wireless automation in process monitoring and control · wireless automation for process monitoring...

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Dr. Stefan Ochs, BTS GmbH, Seite 1 March, 12 th 2009 Stefan Ochs, Bayer Technology Services, Leverkusen Martin Schwibach, BASF SE, Ludwigshafen 8. VDI Jahrestagung Wireless Automation 2009 Wireless Automation in Process Monitoring and Control NAMUR Recommendation NE124

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March, 12th 2009Stefan Ochs, Bayer Technology Services, LeverkusenMartin Schwibach, BASF SE, Ludwigshafen

8. VDI JahrestagungWireless Automation 2009

Wireless Automationin Process Monitoring and ControlNAMUR Recommendation NE124

Wireless Automation for Process Monitoring and Control

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NAMUR - Info

www.namur.de

Wireless Automation for Process Monitoring and Control

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NAMUR Recommendation NE 124

Wireless Automation for Process Monitoring and Control

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Source: Advisory Group ARC

Market Trends: Vendor’s ForecastMarket Trends: Vendor’s Forecast

Use of Wireless Automation in Process Industry

Wireless Automation for Process Monitoring and Control

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Source: Process Marktübersicht 2007

Only for Specialties

28,5 %

Extended Market Penetration within 5 years57,1 %

No Chance3,6 %

Use of Wireless Automation in Process Industry

Market Trends: User’s ExpectationsMarket Trends: User’s Expectations

Wireless Automation for Process Monitoring and Control

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Wireless HART

Relevant Technologies and Standards

The very attractive resource “license free ISM band” is limited because of the great number of possible applications The very attractive resource “license free ISM band” is limited because of the great number of possible applications

Most applications use license free ISM bandsMost applications use license free ISM bands

Long term management for the coexistence of different applications must be established Long term management for the coexistence of different applications must be established

Wireless Automation for Process Monitoring and Control

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Motivation and Use Cases

Substitution of cableReduced installation costsConnection of “difficult topologies” (e.g. flare systems, tank farm ..)No abrasion (trailing cables, collector ring) by moving objects

Substitution of cableReduced installation costsConnection of “difficult topologies” (e.g. flare systems, tank farm ..)No abrasion (trailing cables, collector ring) by moving objects

MobilityMultiple use of solutions for different applicationsUse of information all over the plant

MobilityMultiple use of solutions for different applicationsUse of information all over the plant

FlexibilityTemporary applicationsDifficult accessWiring is a constraint

FlexibilityTemporary applicationsDifficult accessWiring is a constraint

Mobile Process Operation

Mobile Process Operation

Sensor Networks

Mobile ComputingMobile Computing

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NAMUR recommendation NE124 …

Basic ConditionsBasic Conditions

addresses not only one technology (e.g. wireless sensor networks)addresses not only one technology (e.g. wireless sensor networks)

focuses on core characteristics:Reliability Availability Beneficial Use Cases

focuses on core characteristics:Reliability Availability Beneficial Use Cases

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NAMUR recommendation NE124 …

General AmbitionsGeneral Ambitions

… define requirement for wireless communication in process automation

… define requirement for wireless communication in process automation

… define minimal requirements of technologies and devices… define minimal requirements of technologies and devices

… give hints and advise for use cases… give hints and advise for use cases

prevent loss of investmentdrive technical developments more targetedsimplify engineering and operation

prevent loss of investmentdrive technical developments more targetedsimplify engineering and operation

Major GoalsMajor Goals

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Use classes according NE124

Use Class C (Monitoring)no time critical applicationsno process interaction

Use Class C (MonitoringUse Class C (Monitoring)no time critical applicationsno process interaction

Use Class B (Process Control)deterministic real time applicationshigh requirements for availability and reliabilityprocess interaction possible

Use Class B (Process Control)Use Class B (Process Control)deterministic real time applicationshigh requirements for availability and reliabilityprocess interaction possible

actual available technologies meet Use Class CUse Class C

Use Class A (Functional Safety)time critical real time applicationsstrictly deterministic properties

Use Class A (Functional Safety)Use Class A (Functional Safety)time critical real time applicationsstrictly deterministic properties

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General Requirements according NE124

Diagnostics: unified, significant status informationDiagnostics: unified, significant status information

Energy Supply: maintenance, etc.Energy Supply: maintenance, etc.

Lifecycle Management: upward and downward compatibilityLifecycle Management: upward and downward compatibility

Interchangeability: keeping standards, etc.Interchangeability: keeping standards, etc.

Interoperability: no proprietary enhancements, etc.Interoperability: no proprietary enhancements, etc.

Security: access control, encryption, etc.Security: access control, encryption, etc.

Real Time Ability: latency, etc.Real Time Ability: latency, etc.

Reliability: bit error rate etc.Reliability: bit error rate etc.

Availability: radio range, etc.Availability: radio range, etc.

Wireless Automation for Process Monitoring and Control

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Engineering

Engineering ToolsEngineering Tools

One Tool for different Technologies (WLAN, Sensor Networks …)One Tool for different Technologies (WLAN, Sensor Networks …)

3 dimensional scenarios / topologies have to be considered3 dimensional scenarios / topologies have to be considered

Simulation of different scenarios (login, roaming/handover, etc.)Simulation of different scenarios (login, roaming/handover, etc.)

Easy and complete documentation (transmission power, location, network addresses, needed bit rate …)Easy and complete documentation (transmission power, location, network addresses, needed bit rate …)

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Operation & Maintenance

Easy OperationEasy Operation

configuration by standard tools according NE 105configuration by standard tools according NE 105

Network components without process impact should be integrated transparentlyNetwork components without process impact should be integrated transparently

local diagnostics according NE107local diagnostics according NE107

No loss of configuration data after energy outageNo loss of configuration data after energy outage

NE105: Specifications for Integrating Fieldbus Devices in Engineering Tools forField Devices

NE 107: Self-Monitoring and Diagnosis of Field Devices

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Certification

Quality Management: certification procedures assureQuality Management: certification procedures assure

vendor independencevendor independence

standard compliancestandard compliance

efficient Life Cycle managementefficient Life Cycle management

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Coexistence of ApplicationsCoexistence of Applications

Open questions☯ NE124 Requirements

To establish the wide use of Wireless Automation in process industry, vendor has to provide unique, consistent and assessable KPI’s and criteria for:

To establish the wide use of Wireless Automation in process industry, vendor has to provide unique, consistent and assessable KPI’s and criteria for:

Real Time Capability of Wireless InfrastructuresReal Time Capability of Wireless Infrastructures

Availability and Reliability of Wireless SolutionsAvailability and Reliability of Wireless Solutions

Long Term Energy SupplyLong Term Energy Supply

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Most technologies for process automation uses the license free frequency ISM bands.

But: everybody uses that and bandwidth is limited

Most technologies for process automation uses the license free frequency ISM bands.

But:But: everybody uses that and bandwidth is limited

do basic technologies coexist (WLAN, bluetooth …) ?do basic technologies coexist (WLAN, bluetooth …) ?

which limitations and interferences are known already ?which limitations and interferences are known already ?

which basic conditions are required for the application ?which basic conditions are required for the application ?

Which KPI’s are used …… to characterize coexistence ?

Which KPI’s are used …… to characterize coexistencecoexistence ?

Coexistence ☯ ISM Frequency Bands

coexistence of basic technologies do not ensure the co-existence of applications: how can vendors guarantee that ?coexistence of basic technologies do not ensure the co-existence of applications: how can vendors guarantee that ?

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3rd party3rd party

Mobile Logistics: PDAMobile Logistics: PDAIT Meeting

RoomIT Meeting

Room

REJECTED

Change Frequency

Sensor NetworksSensor Networks

Coexistence Certificate

According NE124

Mobile Process Monitoring

Mobile Process Monitoring

limitation of bandwidth

Coexistence within ISM frequency band 2.4 GHz

limitation of bandwidth

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Wireless Communication is non deterministicWireless Communication is non deterministic

which standard guarantees real time capability ?which standard guarantees real time capability ?

which physical restrictions are known already ?which physical restrictions are known already ?

which basic conditions for real time capability are required and have to be provided from the user ?which basic conditions for real time capability are required and have to be provided from the user ?

Open questions☯ Real Time Capability

which KPI’s are used …… to characterize real time capability ?

which KPI’s are used …… to characterize real time capabilityreal time capability ?

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99% availability means 4 days per year no connectivity99% availability means 4 days per year no connectivity

how can vendors guarantee availability ? how can vendors guarantee availability ?

which physical restrictions are already known ?which physical restrictions are already known ?

which basic conditions are required for real time capability of the applications ?which basic conditions are required for real time capability of the applications ?

Open questions☯ Availability and Reliability

which KPI’s are used …… to characterize availability and reliabilty ?

which KPI’s are used …… to characterize availabilityavailability and reliabiltyreliabilty ?

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No maintenance effort for battery exchangeNo maintenance effort for battery exchange

how can the life time of batteries be estimated ? how can the life time of batteries be estimated ?

when will be reliable methods for energy harvesting be available on market ?when will be reliable methods for energy harvesting be available on market ?

which maintenance free concepts are available for the overall life cycle energy supply?which maintenance free concepts are available for the overall life cycle energy supply?

Open questions☯ Energy Supply

which KPI’s are used …… to characterize the quality of energy supply?

which KPI’s are used …… to characterize the quality of energy supplyenergy supply?

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Conclusions

BUTBUT

there is no benefit in competition of standards (e. g. ISA SP100 und Wireless HART)

NAMUR expects a common standard of best in class propertiesa „2nd fieldbus war“ is unacceptable

beneficial use cases must be the center of discussions

there is no benefit in competition of standards (e. g. ISA SP100 und Wireless HART)

NAMUR expects a common standard of best in class NAMUR expects a common standard of best in class propertiespropertiesa a „„2nd fieldbus war2nd fieldbus war““ is unacceptableis unacceptable

beneficial use cases must be the center of discussions

Wireless technologies in general could be an additional platform for flexible communication within or between automation systems and solutions

Wireless technologies in general could be an additional platform for flexible communication within or between automation systems and solutions

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Next Steps

Users will prove vendors promises and capabilities of different technologies

Users will prove vendors promises and capabilities of different technologies

NAMUR launches a Wireless Sensor Business Case and Technology Study

kickoff of a WirelessHART field test at BASF SE in April 2009 to reflect NE124 requirementsEmerson WirelessHART pilot Installation at Bayer and BPno proprietary technologies will be consideredalso ISA SP100 devices and solutions are welcomePresentation of first results at NAMUR annual meeting 2009

NAMUR will provide a NAXXX „Wireless Sensor Networks“in 2010

NAMUR launches a Wireless Sensor Business Case and Wireless Sensor Business Case and Technology StudyTechnology Study

kickoff of a WirelessHART field test at BASF SE in April 2009 to reflect NE124 requirementsEmerson WirelessHART pilot Installation at Bayer and BPno proprietary technologies will be consideredalso ISA SP100 devices and solutions are welcomePresentation of first results at NAMUR annual meeting 2009

NAMUR will provide a NAXXX „Wireless Sensor Networks“in 2010

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… go wireless !

In this case …