WirelessHART Applications ARASU THANIGAI PEPPERL+FUCHS ASIA PTE LTD - PowerPoint PPT Presentation

WirelessHART Applications ARASU THANIGAI PEPPERL+FUCHS ASIA PTE LTD

So what is Wireless HART? • Wireless HART: • Is an open & interoperable standard • Is based on the established HART protocol • Uses known tools and procedures for configuration, maintenance, & diagnosis • Requires minimal training • Allows wireless access to existing field devices • Can be used worldwide without any license 2

A Network that works The Wireless HART network is a mesh network where each sensor acts as both a router and repeater. The range of the network doesn’t depend on the location of the central gateway, allowing set up of large distributed network structures. sensor gateway 3

Mesh Network: How it Works 25-Apr-2017 page 4

Mesh Network: How it Works 25-Apr-2017 page 5

Mesh Network: How it Works 25-Apr-2017 page 6

Essential Components Wireless HART GATEWAY Wireless HART FIELD DEVICE ADAPTER Wireless HART Devices    Serial RS485 & Ethernet interface Upgrade installed field devices single of dual channel converter    Modbus & HART protocol Battery powered Inputs for AI,AO, DI, DO    Redundant power supply Powers the transmitter Battery powered   Operates as a router in a larger installations LED & pushbuttons for status & set up The Wireless HART gateway is The Wireless HART adapter can be The Wireless HART devices the core element of a wireless connected directly to the interface offers multiple ways to connect mesh network. It serves as the of any field device. This can be a physical variables. They are interface between the mesh conventional 4…20 mA or an designed to transfer network and the plant’s process intelligent HART device. measurements directly to the control or asset management. network. 5

New Connectivity to existing Devices Retrofitting Application for existing infrastructures that do not support HART communication today 25-Apr-2017 page 9

Wireless Devices for Measurement & Control 25-Apr-2017 page 10

Typical Applications • Heavy Industry • Extraction, Refining • Conveying, Processing • Manufacturing, Storage • Water/Wastewater • Municipal, Rural • Environmental • Pump Control • Tank Levels • Flow Measurement • Preventative Maintenance 25-Apr-2017 page 11

Product Applications • Tank Farms • Oil Refineries • Rotational Equipment • Mobile Equipment • Ad hoc Monitoring • Pipelines 7

Measuring & Monitoring Level Control Temperature Corrosion A simple Wireless HART Wireless HART monitoring temperature sensor can be instruments can be placed at Wireless HART makes it used to detect & diagnose important measurement easier & more cost effective problem situations long points along pipelines in to monitor the levels in before they result in failures places that previously process & storage tanks by & influence plant availability. couldn’t be reached. eliminating the need to manually take & record the measurements. Ideal Applications or Locations Ideal Applications or Locations   Motors Long pipelines located in remote Ideal Applications or Locations  Pumps & cooling devices locations  Storage vessels   Resources that need monitors Plants with moving vehicles &  Process tanks changes in location 6

Process Monitoring & Control • Hard to reach locations • Process efficiency calculations • Better insight into process • Ad-hoc measurements • Additional measurements from mult ivariable devices • Calculated variables in devices

Equipment Monitoring • Bearing temperatures • Vibration • Corrosion • Oil pressure • Air flow

Application Examples Environmental monitoring: Corrosion 25-Apr-2017 page 16

Application Examples Storage: Continuous Level Measurement 25-Apr-2017 page 17

Application Examples Storage: Discrete Level Measurement 25-Apr-2017 page 18

Application Examples Monitoring: Valve Lever Positioning 25-Apr-2017 page 19

Application Examples Monitoring: Temperature 25-Apr-2017 page 20

More applications …..  Tank Level Monitoring / Control o 4-20 mA output on oil tanks  Railroad o Rural railroad signal control - 2 DI o Yard switch control  Refineries / chemical plants  Steel / metal plants 25-Apr-2017 page 21

Quarry Dredging Hwy. 61 25-Apr-2017 page 22

Mining Installation  Worked with customer on antenna installation to provide reliable communicati ons 25-Apr-2017 page 23

Other Applications  Health and Safety • Safety showers • Gas detectors  Environmental • Steam traps (energy usage) • Water / Discharge Treatment • Flow • pH • Stack emissions • Relief valves

Other Applications  Asset Management • Maintenance • Calibration • Record valve signatures • Radar echo • Diagnostics • Valve position feedback • Device health (status)

Application examples with pictures

Fence Line Gas Detection Tank Level Gas Detection Skid with 5 MACTek Bullets ~ 4-20 mA Transmitter; scaled Engineering 140 meters From Gateway; 4 – analog Units and Multidrop with HART Transmitters transmitters and 2 HART

Portable Gas Monitoring Portable Mixing Tanks - (Pharmaceutical) Place meters within reach of any WH Device Everything wired from one AC power or Gateway; use battery controls to conserv connection; Analog output for Drive Speed, e power; transmit PV and Battery Voltage fo Pressure, Temp, PH, Level r Analog 4-20 non-HART transmitter

Portable Boiler Efficiency Testing Valve monitoring Budget ~$50,000; Savings using Bullets: Paper Machine (Wet End); Dirt and moisture, Project Approved with a savings of $78,000 ( no problem (IP68) 78%) due to multidrop.

Multidrop Used on a “wireless” remote IO Application – 34 transmitters with 10 Bullets!

Multidrop Bullet Direct Power, Multidrop Temperature Solution  Puck Temperature Transmitters  24 Measurements ~ PV = Average or Difference G 1 2 3 ~ SV = Temp 1 G G R R ~ TV = Temp 2 Y Y B B  Easily Repairable W W 4 5  1Second update per transmitter  WirelessHART for less than $3 3 per measurement. 6 8 7

Battery Box – Powering Two Devices Pressure and Temperature used on Rotating Digester

Tank Farm Monitoring – GPB, Mexico  Objectives o Reduce cost o Reduce time to implement  Installation o 10 Level transmitters o 10 WirelessHART Adapters o 1 Gateway o HMI Software via OPC

Rotating Catalyst Driers at BASF The Netherlands  Objectives o Eliminate manual sampling o Improved quality o Increase throughput with short er cycle times  Installation o Pressure and Temperature Tra nsmitters o Wireless HART adapters o Gateway with Modbus output o Modbus to Profibus converter

Rotating Catalyst Driers at BASF • Adapters provide: - Power and wireless connectivity to pressure and temp transmitters - A communication path from the rotation equipment to the gateway - Communication to a Siemens PLC via a Modbus to Profibus converter

Wellhead Monitoring for Heavy Crude Oil Extraction  Objectives o Reduced installation time (from 15 days t o 3 days) o Eliminate expensive cabling and remote I /O  Installation o 800 Instruments o 800 Wireless HART Adapters o 43 Gateways Pacific Rubiales Energy, Colombia

Wellhead Monitoring for Heavy Crude Oil Extraction

Burner Monitoring in Steel Production Stahl Gerlafingen AG  Objectives o Improve reliability of the measu rement systems  Installation o Flow measurement of cooling water o Flow measurement of ingot mol d water o Oxygen supply to burners o Temperature of shaft and ventu ri nozzles o Level of the dust silo Adapter connections to any HART or Analog Device

Burner Monitoring in Steel Production Stahl Gerlafingen AG Oxygen Flow to Burner Dust Silo Level The adapter can be connected anywhere in the 4-20ma loop enabling it to be hundreds of meters from the installed device.

Energy Efficiency Improved at Duke Energy  Objective o Improve cost and speed of conducting efficiency tests o Leverage existing investment in HART instrumentation o Improve reliability by replacing m ultiplexers with gateways and less cabling  Installation o Wireless HART adapters with multidrop wiring topology o Wireless HART Gateways  Results o 100-150 man-hour savings enabling more tests, more often

Temperatures in Railcars at Croda  Objective o Monitor temperature of highly reactive and flammable chemicals in moving rail cars o Maintain wireless temperature measurement as rail c ars move throughout facility  Installation o Wireless temperature transmitters installed on each r ailcar as they arrive at plant o Temperature measurements communicated from gat eway back to the control system Results – Improved safety and Reduced costs  o Eliminated employees climbing to the top of railcars e very day “There are savings of $14,000 per year in reduced operations and maintenance costs, but, the incalculable savings were in safety.” — Denny Fetters, I&E Designer