessHART can do for you Wh Where wireless solutions can b i l l ti be applied co exists How WirelessHART co-exists with other networks How Security and Reliability is addressed dd d How to plan a wireless project

Now You Know . Why we say WirelessHART is

Simple Reliable Secure

That WirelessHART is designed by and for process monitoring and control applications WirelessHART can be applied to all process industries and to many demanding applications That it can be used to keep YOUR plant competitive!

Now You Also Know . The wiring topologies are flexible either STAR STAR, MESH or a combination Can significantly reduce installation cost to add additional measurements Have many power and power saving options including line power, battery or scavenged power Is supported by most of the leading suppliers pp y g pp Is based on approved international standards It Is Available Today! And,

Attributes of WirelessHART - Summary

Attributes Backward Compatibility with 30 M installed devices Designed by and for the Process Industry Can be used in Hazardous Areas Star & mesh wiring topologies Monitoring AND Control Applications Security - Built in Always On in, WirelessHART

Attributes of WirelessHART - Summary

Attributes International & Industry Standards Number of Devices / network > 10,000 Adaptor to use on existing HART device Reliable Secure Simple p WirelessHART

QUESTIONS AND THANK YOU