applying wireless technologies to industry...

Applying Wireless Technologies to Applying Wireless Technologies to Industry AutomationIndustry Automation

UM 4UM 4thth Annual Network Performance Workshop Annual Network Performance Workshop Ann Arbor, May 13, 2009Ann Arbor, May 13, 2009

Penny Chen Ph.D.Principal Systems Architect

Yokogawa IA Global Marketing (USMK)

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OutlineOutlineIntroductionIntroductionBusiness drivers for wirelessBusiness drivers for wirelessWireless application in Industry Automation (IA) Wireless application in Industry Automation (IA) todaytodayKey challenges for applying wireless for IA (focus Key challenges for applying wireless for IA (focus on Industrial Control Systems)on Industrial Control Systems)Recent direction of wireless standard Recent direction of wireless standard --International Society of Automation (ISA)International Society of Automation (ISA)

Wireless Sensor NetworkWireless Sensor NetworkWireless Backhaul Backbone Network Wireless Backhaul Backbone Network Security Standard (ISA99)Security Standard (ISA99)

Vision of wireless application in IAVision of wireless application in IA

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Yokogawa Yokogawa –– ““GEGE”” of Japanof Japan

Corporate Management (ERP*)Integrated business operation systems

SAP, Oracle etc.

Integration

Production Management (MES*)Systems for advanced control,

simulation, production management, and scheduling

Advanced Process Control & Advance Operation AssistanceAPC & AOA

Exa Series, Trainer Exaquantum

PIMS Process Data Acquisition & Management

* ERP = Enterprise Resource Planning* MES = Manufacturing Execution System

Production Control SystemProduction control systems

Field InstrumentsField instruments, sensors, measuring

instruments, analyzers and other equipment

InstrumentationFieldbus NetworksFF, Profibus-DPDeviceNet, Ethernet/IP

Gas Chromatography Analytical Instruments

O2,pH,ISC

Hybrid RTU/SCADA SystemIntegrated Production Control-Safety Instrumented System

CENTUM CS 3000

DCS/SIS

GCNIR

Prosafe RS

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“ As a result of Yokogawa’s high R&D investment and the consistent long term migration policy of the CENTUM DCS family our investment are secure ”

Reliable Distributed Control SystemsReliable Distributed Control Systems

CFFS

HF-Bus

CFCS

COPSF-Bus

250 KBPSDual

RedundantToken Pass

CENTUM

CFCD

1MBPSDual

RedundantToken Pass

CENTUM-XL

EOPS

CFCS EFCD

ENGSPFCS

KFCSLFCSCOPS2

CENTUM V

CFCS2

COPSV

CFCD2

ABC

CENTUM CS

ICS

EWS PICS

V net

10 MBPSDual

RedundantToken Pass HIS

CENTUM CS 3000

AVR

FFCS

HIS

CENTUM CS 3000 R3

HIS

CENTUM VP

Vnet/IP

Christian VermumManager of Electrical Engineering Department Degussa Oxpeno, Germany

2008

1975

1983 1988

1998

2001 2005

1993

FFCS

1Gbps Dual

Redundant

••Unique Pair & Spare reliability technologyUnique Pair & Spare reliability technology

••Seven 9Seven 9’’s (99.9999959) availabilitys (99.9999959) availability

••20,000 systems installed worldwide20,000 systems installed worldwide

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Why Wireless for Industry Automation?Why Wireless for Industry Automation?

Because I always know where my signals are going!

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InstallationsInstallations

Simple starting point, Open space

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Middle of no where, Unmanned

88


Small world that miles away from coast

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Case StudyCase Study

Mountain provides challenge as well as opportunity

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Many high points available above the congestion

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Large tank farm covers hundreds of miles

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Longest shot, wharf to mountain-top tower

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Business Drivers for WirelessBusiness Drivers for Wireless

Staying competitive in digitalization is Staying competitive in digitalization is essentialessentialIndustrial wireless drives down the Industrial wireless drives down the cost of digitalization (e.g. design cost, cost of digitalization (e.g. design cost, material cost, installation cost, material cost, installation cost, maintenance cost, etc.)maintenance cost, etc.)Industrial wireless opens new Industrial wireless opens new opportunities, new demands, new opportunities, new demands, new angle to do businessangle to do businessLots of successful wireless application Lots of successful wireless application stories, lots of tangible benefitsstories, lots of tangible benefits

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Wireless Opens New Opportunities Wireless Opens New Opportunities ––Wireless MeasurementsWireless Measurements

Enhanced Plant Asset Management (PAM)Enhanced Plant Asset Management (PAM)Cost effectively increase process and asset monitoringCost effectively increase process and asset monitoring

Freeing up cable resource for higher priority measurementsFreeing up cable resource for higher priority measurements

Allows measurements that could not be justified beforeAllows measurements that could not be justified before

Reduction of Reduction of ““blind spotsblind spots”” –– higher visibility into higher visibility into operationsoperations

Allows measurements on rotating and/or moving Allows measurements on rotating and/or moving equipmentequipment

Wiring difficult Wiring difficult -- no power availableno power available

Allows measurements in remote locationsAllows measurements in remote locations““UnlockUnlock”” remote processing units in general remote processing units in general ––well heads, tank well heads, tank farms, loading bridges e.g.farms, loading bridges e.g.

Temporary measurements for process diagnostics and Temporary measurements for process diagnostics and optimizationoptimization

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Wireless Opens New Opportunities Wireless Opens New Opportunities ––Wireless Camera & MobilityWireless Camera & Mobility

Field inspection data gathering and sharing using Field inspection data gathering and sharing using mobile devices anywhere anytimemobile devices anywhere anytime

Bring global virtual field environment to control centerBring global virtual field environment to control centerVideo stream bring field virtually Video stream bring field virtually ---- Pipeline FacilitiesPipeline Facilities

Local indicator measurement data collectionLocal indicator measurement data collectionHistoric process data trend (last 8 values)Historic process data trend (last 8 values)

Visual inspection & repair management of any Visual inspection & repair management of any equipment in the fieldequipment in the field

Valves, pumps, leakages, dangerous situations in generalValves, pumps, leakages, dangerous situations in general

Time stamping & reportingTime stamping & reporting

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Wireless Opens New Opportunities Wireless Opens New Opportunities ––Wireless Location Aware & Asset ManagementWireless Location Aware & Asset Management

RTLS/RFID RTLS/RFID Location Aware Safety System (LASSLocation Aware Safety System (LASS™™))

Provider Safety alarm for field personnelProvider Safety alarm for field personnel

Mobile warehouse & mobile maintenanceMobile warehouse & mobile maintenanceFuel trucks tracking Fuel trucks tracking RFID tag based remote workforce managementRFID tag based remote workforce management

RFID concept is guiding mobile worker RFID concept is guiding mobile worker –– Task TrackerTask Tracker

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Industrial RequirementsIndustrial Requirements

Mission CriticalMission CriticalContinuous OperationContinuous OperationLarge EnergyLarge EnergyExtraordinary IncidentExtraordinary Incident

Harsh EnvironmentHarsh EnvironmentAmbient ConditionAmbient ConditionExplosive GasExplosive GasStrong EM NoiseStrong EM Noise

System AttributeSystem AttributeWide AreaWide AreaLarge ScaleLarge ScaleComplexComplexLong Plant Life TimeLong Plant Life Time

ReliabilityReliabilityRobustnessRobustnessQuick ResponseQuick ResponseRegulatory ComplianceRegulatory Compliance

ScalabilityScalabilityFlexibilityFlexibilityMaintainabilityMaintainability

+ Wireless Property+ Wireless Property

Characteristics Requirements

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2020

Landscape of Wireless TechnologiesLandscape of Wireless Technologies

IEEE 802.15.4

Different wireless technology has its characteristics Different wireless technology has its characteristics that can be best suited for particular applicationsthat can be best suited for particular applications

2121

Blanket the Facility with RF EnergyBlanket the Facility with RF Energy

2222

Current Challenges for Wireless ApplicationCurrent Challenges for Wireless ApplicationImplemented as silosImplemented as silos

Inconsistent common security Inconsistent common security -- Authentication, Authorization, Authentication, Authorization, EncryptionEncryptionInconsistence network serviceInconsistence network serviceSpotty supportSpotty supportLacks endLacks end--toto--end data supportend data support

No uniformed implementationNo uniformed implementationUnable to leverage scale, difficult to replicate success Unable to leverage scale, difficult to replicate success Higher support cost Higher support cost Unreliable Unreliable

Entry cost is high Entry cost is high –– first application pays the toll for first application pays the toll for backbonebackboneApproached as infrastructure solution rather than overall Approached as infrastructure solution rather than overall integrated system solutionintegrated system solution

2323

OpennessEasy Deployment

Scalability

Reliability

Technical Technical IssueIssuess

Multi-function

Security, Robustness,Fault tolerance, Co-Existence, …

Small & Large,Radio range,Throughput, …

Interoperability,Global Standardization, …

Installation, Management,Maintenance, Power, Lifetime…

Multi-protocol,Use case coverage, Latency, …

Individual Tech. is ready,but Balance is needed

http://images.google.co.jp/imgres?imgurl=http://www.fotosearch.jp/thumb/ARP/ARP115/Battery.jpg&imgrefurl=http://www.fotosearch.jp/illustration/%25E5%258A%259B-%25E6%25BA%2590.html&h=120&w=64&sz=4&hl=ja&start=9&tbnid=2CMyDoVgSPkmtM:&tbnh=88&tbnw=47&prev=/images%3Fq%3D%25E9%259B%25BB%25E6%25B1%25A0%25E3%2580%2580%25E3%2582%25AF%25E3%2583%25AA%25E3%2583%2583%25E3%2583%2597%25E3%2582%25A2%25E3%2583%25BC%25E3%2583%2588%25E3%2580%2580%25E3%2582%25A4%25E3%2583%25A9%25E3%2582%25B9%25E3%2583%2588%26gbv%3D2%26svnum%3D10%26hl%3Dja

http://images.google.co.jp/imgres?imgurl=http://www.fotosearch.jp/thumb/OMU/OMU118/01P0207.jpg&imgrefurl=http://www.fotosearch.jp/illustration/%25E3%2583%25A1%25E3%2583%2580%25E3%2583%25AB.html&h=120&w=75&sz=3&hl=ja&start=6&tbnid=495HrwmdlzI73M:&tbnh=88&tbnw=55&prev=/images%3Fq%3D%25E3%2583%25A1%25E3%2583%2580%25E3%2583%25AB%25E3%2580%2580%25E3%2582%25A4%25E3%2583%25A9%25E3%2582%25B9%25E3%2583%2588%26gbv%3D2%26svnum%3D10%26hl%3Dja

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Security Issues in ICSSecurity Issues in ICSCharacteristicsCharacteristics

Poor Authentication and AuthorizationPoor Authentication and AuthorizationMany fields devices lack crypto supportMany fields devices lack crypto supportMany unmanned field sites can be easy backdoor to the Many unmanned field sites can be easy backdoor to the control centercontrol center

Availability, Integrity and ConfidentialityAvailability, Integrity and ConfidentialityEnterprise networks require CEnterprise networks require C--II--AA

Confidentiality of intellectual property matters mostConfidentiality of intellectual property matters most

ICS requires AICS requires A--II--CCAvailability and integrity of control matters mostAvailability and integrity of control matters mostControl data has low confidentialityControl data has low confidentialityMany ICS vendors provide Five to Seven 9Many ICS vendors provide Five to Seven 9’’s of availabilitys of availability

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QoS & Priority of Service (QoS & Priority of Service (PoSPoS))QoS are determined by a traffic classQoS are determined by a traffic class’’s tolerance to:s tolerance to:

Delay Delay ---- How much delay in packet delivery can be tolerated?How much delay in packet delivery can be tolerated?Loss Loss ---- To what degree can packet loss be tolerated?To what degree can packet loss be tolerated?Jitter Jitter ---- How much variability in packet delay be tolerated?How much variability in packet delay be tolerated?

PoSPoSApplication L3 Classification

DSCPPHB RFC

Low-Latency Data 18AF21 RFC 2597Broadcast Video 24CS3 RFC 2474

Real-Time Interactive 32CS4 RFC 2474

Call Signaling 40CS5 RFC 2474VoIP Telephony 46EF RFC 3246

OAM 16CS2 RFC 2474

IETF

High-Throughput Data 10AF11 RFC 2597

Low-Priority Data 8CS1 RFC 3662

Network Control 48CS6 RFC 2474

Multimedia Streaming 26AF31 RFC 2597

Best Effort 0DF RFC 2474

Multimedia Conferencing 34AF41 RFC 2597

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Emerging Wireless RequirementsEmerging Wireless Requirements

(WiMAX, Cellular, Satellite)

(802.11, Optical wave)

(802.15.4, 802.11,UWB, RFID)

A variety of wireless technologies have been or is going to be deployed for different type of applications in mix environment.• RFID, UWB – asset tracking and location awareness• ISA100.11a, Wireless HART –field sensor wireless• 802.11a/b/g/n – multimedia applications for data , video, VoIP• WiMAX, Cellular, Satellite –middle and long range data carrier

The key successful elements for wireless solutions are:• Interoperability• End-to-End Security • End-to-End QoS

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Success Criteria for WirelessSuccess Criteria for WirelessCommon BackboneCommon Backbone infrastructure supporting infrastructure supporting all wireless applications all wireless applications Appropriate PrioritizationAppropriate Prioritization and and QoSQoS for for application classesapplication classesWorks with Works with Many Transports MediasMany Transports MediasCommon SupportCommon Support ServicesServices such as such as Authentication, Authorization, AdministrationAuthentication, Authorization, AdministrationCommon ManagementCommon Management backhaul with one HMIbackhaul with one HMIProvide Robust, SecureProvide Robust, Secure communications for all communications for all wireless applications wireless applications Low Initial Entry CostLow Initial Entry CostCost Effectively Cost Effectively support of less dense support of less dense applications (Tank Farms, Perimeter Security, applications (Tank Farms, Perimeter Security, Gate Systems)Gate Systems)Future ApproveFuture Approve

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Why Standard?Why Standard?

Because somebody will always invent an adapter

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ISA100.9 User GuideMarty Zielinski

ISA100.8 Users WGJim Reizner & Dick Caro

ISA100.5 Co-existencePat Kinney & Peter Fuhr

ISA100.6 InteroperabilityHesh Kagan

ISA100.2 - TRECTom Phinney & Sicco Dwars

ISA100.10 MarketingPaul Sereiko & Larry Pereira

ISA100.7 NetworkingJosé Gutierrez & Mike Mets

ISA100.14 Trustworthy WirelessWayne Manges & Scott Mix

ISA100.21 People & Asset Tracking & IdentificationPeter Fuhr & Nacer Hedrong

ISA100.12 WirelessHART ConvergencePaul Sereiko & Dick Caro

ISA100.1 - Integration and Ongoing Study GroupDan Sexton & Rick Enns

ISA100.15 Wireless Backhaul Backbone NetworkPenny Chen & Dave Glanzer

ISA100.3 ISA100.11aPat Kinney & Dan Sexton

ISA100.16 Factory AutomationJim Reizner & Cliff Whitehead

SP100Wayne Manges & Patrick Schweitzer

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ISA100 OverviewISA100 Overview

A Complimentary Family of Standards that Accommodate your Plant-wide Needs

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Two major field sensor wireless solutionsTwo major field sensor wireless solutionsISA100.11aWirelessHART

3333

802.11a/b/g/n

OthersUWB

RFID

ISA100.1

1a

Wireles

sHART

Sate

llite

Opt

ical

W

ave

WiM

AX

Cel

lula

r

Oth

ers

Control Network

Network Common InterfaceT T T T T

T=Protocol Translator

ISA

100.

15

ISA100.15 Wireless Backhaul Network WGISA100.15 Wireless Backhaul Network WGMission:Mission:

The ISA100 Wireless Backhaul Backbone Network The ISA100 Wireless Backhaul Backbone Network Working Group will develop and maintain a standard to Working Group will develop and maintain a standard to address one or more dedicated or shared wireless address one or more dedicated or shared wireless backhaul backbone to support one or more technologies, backhaul backbone to support one or more technologies, running multiple applications. running multiple applications.

Focused on: Focused on: Interoperability Interoperability EndEnd--toto--End Security End Security EndEnd--toto--End QoSEnd QoS

Cooperation with FFCooperation with FF

3434

ISA99 Security StandardISA99 Security Standard

ISA99 ISA100ISCI

WG4: Technical Requirement

WG1: Security Technologies

WG2: Implementing

Security

IEC/ISO NISTDHS

Certification

WG3: Audit and Metrics, Common Language

and Model

TG2: Foundational Requirement

TG4: Derived Requirement

TG3: Zone Conduit

TG5: Security Matrix

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ISA Compliance InstitutesISA Compliance Institutes

ISA ASCI

ISA Security Compliance Institute

Security Interest GroupSafety

Wireless Compliance Institute

Professional Management Services

Allocated ServicesExpertise From ISA

Other InterestGroups

Sponsored Interest Groups

Governing Board

Technical Steering Committee

Working Groups

Governing Board

Technical Steering Committee

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Wireless Digital Umbrella VisionWireless Digital Umbrella Vision

Integrated Solution to Provide Common Service for All Integrated Solution to Provide Common Service for All Wireless ApplicationsWireless Applications

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High Security Network ArchitectureHigh Security Network Architecture

C200 Controller

Process Control

Supervisory Control

Level 1

Level 4

Level 3

Level 2

BCKSvr

DMZ

DomainController &

IAS

Data Syn Svr

Level 3.5OS Patch & Virus

ProtectionSrv

TerminalServices

SrveServer

Switch Pair

Switch Pair

Switch Pair

Switch Pair

DVM PHD/S

PKS Svrs

NIM

ES-T

ESVT

PHD

LCN

FSCPMFamily

Advanced Control

PHDS

L1 to L1 Lim

ited

L2 to

L1

L2 to L2

L3 to L3

Lim

ited

L2 to

L3

Limited L3.5 to L3.5

Very

Lim

ited

L3

to L

3.5

Very

Lim

ited

L2 to

L3.

5

Comm flowL4 to L4

Very

Lim

ited

L3

.5 to

L4

No

Dire

ct c

omm

unic

atio

ns b

etw

een

L4 &

L3

or L

2N

o co

mm

unic

atio

ns b

etw

een

L1 &

L3

or L

4

NON-FTE redundancy

FTE

NON-FTE redundancy

Optional Router depending on PCN complexity (may connect directly to FW)

Control Firewall

Pair

C300 Controller

ACE ESF ESC DC

FTE

Level 3.5 Wireless DMZBusiness

LAN

•DMZ = Demilitarized Zone

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Lots of Issues ==

Lots of Opportunities

Thank you!

For more information, please contact:[email protected]

applying wireless technologies to industry...

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