802.11 for plant-wide optimization and process automation chuck nehonsky east central region

802.11 for Plant-Wide Optimization

and Process AutomationChuck NehonskyEast Central Region

Wireless Applications

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Oil & Gas

Factory Automation Mining, Materials & Cement

Water & Waste Water• Pipeline Monitoring• Pump Control• Refinery Automation• Off-shore Platform• Drilling & Fracturing

Energy & Utilities

• Water Treatment• Well, Lift Station, Pump

& Tank Control

• Packaging• Bottling• Crane Control• Robotic Automation• Inventory Retrieval

• Stacker / Reclaimer• Metal Refining• Open Pit & Strip Mining• Underground Mining

• Automatic Meter Reading• Load Management• Substation IED Communication• Wind Farm• Nuclear Power

ProSoft Technology Confidential

Topics for Today

• Overview• Challenges of Industrial wireless networks• 802.11 technologies that help• Security

• Basics we need to know about the application• Performance requirements – data!• Network layout• Physical environment

• Application ExamplesProSoft Technology Confidential

ProSoft Technology Industrial Wireless solutions

Industrial Wireless Solutions

• Ethernet & Serial modems

900 & 2.4 GHz (license free) Frequency Hopping

• Cellular modems

GSM / GPRS / 3G Serial / Ethernet

• Industrial Hotspot

Wi-Fi compliant 802.11abgn IP 66 / 67 version

Copyright © 2014 ProSoft Technologies

License Free Wireless Choices

License Free Wireless Choices Frequency Hopping - 900 MHz & 2.4 GHz

802.11 a/b/g/n - 2.4 GHz & 5 GHz

Frequency Hopping vs. 802.11 (Wi-Fi)• Slower data rates, up to 1Mb/s. Very fast data rates, Up to 300 Mb/s.• High power Need good line of site.• Great Distances up to 30 miles. Distances up to 10-15 miles.

Copyright © 2014 ProSoft Technologies

Industrial Wireless ChallengesMust be reliable & secureCo-exist with other wireless systemsCommunicate in and around metal structuresSupport industrial protocols & update timesSupport motion and mobilityUseful diagnosticsHarsh environments/certificationsIT Involvement – early & often


802.11b/g Frequency Channels.

How 802.11 b/g Works:• A channel is centered on frequency.• Data sent in 1 channel.

US: 11 Channels availableEurope: 13 Channels availableUsing Channel 1,6 11 avoid overlapping

1 2 53 4 76 8 131211109

2.412 Ghz 2.437 Ghz

3 Mhz

2.462 Ghz

1 6 11

3 Mhz


RF Bands –5 GHz

802.11 a/n Frequency Channels

5.150 to 5.825GHz – 700MHz of Bandwidth

Over 20 non-overlapping channels in 5 GHz band


Along comes 802.11n

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RF Rates 6-54 Mbps 6-450 Mbps

• Antennas 1(2) 1 - 4

• Bands g (2.4GHz) ng (2.4GHz)a (5 GHz) na (5GHz)

• UDP Stream 3,500 pps 13,000 pps

• E/IP Implicit Rates 1,000 pps 4,000 pps

Feature 802.11a/g 802.11n

• MIMO • Channel Bonding• Streams• Multipath


802.11n – Streams

Streams

• 802.11n radios can send 1, 2 or 3 streams of data at a time if the conditions are right.

• At least 2 antennas must be connected to each radio.

• Multipath is important to keep the streams separate – the different streams take (slightly) different paths

• The packet is divided between the streams to speed data transfer.

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Stream 1

Stream 3

Stream 2


802.11n – MIMO Antennas

Multiple Input Multiple Output (MIMO)One antenna, three elementsIntentionally creates multiple paths (reflections)Required for multiple streamsThree antenna leadsOmni-directional & directional

11 ProSoft Technology Confidential

MIMO applications

• All mobile applications• Applications with lots of reflections

• Video (high throughput)• Close range fast PLC applications• All 802.11n applications


802.11n – Channel BondingChannel Bonding

• 2 Adjacent Channels can be used at the same time

• Twice the data can be sent at a time

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Ch. 36 Ch. 40

40MHz

Bonded

20MHz 20MHz


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Security components Authentication – allow those certified Encryption – scramble data to make it unreadable Integrity – protect against false data

Standards Progression WEP 64 & 128 (2000) – Weak, known faults WPA – TKIP (2004) – Software patch to WEP WPA2 – AES (2006) – Robust standard

adopted by NIST & US Govt., approved by NSA for secure communications

802.11i & WPA2 Passphrase – WPA2-PSK RADIUS Service – WPA2-Enterprise

802.11 Security


802.11 Security

• WPA2 / IEEE 802.11i• Replaces WEP/WPA with 128 bit AES encryption• Shared key – manually entered or RADIUS server

• VLAN – limit user access to only needed systems

• MAC ID access list – limits connections• SSID beacon can be turned off - stealth• Limit range / direction to limit detection

• Security --- TURN IT ON!


Security Settings

Encryption and WPA phrase must be the same in all radios on the network. WPA phrase is the key

used to encrypt the data. MAC filtering allows an extra layer of

security by specifying which devices based on

MAC ID can link to a radio

Hide Network SSID – when checked the prevents the radio

from broadcasting its Network SSID


• Antennas• Antennas are passive• Focus radio Energy – NOT amplify it• Work equally well transmitting or receiving

RF energy• Proper alignment is usually the only

necessary consideration• Mount Omnis above/below metal or 1m from

metal• Select directional antennas if you need to

• Avoid other networks• Increase gain to compensate for path loss• Avoid Multi-path

System Design – Antennas


Path Study• GPS coordinates• Digital terrain data• Paths feasible?• Antenna height• Repeaters? Location• Performance

prediction

ProSoft Technology

Fodderstack RepeaterLatitude 36 06 27.02 NLongitude 084 24 54.04 WAzimuth 42.95°Elevation 3330 ft ASLAntenna CL 40.0 ft AGL

PeeweeLatitude 36 13 51.51 NLongitude 084 16 22.92 WAzimuth 223.04°Elevation 2963 ft ASLAntenna CL 40.0 ft AGL

Frequency (MHz) = 2400.0K = 1.33

%F1 = 50.00

Path length (11.64 mi)

0 1 2 3 4 5 6 7 8 9 10 11

Ele

va

tio

n (

ft)

1000

1500

2000

2500

3000

3500


Radiating Cable SystemRadiating Cable (RC)

RF transmitted through slots cut into the shield (under the insulation)

Acts as a long, flexible antenna

Provides uniform RF signalingalong monorail tracks

Solves line-of-sight challenges incorridors and tunnels

Supports 802.11 2.4 GHz and 5 GHz wireless systems

Moving equipment/machines/platforms

Confined spaces

Monorail systems

Tunnels with turnsProSoft Technology Confidential

FAST ROAM TechnologyFast Roam between Access Points

Less than 50 msec roam time

Bridging – multiple Ethernet devices on machines/carriers

No Wireless Controller required

Overhead Cranes

Automotive Assembly

Automatic Guided Vehicles


Wireless PLC & I/O

High speed 802.11nWireless integrated I/OMobile Worker

-

ENBT

RLX2 802.11g/n Access Point

RSLogix 5000

RLX2 802.11g/n Access Point

** When Applying Wireless

• Familiarity with wireless applications• How will the end devices communicate• Single, multiple , alternative paths

• What the protocol• CIP, Modbus, etc

• What is the throughput requirements• I/O , Safety, Video

• What Channels and frequency• 2.4 GHZ, , 5 Ghz, cellular


** Network Layout• Will Radio be installed outside / inside

• Environment consideration

• Coverage Area

• Type of devices (roaming)

• How many sites

• Security


** Path Layout

• Line of Site

• Obstructions (high, wall, etc.)

• Site Survey and who will do it

• Tools that are available

• Antenna Selection

• Site restrictions (height , mobile devices, etc)


ICX30-HWC Cellular Gateway

AT&T / Verizon

Single 3G platform support of HSUPA & CDMA

Ethernet & Serial ports

1 Analog input, 2 Discrete inputs/outputs (programmable)

EtherNet/IP object - SMS, I/O access & Diagnostics

Remote configuration

Extended temp operation & hazardous locations

Micro 830 SMS

Micro 830 SMS Text Module Has certifications/productionCountries: US, India, Australia, Brazil, EU

CONFIDENTIAL - INTERNAL USE ONLY

Wireless I/O (NEW)

What it is and what it is not:Replaces traditional I/O wiring runs

Made for monitoring and simple controls – not high speed I/O

Not networked I/O, needs I/O interfaces at PLC, RTU etc.

Copyright ©2015 ProSoft Technology, Inc. All rights Reserved. COMPANY CONFIDENTIAL

Bi-Directional

Specifications (NEW)

US/North Am: 900 MHz, 250mWUp to 4 miles

US/International: 2.4 GHz (2400 MHz) 63mW US, 10mW InternationalUp to 1 mile

Australian: 915 MHzUp to 6.5 km

Receiver Sensitivity: 900 MHz -101dBm, 2.4 GHz -100 dBm

RF Security: 128 bit AES

Operational Temp: -40C to 85C

Environmental: UL Class 1 Div 2, ATEX Zone 2

All Boards Conformal Coated


All I/O Modules Provide Isolation 2500 V r.m.s.

I/O Modules (NEW)

3-30 VDC Digital

4 In / 4 Out


4-20mA Analog2 In / 2 Out

0-10 V Analog2 In / 2 Out

System supports up to 16 Pairs* (NEW)


* Number of I/O modules limited by backplane power. Consult power budget calculator.

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Path Studies & Surveys

Part Selection Field Knowledge

Training• Path Studies• Site Surveys• Customer site

support

• Conferences• Webinars• Videos• Training Classes• Tech Notes

• 100+ Accessories• ProSoft Wireless

Designer• Pre-sales free

phone support

• EtherNet/IP• Modbus TCP• Profibus & Profinet• SCADA• FH, Cellular, 802.11

Expertise

ProSoft Technology

Fodderstack RepeaterLatitude 36 06 27.02 NLongitude 084 24 54.04 WAzimuth 42.95°Elevation 3330 ft ASLAntenna CL 40.0 ft AGL

PeeweeLatitude 36 13 51.51 NLongitude 084 16 22.92 WAzimuth 223.04°Elevation 2963 ft ASLAntenna CL 40.0 ft AGL

Frequency (MHz) = 2400.0K = 1.33

%F1 = 50.00

Path length (11.64 mi)0 1 2 3 4 5 6 7 8 9 10 11

Ele

va

tio

n (f

t)

1000

1500

2000

2500

3000

3500

ProSoft Technology Confidential - For Internal Use Only

Consumer Products – Slip Ring Replacement

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Filler slip ring replacementChallenge¨ Rotating machine: Constant and severe twisting of

the Ethernet cables results in fatigue and failure¨ Significant downtime attributed to cable

troubleshooting and repair¨ Attempts to improve with heavy duty cabling

Solution Details¨ ControlLogix Processor at central control¨ CompactLogix on each Filler Head¨ 802.11a Wireless to rotating machine

Benefit¨ Redundancy & fewer dropped packets¨ No downtime associated with communication errors¨ IT team buy in and involvement

Rockwell Technology:

• ControlLogix• CompactLogix

802.11a


Water Treatment - Process

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Challenge¨ 10 Remote MicroLogix up to 1,500 feet away¨ Wireless Laptops for plant workers

Solution Details¨ CompactLogix Processor at central control room¨ MicroLogix 1100 on each clarifier arm¨ RLX-IHW-66 802.11a/g

Benefit¨ Ease of installation¨ Communication with mobile workers¨ Low cost of installation

Rockwell Technology:

• CompactLogix• MicroLogix1100

802.11


Oil & Gas Production

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Challenge¨ Distance – Covers > 12 sq. mi.¨ More than 100 sites monitored¨ 3,500 Discrete & 1,000 Analog I/O¨ Enhanced Oil Recovery Waterflood¨ Monitor pressure & flow

Solution Details¨ 4 ControlLogix Concentrators¨ 100+ MicroLogix 1100¨ Central SCADA – Production Models¨ 100+ High Power 802.11b radios and repeaters

Oil & Gas Production


Iron Foundry Crane Control

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Challenge¨ Accurately relay material composition for ISO records.¨ Communications with mobile cranes via wire unreliable.

Solution details¨ PLCs installed on each crane to collect data¨ Touch screen HMI added for data verification¨ 802.11a/g Radios installed for ethernet comms

Benefit¨ Enabled crane to crane communications¨ Material composition sent direct to data base¨ Increased production throughput 50%

802.11


Global Tech Support


North AmericaLanguages spoken: English, Spanish

[email protected]

Europe / Middle East / AfricaLanguages spoken: French, EnglishPolish, Russian, German

[email protected]

Asia PacificLanguages spoken: Chinese, English

[email protected]

Latin America (Brasil)Languages spoken: Portuguese, English

[email protected]

Latin America (Spanish Speaking Countries)Languages spoken: Spanish, English

[email protected]

*

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802.11 for plant-wide optimization and process automation chuck nehonsky east central region

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