Wireless - What Do We Want from It? Phil Ng & Jose Maria Moyano Mena, Honeywell

What Do We Want? Save Money! Be Reliable Be Secure Be Scalable Allow for System Flexibility

Market Growth The total revenues for wireless sensors and transmitters in industrial applications in 2009 reached $526.7 Million.*Sensor Online New analysis from Frost & Sullivan, Global Wireless Sensor Networks Market, finds that the market earned revenues of $1.20 Billion in 2014 and estimates this to reach $3.26 Billion in 2020 at a compound growth rate of 18.1 percent That’s a lot!

Honeywell Has the Product Line and Experience Market Growth Forecasted CAGR = 13% (2019) Honeywell growth over last 2 years > 20% 2015 Sales Channels reporting surge in wireless, renewed interest Networks and transmitters Wireless product interest Pressure/flow Remote I/O Gateways Access points Standalone radio (adapters) Honeywell Has the Product Line and Experience

Save Money Lower Installation Cost In one case, estimated cost of traditional wiring and conduit for monitoring outside storage units was $15,000 to $22,000 per tank Up to 90% of that cost was for cable, conduit and related construction. 18 tanks x $15,000 each = $270,000 Figures from an actual customer. Need to find wellhead applications – KOC project wellhead.

Even Less Costly for Future Adds Save Money With wireless18 tanks would be about $60K list price In comparison, cable and conduit alone is more than 4x the cost of the entire wireless system ($270k vs $60k USD) Ma’Aden 2010 Study 19% estimated cost savings over Foundation Fieldbus US $695,000 savings using older Honeywell infrastructure Includes both hardware and engineering savings Even Less Costly for Future Adds

More Money, More Problems Past equipment cost alone, installation of wirelessly connected devices can be up to 10 times cheaper than the wired alternative and offers much faster start-ups to accelerate profits Reduce project risk Wireless drastically reduces engineering time and cost required to route wire back to junction boxes or control rooms

Project Justification Recommendation BASF Freeport, Texas Justify on Safety Faster to complete a project One time savings in effort Avoid justification on Productivity, recurring time savings This leads to staff reductions

Be Reliable - Deterministic Mesh Algorithm based system designed to always “determine” the most efficient way to get the value from the process to the end user Hop count is the most important factor. The system will always select the path with the fewest wireless hops back to the Ethernet connected FDAP. The green line is duopath It doesn’t form up like they think it should (it bypasses the closer FDAP), cuts out a hop. The algorithm is smart enough to figure out the better path. The trnasmitter decide which one to talk to. We suggest network layout (e.g. FDAP placement) to cover the site, for optimal coverage.

Be Reliable - Redundant Path Creation Redundant Path Selection and Duo Casting 700-1 dotted line indicates an inactive path (possible failure). Shows better signal strength than an active line. It will bypass the extra hop. Incactive path does not show on every xmtr.

Be Reliable – Tolerate Multipath Multipath is the combination of the original signal plus the duplicate wave fronts Result is multiple wave reflections off of obstacles between the transmitter and the receiver Diversity antennas are not designed to create two separate coverage cells, but to enhance the coverage of a single cell Overcomes the issues that arise from multipath reflections Unique to Hon and how it helps with performance, it is a big deal. Out of phase – the data is mixed up. The receiving device has to put it back into order. (CRC error cyclical redundancy checkbit) The receiving device runs the CRC, if too high, it will deem the path bad and drop. Diversity reorders the packet before it sends it on. So it ensures the communication is. The 2 antennas is not individual. 1 antenan is transmits and receives and one is only receives. Honeywell Patented Technology

Be Secure - Authentication Authentication and provisioning are controlled by the Wireless Device Manager (WDM) Requires any device joining the network to provide all of its credentials by using a join key generated by the WDM Two main methods for this: Over the Air Provisioning (OTA) Infrared Device Provisioning using a handheld OTA – unique to ISA100 (not WirelessHART) Also firmware upgrades are possible with our system.

Be Secure- Encryption ISA100 Wireless ensures that all process data is128-bit AES encrypted Approved by US National Security Agency (NSA). Commercial banking uses AES The data is encrypted at the source and decrypted at the destination to provide end-to-end message level security for the process data ISA100 also has hop to hop security Reference the actual spec…128 bit AES encryption. Diagram courtesy of Wireless Compliance Institute

Be Secure - Firewall The WDM uses an embedded firewall that inspects all data packets and limits access to and from the WDM. The firewall ensures that no traffic flows between the ISA100 wireless field device network and the plant control network. Only ISA100 wireless traffic from an authenticated wireless device is allowed to pass to the plant network FDAP only accepts from ISA100 compliant devices. there is no other application can see the network devices channel hopping rogue devices can’t see that the network exists. Security concerns is really around Wi-Fi (fixed channel)

No. of Devices Supported Be Scalable Honeywell wireless uses IPv6 on the field device network allowing much larger capacity as well as future proofing the investment Internet of Things (IOT) predicted to use IPv6 (internet protocol addressing). 3.4 x 10 38 addresses. Nov release, OneWireless system capacity is 250 transmitters in R240 Free upgrade to R240 until 1Q2016 Network expansion is as simple as adding FDAPs where additional coverage is needed Update Rate (Seconds) No. of Devices Supported 1 100 1+ (5,10,30,60) 50+200 5,10,30,60 250 iIOT – will most leverage IPv6 addressing (WirelessHART devices do not use IPv6)

Build Your Network, Build It! Process Control Network Redundant WDMs shown

Be Scalable Economy of scale: Deploying additional points in an existing network becomes extremely cost effective The more transmitters added, the lower the total per point cost for the network becomes Speaks to laying out the FDAPs for coverage. Speaks to economy of scale – add more, save more. easier project justification for future projects.

Be Flexible - Design The algorithm based link formation technique allows design flexibility by forming device links based on pre- determined metrics No manual setup The user does not have to be involved. Plug and play system. zero configuration.

Be Flexible - Device Routing We have the option to use transmitter routing (mesh) Remember, this isn’t a design method but it is an option to support isolated devices or solve coverage issues that come up after install! Design for the performance required Design with no routing. Use FDAPs for coverage. Then if there are issues, use transmitter routing later on. If you use routing in the transmitter up front, you have no insurance. Min FDAPs (lower cost) but lose benefits of the system and potential remedies.

Be Flexible - Open Standard ISA100 Wireless is an open communication protocol built using the OSI 7 layer model- that’s the same design model that the IEEE used to give us IP (internet) Leads to predictable, interoperable performance with other ISA100 certified devices and opens up many more uses for the network giving the customer a better value for their investment ISA Devices

Be Flexible - Open Standard Company Key Products Armstrong Steam Trap Monitors Azbil Control Valves CDS ISA100 Wireless SDK, Disposable satellite sensors Centero ISA100 Wireless SDK, integration support, test kits COSASCO Corrosion Sensors Eltav Manual Valve position sensor Flowserve Control Valve, position sensor GE Bently Nevada Vibration monitoring Murata ISA100 Wireless modules and infrastructure devices HIKOB Sensors and Data Acquisition for Roads & Civil Projects New Cosmos Gas Detection Systems Nexcom Infrastructure Devices, Gateways, Access Points, Routers Riken Keiki Scott Safety SKF Bearings and Asset Monitoring – vibration monitoring Spirax Sarco Boiler controls, steam traps, valves TLV Steam Ttrap and valves Yokogawa Universal Antenna, Modbus, HART and, Profibus Adaptors http://www.isa100wci.org/en-US/End-User-Resources/Product-Portfolio

Phillips 66 Sweeny Refinery Requirements Phillips 66 has strong motivations for implementing industrial wireless at the Sweeny Refinery Enable opportunities for comprehensive process monitoring Replaced dated level gauging systems with wireless field instruments Connect to points that were physically or economically difficult to access Add new measurement or actuation points for simply the cost of the transmitter

What We Learned – Phillips 66 Sweeny Industrial wireless can optimize plant productivity, reliability and safety, but only if qualified personnel take ownership of the technology If properly supported, wireless allows engineers and operators to react quickly to changing conditions and gather information they need to optimize processes With the right installation, wireless can significantly reduce infrastructure investments for process monitoring Projects that previously could not occur now become worthwhile

Summary All of these features and benefits we’ve talked about combine to make wireless instrumentation a very attractive option A wireless network can save a customer a lot of money on equipment, installation, as well as long term ownership The reliability mechanisms along with the security features insure that, when properly implemented, the system will work and give the customer confidence to grow The system is easy to design and implement The ISA100 Wireless standard is being adopted by more manufactures all the time so the options, i.e. value for the customer, is ever increasing, giving the customer peace of mind that they made a good investment

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